Toro 30412 User Manual

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Page 1

Part No. 08161SL (Rev. A)

Service Manual

(Model 30412)

Groundsmaster

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 (Model 30412).

REFER TOTHEOPERATOR’S MANUALFOROPERATING, MAINTENANCE AND ADJUSTMENT INSTRUCTIONS. For reference, insert a copy of the Operator’sManualandParts Catalog for your machine into Chapter 2 of this service manual. Additional copies of the Operator’s Manual and Parts Catalog are available on the internet at www.Toro.com.

TheToroCompany reservestheright tochange product specifications or this publication without notice.

4000--D

This safety symbol means DANGER, WARNING, or CAUTION, PERSONAL SAFETY INSTRUCTION. When you see this symbol, carefully read the instructions that follow. Failure to obey the instructions may result in personal injury.

NOTE: ANOTE willgivegeneral informationabout the

correct operation, maintenance, service, testing or repair of the machine.

IMPORTANT: The IMPORTANT notice will give im portantinstructionswhichmustbefollowed to prevent damage to systems or components on the machine.

E The Toro Company -- 2008, 2012

Page 2

This page is intentionally blank.

Groundsmaster 4000--D

Page 3

Chapter 1 -- Safety

General Safety Instructions 1 -- 2..................

Jacking Instructions 1 -- 4.........................

Safety and Instruction Decals 1 -- 5................

Chapter 2 -- Product Records and Maintenance

Product Records 2 -- 1...........................

Maintenance 2 -- 1...............................

Equivalents and Conversions 2 -- 2................

Torque Specifications 2 -- 3.......................

Chapter 3 -- Kubota Diesel Engine

General Information 3 -- 2........................

Specifications 3 -- 3..............................

Service and Repairs 3 -- 4........................

KUBOTA WORKSHOP MANUAL, DIESEL ENGINE,

V2403--M--T--E3B SERIES

Chapter 4 -- Hydraulic System

Specifications 4 -- 2..............................

General Information 4 -- 3........................

Hydraulic Schematic 4 -- 8........................

Hydraulic Flow Diagrams 4 -- 10...................

Special Tools 4 -- 26.............................

Troubleshooting 4 -- 28...........................

Testing 4 - - 31...................................

Adjustments 4 -- 60..............................

Service and Repairs 4 -- 61.......................

EATON MODEL 72400 SERVO CONTROLLED PIS-

TON PUMP REPAIRINFORMATION

EATONMODEL 74318 and 74348 PISTONMOTORS:

FIXED DISPLACEMENT, VALVE PLATE DESIGN REPAIR INFORMATION

Chapter 5 -- Electrical System

General Information 5 -- 2........................

Special Tools 5 -- 3..............................

Troubleshooting 5 -- 5............................

Electrical System Quick Checks 5 -- 8..............

Component Testing 5 -- 9.........................

General Information 5 -- 34.......................

Chapter 6 -- Axles, Planetaries and Brakes

Specifications 6 -- 2..............................

General Information 6 -- 3........................

Service and Repairs 6 -- 4........................

Chapter 7 -- Chassis

General Information 7 -- 1........................

Service and Repairs 7 -- 2........................

Chapter 8 -- Cutting Decks

Specifications 8 -- 2..............................

General Information 8 -- 3........................

Troubleshooting 8 -- 4............................

Service and Repairs 8 -- 6........................

Chapter 9 -- Foldout Drawings

Hydraulic Schematic 9 -- 3........................

Electrical Schematics 9 -- 4.......................

Circuit Diagrams 9 -- 6...........................

Wire Harness Drawings 9 -- 12....................

SafetyProduct Records

and Maintenance

Kubota

Diesel Engine

System

Hydraulic

System

Electrical

Axles, Planetaries

and Brakes

Groundsmaster 4000--D

Cutting Decks Chassis

Foldout

Drawings

Page 4

This page is intentionally blank.

Groundsmaster 4000--D

Page 5

Table of Contents

GENERAL SAFETY INSTRUCTIONS 2............

Before Operating 2............................

While Operating 2.............................

Maintenance and Service 3....................

JACKING INSTRUCTIONS 4.....................

SAFETY AND INSTRUCTION DECALS 5..........

Chapter 1

Safety

Groundsmaster 4000--D

Page 1 -- 1

Safety

Page 6

General Safety Instructions

TheGROUNDSMASTER 4000-D istestedandcertified by Toro for compliance with existing safety standards and specifications. Although hazard control and accidentpreventionpartiallyare dependentuponthe design andconfigurationofthemachine,thesefactors are also dependent upon the awareness, concern and proper trainingofthepersonnelinvolvedintheoperation,transport,maintenance and storage of the machine. Improperuseormaintenanceofthemachinecanresultininjury ordeath.Toreducethepotentialforinjuryordeath,comply with the following safety instructions.

Before Operating

WARNING

To reduce the potential for injury or death, comply with the following safety instructions.

1. Review and understand the contents of the Operator’s Manual and Operator’s DVD before starting and operatingthe vehicle. Become familiar with the controls and know how to stop the vehicle and engine quickly. AdditionalcopiesoftheOperator’sManualareavailable on the internet at www.Toro.com.

2. Keepall shields, safetydevices and decals in place. Ifa shield, safety device or decal isdefective,illegibleor damaged, repair or replace it before operating the machine.Also tighten anyloosenuts,bolts or screws toensure machine is in safe operating condition.

3. Assure interlock switches are adjusted correctly so engine cannot be started unless traction pedal is in NEUTRAL and cutting decks are DISENGAGED.

While Operating

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). C. Afterengineis started,releaseparking brakeand

keepfootofftraction pedal. Machine must not move. If movement is evident, the traction pedal linkage is adjusted incorrectly; therefore, shut engine off and adjust until machine does not move when traction pedal is released.

4. Sincediesel fuel is highly flammable, handle it carefully:

A. Use an approved fuel container. B. Donotremovefuel tank capwhileengine ishotor

running. C. Do not smoke while handling fuel. D. Fillfueltankoutdoors and onlytowithinan inch of

the top of the tank, not the filler neck. Do not overfill. E. Wipe up any spilled fuel.

5. Before getting off the seat: A. Ensure that traction pedal is in neutral. B. Apply the parking brake. C. Disengage cutting decks and wait for blades to

stop. D. Stop engine and remove key from switch. E. Toro recommends that anytime the machine is

parked(shortor long term), the cutting decksshould be lowered to the ground. This relieves pressure from the lift circuit and eliminates the risk of cutting decks accidentally lowering to the ground.

3. Do not run engine in a confined area without adequate ventilation. Exhaust fumes are hazardous and could possibly be deadly.

4. Do not touch engine, muffler or exhaust pipe while engineisrunningorsoonafteritisstopped.Theseareas could be hot enough to cause burns.

Safety

Page 1 -- 2

F. Donotparkonslopesunlesswheels arechocked or blocked.

Groundsmaster 4000--D

Page 7

Maintenance and Service

1. Before servicing or making adjustments, lower decks, stop engine, apply parking brake and remove key from the switch.

2. Makesure machine isin safe operating condition by keeping all nuts, bolts and screws tight.

3. Never store the machine or fuel container inside wherethereisanopenflame,suchasnearawaterheater or furnace.

4. Makesureall hydraulic line connectors are tight and all hydraulic hoses and lines are in good condition before applying pressure to the system.

5. Keepbodyandhandsaway frompin holeleaks inhydrauliclinesthateject high pressure hydraulic fluid. Use cardboard or paper to find hydraulic leaks. Hydraulic fluid escaping under pressure can penetrate skin and cause injury. Fluid accidentally injected into the skin mustbe surgically removed within a few hours by a doctor familiar with this form of injury or gangrene may result.

6. Beforedisconnecting or performing any work on the hydraulic system, all pressure in system must be relievedby stopping engine and lowering cutting decks to the ground.

10.Do not overspeed the engine by changing governor setting.Toassuresafety andaccuracy,checkmaximum engine speed.

11.Shut engine off before checking or adding oil to the crankcase.

12.Disconnect battery before servicing the machine. Disconnect negative cable first and positive cable last. If battery voltage is required for troubleshooting or test procedures,temporarilyconnectthebattery.Reconnect positive cable first and negative cable last.

13.Battery acid is poisonous and can cause burns. Avoidcontact with skin, eyes and clothing. Protect your face, eyes and clothing when working with a battery.

14.Battery gases can explode. Keep cigarettes, sparks and flames away from the battery.

15.At the time of manufacture, the machine conformed tothesafety standards for riding mowers. Toassure optimumperformance and continuedsafetycertificationof the machine, use genuine Toro replacement parts and accessories.Replacementparts andaccessoriesmade by other manufacturers may result in non-conformance with the safety standards and the warranty may be voided.

Safety

7. Ifmajor repairs are everneeded or assistance is desired, contact an Authorized Toro Distributor.

8. To reduce potential fire hazard, keep engine area free of excessive grease, grass, leaves and dirt. Clean protective screen on machine frequently.

9. Ifengine must berunningtoperformmaintenanceor an adjustment, keep hands, feet, clothing and other parts of the body away from cutting decks and other moving parts. Keep bystanders away.

16.When changing attachments, tires or performing other service, use correct blocks, hoists and jacks. Make sure machine is parked on a solid level surface suchasaconcrete floor.Priortoraising themachine,remove any attachments that may interfere with the safe and proper raising of the machine. Always chock or block wheels. Use appropriate jack stands to support the raised machine. If the machine is not properly supported by jack stands, the machine may move or fall, whichmay resultinpersonal injury(seeJacking Instructions in this chapter).

Groundsmaster 4000--D

Page 1 -- 3

Safety

Page 8

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 themachine.Always chockorblockwheels.Use jackstands to support the raised machine.If the machine is not properly supported by jack stands, the machine may move or fall, which may result in personal injury.

Jacking the Front End (Fig. 1)

1. Set parking brake and chock both rear tires to prevent the machine from moving.

2. Positionjack securelyunder the frame, just to the inside of the front tire. Jack front wheel off the ground.

1. Frame jacking point 2. Front tire

Figure 1

3. Once the machine is raised, position jack stand under the frame as close to the wheel as possible to support the machine.

Jacking the Rear End (Fig. 2)

1. Place jack securely under the center of rear axle.

2. Chock both front tires. Jack rear of machine off the ground.

3. Once the machine is raised, use jack stands under the axle to support the machine.

1. Rear axle jacking point 2. Rear tire

Figure 2

Safety

Page 1 -- 4

Groundsmaster 4000--D

Page 9

Safety and Instruction Decals

Numerous safety and instruction decals are affixed to theGroundsmaster4000--D.If anydecalbecomes illegible or damaged, install a new decal. Decal part numbers are listed in your Parts Catalog.

Safety

Groundsmaster 4000--D

Page 1 -- 5

Safety

Page 10

This page is intentionally blank.

Safety

Page 1 -- 6

Groundsmaster 4000--D

Page 11

Product Records and Maintenance

Table of Contents

PRODUCT RECORDS 1.........................

MAINTENANCE 1..............................

EQUIVALENTS AND CONVERSIONS 2...........

Decimal and Millimeter Equivalents 2............

U.S. to Metric Conversions 2...................

TORQUE SPECIFICATIONS 3...................

Fastener Identification 3.......................

Using a Torque Wrench with an Offset Wrench 3.. Standard Torque for Dry, Zinc Plated and

Steel Fasteners (Inch Series) 4...............

Standard Torque for Dry, Zinc Plated and

Steel Fasteners (Metric) 5....................

Other Torque Specifications 6..................

Conversion Factors 6.........................

Chapter 2

Product Records

and Maintenance

Product Records

Insert Operator’s Manuals and Parts Catalogs for your Groundsmaster at the end of this chapter. Additionally, if any optional equipment or accessories have been installed to your machine, insert the Installation Instructions, Operator’s Manuals and Parts Catalogs for those options at the end of this chapter.

Maintenance

Maintenanceprocedures and recommended service intervalsforyourGroundsmasterarecoveredin theOperator’sManual.Refertothatpublicationwhenperforming regular equipment maintenance.

Groundsmaster 4000--D Page 2 -- 1 Product Records and Maintenance

Rev. A

Page 12

Equivalents and Conversions

0.09375

Groundsmaster 4000--DPage 2 -- 2Product Records and Maintenance

Page 13

Torque Specifications

Recommended fastener torque values are listed in the following tables. For criticalapplications,as determined byToro,eitherthe recommended torque or a torquethat is unique to the application is clearly identified and specified in this Service Manual.

These Torque Specifications for the installation and tightening of fasteners shall apply to all fasteners which do not have a specific requirement identified in this Service Manual. The following factors shall be considered when applying torque: cleanliness of the fastener, use of a thread sealant (e.g. Loctite), degree of lubrication on the fastener,presence of a prevailing torque feature (e.g. Nylock nut), hardness of the surface underneath thefastener’sheador similar conditionwhichaffectsthe installation.

Fastener Identification

Asnoted inthefollowingtables, torquevaluesshould be reduced by 25% for lubricated fasteners to achieve the similar stress as a dry fastener. Torque values may also have to be reduced when the fastener is threaded into aluminum or brass. The specific torque value should be determined based on the aluminum or brass material strength, fastener size, length of thread engagement, etc.

The standard method of verifying torque shall be performed by marking a line on the fastener (head or nut) and mating part, then back off fastener 1/4 of a turn. Measurethetorquerequiredto tighten the fastener until thelinesmatchup.

Product Records

and Maintenance

Grade 1 Grade 5 Grade 8

Inch Series Bolts and Screws

Figure 1

Using a Torque Wrench with an Offset Wrench

Useof anoffsetwrench(e.g.crowfoot wrench)willaffect torquewrench calibration due to the effective change of torque wrench length.When using atorque wrench with an offset wrench, multiply the listed torque recommendation by the calculated torque conversion factor (Fig.

3) to determine proper tightening torque. Tightening torque when using a torque wrench with an offset wrench will be lower than the listed torque recommendation.

Example: The measured effective length of the torque wrench (distance from the center of the handle to the center of the square drive) is 18”.

Themeasuredeffectivelengthofthe torquewrenchwith the offset wrench installed (distance from the center of the handle to the center of the offset wrench) is 19”.

Class 8.8 Class 10.9

Metric Bolts and Screws

Figure 2

If the listed torque recommendation for a fastener is from 76 to 94 ft--lb, the proper torque when using this torque wrench with an offset wrench would be from 72 to 89 ft--lb.

(effective length of

torque wrench)

(effective length of torque

wrench + offset wrench)

TORQUE CONVERSION FACTOR = A / B

T orque wrenchOffset wrench

The calculated t orque conversion factor for this torque wrenchwith this offset wrench would be 18 / 19= 0.947.

Groundsmaster 4000--D Page 2 -- 3 Product Records and Maintenance

Rev. A

Figure 3

Page 14

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--24UNC

#10--32UNF

1/4 -- 20 UNC 48 + 7 53 + 7 599 + 79 100 + 10 1130+ 113 140 + 15 1582+ 169

1/4 -- 28 UNF 53 + 7 65 + 10 734 + 113 115 + 12 1299 + 136 160 + 17 1808 + 192

5/16 -- 18 UNC 115 + 15 105 + 15 1186+ 169 200 + 25 2260 + 282 300 + 30 3390 + 339

5/16 -- 24 UNF 138 + 17 128 + 17 1446 + 192 225 + 25 2542 + 282 325 + 33 3672+ 373

3/8 -- 16 UNC 16 + 2 16 + 2 22 + 3 30 + 3 41 + 4 43 + 5 58 + 7

Grade 1, 5 &

8withThin

Height Nuts

in--lb in--lb N--cm in--lb N--cm in--lb N--cm

10 + 2 13 + 2 147 + 23

13 + 2 25 + 5 282 + 56

18 + 2 30 + 5 339 + 56

ft--lb ft--lb N--m ft--lb N--m ft--lb N--m

SAE Grade 1 Bolts, Screws, Studs &

Sems with Regular Height Nuts

(SAE J995 Grade 2 or Stronger Nuts)

SAE Grade 5 Bolts, Screws, Studs &

Sems with Regular Height Nuts

(SAE J995 Grade 2 or Stronger Nuts)

15 + 2 169 + 23 23 + 3 262 + 34

17 + 2 192 + 23 25 + 3 282 + 34

29 + 3 328 + 34 41 + 5 463 + 56

31 + 4 350 + 45 43 + 5 486 + 56

42 + 5 475 + 56 60 + 6 678 + 68

48 + 5 542 + 56 68 + 7 768 + 79

SAE Grade 8 Bolts, Screws, Studs &

Sems with Regular Height Nuts

(SAE J995 Grade 5 or Stronger Nuts)

3/8 -- 24 UNF 17 + 2 18 + 2 24 + 3 35 + 4 47 + 5 50 + 6 68 + 8

7/16 -- 14 UNC 27 + 3 27 + 3 37 + 4 50 + 5 68 + 7 70 + 7 95 + 9

7/16 -- 20 UNF 29 + 3 29 + 3 39 + 4 55 + 6 75 + 8 77 + 8 104 + 11

1/2 -- 13 UNC 30 + 3 48 + 7 65 + 9 75 + 8 102 + 11 105 + 11 142 + 15

1/2 -- 20 UNF 32 + 4 53 + 7 72 + 9 85 + 9 115 + 12 120 + 12 163 + 16

5/8 -- 11 UNC 65 + 10 88 + 12 119 + 16 150 + 15 203 + 20 210 + 21 285 + 28

5/8 -- 18 UNF 75 + 10 95 + 15 129 + 20 170 + 18 230 + 24 240 + 24 325 + 33

3/4 -- 10 UNC 93 + 12 140 + 20 190 + 27 265 + 27 359 + 37 375 + 38 508 + 52

3/4 -- 16 UNF 115 + 15 165 + 25 224 + 34 300 + 30 407 + 41 420 + 43 569 + 58

7/8 -- 9 UNC 140 + 20 225+ 25 305 + 34 430 + 45 583 + 61 600 + 60 813 + 81

7/8 -- 14 UNF 155 + 25 260 + 30 353 + 41 475 + 48 644 + 65 667 + 66 904 + 89

NOTE: Reduce torque values listed in the table above by 25% for lubricated fasteners. Lubricated fasteners are defined as threads coated with a lubricant such as engine oil or thread sealant such as Loctite.

NOTE: The nominal torque values listed above for Grade 5 and 8 fasteners are based on 75% of the minimumproof load specified in SAE J429. The tolerance is approximately +

10% of the nominal torque value. Thin

height nuts include jam nuts. NOTE: Torque values may have to be reduced when installing fasteners into threaded aluminum or brass. The specific torque value should be determined based on the fastener size, the aluminum or base material strength, length of thread engagement, etc.

Groundsmaster 4000--DPage 2 -- 4Product Records and Maintenance

Page 15

Standard Torque for Dry, Zinc Plated and Steel Fasteners (Metric Series)

Class 8.8 Bolts, Screws and Studs with

Thread Size Regular Height Nuts

(Class 8 or Stronger Nuts)

M5 X 0.8 57 + 6in--lb 644 + 68 N--cm 78 + 8in--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 + 2ft--lb 26 + 3N--m 28 + 3ft--lb 38 + 4N--m M10 X 1.5 38 + 4ft--lb 52 + 5N--m 54 + 6ft--lb 73 + 8N--m

M12 X 1.75 66 + 7ft--lb 90 + 10 N--m 93 + 10 ft--lb 126 + 14 N--m

M16 X 2.0 166+ 17 ft--lb 225 + 23 N--m 229 + 23 ft--lb 310 + 31 N--m M20 X 2.5 325 + 33 ft--lb 440 + 45 N--m 450 + 46 ft--lb 610 + 62 N--m

NOTE: Torque values may have to be reduced when installing fasteners into threaded aluminum or brass. The specific torque value should be determined based on the fastener size, the aluminum or base material strength, length of thread engagement, etc.

NOTE: The nominal torque values listed above are based on 75% of the minimum proof load specified in SAEJ1199.Thetoleranceisapproximately+ nominal torque value.

Class 10.9 Bolts, Screws and Studs with

Regular Height Nuts

(Class 10 or Stronger Nuts)

10%ofthe

Product Records

and Maintenance

Groundsmaster 4000--D Page 2 -- 5 Product Records and Maintenance

Page 16

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 + 3ft--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 + 5in--lb

Wheel Bolts and Lug Nuts

Thread Size

7/16 -- 20 UNF

Grade 5

1/2 -- 20 UNF

Grade 5

M12 X 1.25

Class 8.8

M12 X 1.5

Class 8.8

** For steel wheels and non--lubricated fasteners.

Thread Cutting Screws

(Zinc Plated Steel)

Thread

Size

No. 6 18 20 20 + 5in--lb

Threads per Inch Type A Type B

Recommended Torque**

65 + 10 ft--lb 88 + 14N--m

80 + 10 ft--lb 108 + 14 N--m

Baseline Torque

No. 8 -- 32 UNC 30 + 5in--lb

No. 10 -- 24 UNC 38 + 7in--lb

1/4 -- 20 UNC 85 + 15 in--lb

5/16 -- 18 UNC 110 + 20 in--lb

3/8 -- 16 UNC 200 + 100 in--lb

Conversion Factors

in--lb X 11.2985 = N--cm N--cm X 0.08851 = in--lb

ft--lb X 1.3558 = N--m N--m X 0.7376 = ft--lb

No. 8 15 18 30 + 5in--lb No. 10 12 16 38 + 7in--lb No. 12 11 14 85 + 15 in--lb

*Holesize,materialstrength,materialthicknessandfinish must be considered when determining specific torquevalues. Alltorquevalues arebasedonnon--lubricated fasteners.

Groundsmaster 4000--DPage 2 -- 6Product Records and Maintenance

Page 17

Table of Contents

GENERAL INFORMATION 2.....................

Operator’s Manual 2..........................

Stopping the Engine 2.........................

SPECIFICATIONS 3.............................

SERVICE AND REPAIRS 4......................

Air Filter System 4............................

Exhaust System 6............................

Fuel System 8................................

Check Fuel Lines and Connections 9...........

Empty and Clean Fuel Tank 9.................

Fuel Tank Removal 9........................

Fuel Tank Installation 9.......................

Radiator 10..................................

Engine 12....................................

Engine Removal 12..........................

Engine Installation 14........................

Spring Coupler 16.............................

KUBOTA WORKSHOP MANUAL, DIESEL ENGINE,

V2403--M--T--E3B SERIES

Chapter 3

Kubota Diesel Engine

Kubota

Diesel Engine

Groundsmaster 4000--D Page 3 -- 1 Kubota Diesel Engine

Page 18

General Information

ThisChapter gives informationaboutspecificationsand repair of the diesel engine used in the Groundsmaster 4000--D.

Generalmaintenance procedures are described inyour Operator’sManual.Informationonenginetroubleshooting,testing, disassembly and reassemblyis identifiedin the Kubota Workshop Manual, Diesel Engine, V2403--M--T--E3Bthat is included at the endofthissection.

Most repairs and adjustments require tools which are commonly available in many service shops. Special

Operator’s Manual

The Operator’s Manual provides information regarding the operation, general maintenance and maintenance intervalsfor yourGroundsmastermachine.Refer tothat publicationfor additional informationwhenservicingthe machine.

Stopping the Engine

tools are described in the Kubota Workshop Manual, DieselEngine,V2403--M--T--E3B.Theuseofsomespecialized test equipment is explained. However,the cost of the test equipment and the specialized nature of somerepairsmaydictatethattheworkbedoneatanengine repair facility.

Service and repair parts for Kubota engines are supplied through your Authorized Toro Distributor. If no partslistisavailable,bepreparedtoprovideyourdistributor with the Toro model and serial number.

IMPORTANT: Before stopping the engine after mowing or full load operation, cool the turbo-charger by allowing the engine to run at low idle speed for five (5) minutes. Failure to do so may lead to turbo-charger trouble.

Groundsmaster 4000--DPage 3 -- 2Kubota Diesel Engine

Page 19

Specifications

Item Description

Make / Designation Kubota Model V2403--M--T--E3B: 4--Cycle, 4 Cylinder,

Water Cooled, Turbocharged, Diesel Engine

Bore 3.43” (87.0 mm)

Stroke 4.031” (102.4 mm)

Total Displacement 148.5 in3(2434 cc)

Firing Order 1 (closest to gear case end) -- 3 -- 4 (closest to flywheel end) -- 2

Combustion Chamber Spherical Type (E--TVCS)

Compression Ratio 23.0:1

Direction of Rotation Counterclockwise (viewed from flywheel)

Fuel Diesel or Biodiesel (up to B20) Fuel with Low or Ultra Low

Sulfur Content

Fuel Capacity 19.0 U.S. Gallons (72 Liters)

Fuel Injection Pump Denso PFR 4M Type Mini Pump

Injection Nozzle Denso OPD Mini Nozzle

Kubota

Diesel Engine

Governor Centrifugal Mechanical

Low Idle (no load) 1425 + 50 RPM

High Idle (no load) 2870 + 50/--120 RPM

Engine Oil API CH--4, CI--4 or higher

Engine Oil Viscosity See Operator’s Manual

Crankcase Oil Capacity 10.0 U.S. Quarts (9.5 Liters) with Filter

Oil Pump Trochoid Type

Coolant Capacity 13 U.S. Quarts (12.3 Liters)

Starter 12 VDC, 2.0 kW

Alternator/Regulator 12 VDC

Standard Alternator 40 amp Optional Alternator 90 amp

Engine Dry Weight 419 U.S. Pounds (190 Kg)

Groundsmaster 4000--D Page 3 -- 3 Kubota Diesel Engine

Page 20

Service and Repairs

Air Filter System

RIGHT

FRONT

1. Air cleaner hose

2. Hose clamp

3. Air cleaner assembly

4. Indicator

5. Air cleaner strap

6. Lock nut (2 used)

Figure 1

7. Hose clamp

8. Air cleaner hose

9. Hose clamp

10. Cap screw (2 used)

11. Flat washer (4 used)

12. Spring (2 used)

12 to 15 in--lb

(1.4 to 1.6 N--m)

13. Flat washer (2 used)

14. Cap screw (2 used)

15. Adapter

16. Lock nut (2 used)

17. Flat washer (2 used)

VACUATOR DIRECTION

Groundsmaster 4000--DPage 3 -- 4Kubota Diesel Engine

Page 21

Removal (Fig. 1)

1. Park machine on a level surface, lower cutting decks, stop engine, apply parking brake and remove key from the ignition switch.

2. Raise and support hood.

3. Remove air cleaner components as needed using Figure 1 as a guide.

Installation (Fig. 1) IMPORTANT: Any leaks in the air filter system will

causeserious engine damage.Make surethat allair cleaner components are in good condition and are properly secured during assembly.

1. Assemble air cleaner system using Figure 1 as a guide.

A. If service indicator (item 8) and adapter (item 9) wereremovedfromaircleanerhousing,applythread sealant to adapter threads before installing adapter and indicator to housing. Install adapter so that groovesinadapter hexandadapterfilter elementare installed toward serviceindicator (Fig. 3). Torque indicator from 12 to 15 in--lb (1.4 to 1.6 N--m).

1. Air cleaner housing

2. Safety filter element

3. Air filter element

Figure 2

4. Air cleaner cover

5. Vacuator valve

Kubota

Diesel Engine

2. When installing air cleaner hose (8) between air cleaner and turbo--charger (Fig. 4):

A. Make sure that hose does not contact engine valve cover. To ensure clearance, move and/or rotate air cleaner body in air cleaner strap.

B. Position hose to allow maximum clearance between air cleaner hose and muffler bracket.

3. Lower and secure hood.

1. Air cleaner assembly

2. Service indicator

1. Air cleaner hose

2. Engine valve cover

3. Air cleaner strap

Figure 3

3. Adapter

Figure 4

4. Air cleaner slots

5. Muffler bracket

Groundsmaster 4000--D Page 3 -- 5 Kubota Diesel Engine

Page 22

Exhaust System

RIGHT

FRONT

16 to 22 ft--lb

(21to29N--m)

16 to 22 ft--lb

(21to29N--m)

16 to 22 ft--lb

(21to29N--m)

16 to 22 ft--lb

(21to29N--m)

13 ft--lb

(17.6 N--m)

1. Muffler

2. Muffler bracket

3. Exhaust pipe

4. Flange head screw (4 used)

5. Exhaust gasket

6. Lock nut (2 used)

Figure 5

7. Cap screw (2 used)

8. Flat washer (4 used)

9. Spacer (2 used)

10. Rubber hanger

11. Flange nut (4 used)

12. Flange head screw (2 used)

13. Engine mount

14. Muffler clamp

15. Exhaust mount

16. Flange head screw (2 used)

Groundsmaster 4000--DPage 3 -- 6Kubota Diesel Engine

Page 23

Removal (Fig. 5)

CAUTION

The muffler and exhaust pipe may be hot. To avoid possible burns, allow the engine and exhaust system to c ool before working on the muffler.

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 exhaust system components from the engine as necessary using Figure 5 as a guide.

Installation (Fig. 5) IMPORTANT: If exhaust studs were removed from

engine cylinder head, thoroughly clean threads in head and apply Loctite #277 (or equivalent) to stud threads before installing studs into head.

NOTE: Make sure muffler flange and exhaust manifold

sealing surfaces are free of debris or damage that may prevent a tight seal.

Kubota

Figure 6

Diesel Engine

1. Install new exhaust gasket if original gasket is damaged or torn.

IMPORTANT: Failure to follow the suggested muffler fastener sequencemay result in prematuremuffler failure.

2. Installexhaust system components to theengineusing Figure 5 as a guide. Hand tighten exhaust system fastenersand thentorqueinthesequence showninFig. 6 as follows:

A. Torque lock nuts used on rubber hanger cap screws from 16 to 22 ft--lb (21 to 29 N--m).

B. Torque flange nuts that secure muffler to muffler bracket from 16 to 22 ft--lb (21 to 29 N--m).

C. Torque flange head screws that secure muffler flange to engine from 16 to 22 ft--lb (21 to 29 N--m).

D. T orqueflangenuts that securemuffler bracketto engine from 16 to 22 ft--lb (21 to 29 N--m).

E. Torqueflange screws that secure exhaust mount to engine to 1 3 f t -- l b ( 1 7 . 6 N -- m ) .

3. Tailpipeshouldhave equalclearancebetweenframe and engine after installation.

4. Lower and secure hood. Groundsmaster 4000--D Page 3 -- 7 Kubota Diesel Engine

Rev. A

Page 24

Fuel System

RIGHT

FRONT

1. Fuel tank

2. Fuel tank bracket

3. Air breather

4. Female hose barb

5. Tank support assembly

6. Fuel hose

7. Flange nut (6 used)

8. Cap screw (4 used)

9. Flat washer (4 used)

10. Cap screw (4 used)

11. Carriage screw (2 used)

12. Washer (2 used)

13. Battery strap

14. Battery

60 to 80 in--lb

(7 to 9 N--m)

Figure 7

15. Retaining ring (2 used)

16. Battery cover

17. Flat washer (2 used)

18. Knob (2 used)

19. Battery plate

20. Negative cable

21. Positive cable

22. Carriage screw

23. Gasket

24. Bushing (3 used)

25. Stand pipe

26. Fuel sender

27. Lock washer (5 used)

28. Phillips head screw (5 used)

135 to 165 ft--lb

(183 to 223 N--m)

29. Fuel hose

30. Hose clamp

31. Elbow fitting (2 used)

32. Fuel cap

33. Locking flange nut (2 used)

34. Speed nut

35. Tank cover (2 used)

36. Phillips head screw (4 used)

37. Vent tube

38. Insulated clip (3 used)

39. Washer head screw (3 used)

40. Hose clamp (4 used)

41. ROPS assembly

Groundsmaster 4000--DPage 3 -- 8Kubota Diesel Engine

Page 25

Fuel Tank Installation (Fig. 7)

DANGER

Becausedieselfuel ishighly 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.

Check Fuel Lines and Connections

Checkfuel lines and connectionsperiodicallyasrecommendedinthe Operator’sManual.Check lines for deterioration, damage, leaking or loose connections. Replace hoses, clamps and connections as necessary.

Empty and Clean Fuel Tank

Empty and clean the fuel tank periodically as recommended in the Operator’s Manual. Also, empty and clean the fuel tank if the fuel system becomes contaminated or if the machine is to be stored for an extended period.

1. Install fuel tank using Figure 7 as a guide. A. Torquetwo(2)flange nuts(item7)thatsecure the

fuel tank to the frame from 60 to 80 in--lb (7 to 9 N--m).

2. Install two (2) tank covers to ROPS assembly.

3. Connect fuel hose to the standpipe and venting

hoses to the elbow fittings.

4. Connect electrical wiring to the sending unit. A. Connect white wire to the center terminal and

black wire to any of the screws that secure the fuel sender to the fuel tank.

B. Apply skin--over grease to the wire terminal connections.

CAUTION

Connecting battery cables to the wrong battery post could result in personal injury and/or damage to the electrical system.

Kubota

Diesel Engine

To clean fuel tank, flush tank out with clean diesel fuel. Make sure tank is free of contaminates and debris.

Fuel Tank Removal (Fig. 7)

1. Park machine on a level surface, lower cutting decks, stop engine, apply parking brake and remove key from the ignition switch.

2. Raise and support operator seat and hood.

3. Remove battery cover and strap. Disconnect negative battery cable first and then positive battery cable. Remove battery from machine.

4. Usea fuel transfer pump toremove fuelfrom the fuel tank and into a suitable container.

5. Disconnect electrical wiring from the sending unit.

6. Disconnectfuelhosefromthestandpipe andventing hoses from elbow fittings in top of tank.

7. Remove phillips head screws that secure two (2) tank covers to ROPS assembly.Remove tank covers.

5. Positionbatteryinmachine.Connectpositivebattery

cable first and then negative battery cable. Install battery strap and cover.

6. Lower seat and hood.

7. Fill fuel tank.

8. Remove fuel tank using Figure 7 as a guide.

Groundsmaster 4000--D Page 3 -- 9 Kubota Diesel Engine

Page 26

Radiator

RIGHT

FRONT

45 54

49 10 60

1. Radiator cap

2. Foam strip (2 used)

3. Foam strip (2 used)

4. Lower radiator hose

5. Upper radiator hose

6. Clamp (4 used)

7. Lower radiator shroud

8. Temperature sender

9. Radiator

10. Hose clamp (3 used)

11.Hose(2used)

12. Screw (4 used)

13. Rubber grommet

14. Flange nut (4 used)

15. Retaining ring (2 used)

16. Knob (2 used)

17. Bulb seal

18. Top radiator support

19. Retaining ring (2 used)

20. Oil cooler bracket

21. Oil cooler

3639

Figure 8

22. Carriage screw (2 used)

23. 90

hydraulic fitting (2 used)

24. Cap screw (6 used)

25. Lock washer (6 used)

26. Oil cooler mount plate (2 used)

27. Upper radiator shroud

28. Flange nut (10 used)

29. Foam plug (2 used)

30. Lock nut (6 used)

31. Foam strip

32. Base bracket

33. Flange head screw (6 used)

34. Bulb seal (2 used)

35. Grommet (2 used)

36. Cover

37. Flange head screw (4 used)

38. Plate (2 used)

39. Flat washer (2 used)

40. Knob (2 used)

41. Cap screw (6 used)

42. Cable tie

43. Coolant reservoir

44. Tank bracket

45. Flat washer (10 used)

46. Foam pad

47. Cap screw (7 used)

48. Foam seal

49. Cap screw (3 used)

50. LH radiator support

51. RH radiator support

52. Flange nut (6 used)

53. Cap screw (6 used)

54. Fan motor bracket

55. Grommet (2 used)

56. Grommet

57. Harness clip

58. R--clamp (2 used)

59. Foam pad

60. Reservoir cap

61. Air cleaner hose

62. Plug

Groundsmaster 4000--DPage 3 -- 10Kubota Diesel Engine

Page 27

Removal (Fig. 8)

Installation (Fig. 8)

1. Park machine on a level surface, lower cutting decks, stop engine, apply parking brake and remove key from the ignition switch.

2. Open and support hood.

CAUTION

Do not open radiator cap or drain coolant if the 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.

3. Drain radiator into a suitable container using the radiator drain. The radiator drain hose is located near the engine oil filter.

4. Disconnectupper and lower radiator hoses fromthe radiator.

5. Remove air cleaner hose (item 61).

6. Disconnect reservoir hose from the vent tube near the radiator cap.

1. Remove all plugs placed during the removal procedure.

2. Carefully position radiator to the support frame. Secure radiator to the support frame with cap screws and flange nuts.

3. Positionlower radiatorshroudandfan motor bracket assembly to the radiator.

4. Secure fan motor bracket to radiator with six (6) flange head screws and flange nuts.

5. Position upper radiator shroud to lower radiator shroud to radiator. Secure shrouds with removed fasteners.

6. Attach radiator shroud assembly to the radiator with cap screws and flat washers. Make sure that clearance between shroud and cooling fan is at least 0.180” (4.6 mm) at all points.

7. Connectreservoir hose to the vent tube near the radiator cap.

8. Connectupperandlowerradiatorhosesto theradiator.

9. Reinstall air cleaner hose (item 61).

Kubota

Diesel Engine

7. Detach upper radiator shroud from the radiator and lower radiator shroud. Remove upper shroud from machine.

8. Removefasteners that secure lower radiatorshroud to radiator.

9. Remove six (6) flange head screws and flange nuts that secure fan motor bracket to radiator.

10.Position lowerradiatorshroudand fan motorbracket assembly away from radiator.

11.Removecapscrewsand flangenutssecuringthe radiator to the support frame. Carefully pull radiator from the machine.

12.Plugallradiatororhoseopeningstopreventcontamination.

10.Make sure radiator drain is closed. Fill radiator with coolant.

11.Close and secure hood.

Groundsmaster 4000--D Page 3 -- 11 Kubota Diesel Engine

Page 28

Engine

RIGHT

FRONT

28 to 32 ft--lb

(38to43N--m)

1. Engine

2. Cap screw (4 used)

3. LH engine mount

4. Lock washer

5. Cap screw

6. Lock washer (5 used)

7. Cap screw (5 used)

8. Engine support (4 used)

9. Flange nut (12 used)

28 to 32 ft--lb

(38to43N--m)

10. Rebound washer (4 used)

11. Cap screw (8 used)

12. Spring coupler

13. Washer (14 used)

14. Cap screw (6 used)

15. Flywheel plate

16. Cap screw (4 used)

17. Cap screw (2 used)

18. Lock washer (2 used)

Engine Removal (Fig. 9)

1. Park machine on a level surface, lower cutting decks, stop engine, apply parking brake and remove key from the ignition switch.

Loctite #242

29 to 33 ft--lb

(40to44N--m)

Figure 9

19. LH engine mount

20. Cap screw (4 used)

21. RH engine mount

22. Cap screw (PTO manifold)

23. Lock washer

24. Ground cable

25. Cap screw

26. Lock washer

27. RH engine mount

2. Remove battery cover and strap. Disconnect negative battery cable first and then positive battery cable. Remove battery from machine.

3. Open and support hood.

Groundsmaster 4000--DPage 3 -- 12Kubota Diesel Engine

Page 29

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.

4. Drain coolant from the radiator into a suitable container (see Radiator Removal in this section). Disconnect upper and lower hoses from the radiator.

CAUTION

The muffler and exhaust pipe may be hot. To avoid possible burns, allow the exhaust system to cool before working on or near the muffler.

5. Remove exhaust system from engine (see Exhaust System Removal in this section).

6. Removeaircleaner system from engine (see Air Filter System Removal in this section).

7. Note location of cable ties used to secure wire harness to the machine. Disconnect wires and/or electrical connections from the following electrical components:

A. The dual temperature switch, temperature sender and alternator (Fig 10).

1. Dual temp switch

2. Temperature sender

1. Glow plug wire

2. Glow plug lead

Figure 10

Figure 11

3. Alternator

3. Cylinder #4 glow plug

Kubota

Diesel Engine

B. The glow plugs (Fig. 11). C. The engine run solenoid (Fig. 12).

D. Battery,frameandwireharness groundattheengine block.

E. The electric starter and low oil pressure switch (near electric starter).

8. Disconnect fuel line from injection pump.

9. Disconnect throttle cable from the speed control lever by removing the flat washer and lock nut (Fig. 13). Loosenjam nut andseparate cable from cable support. Position cable away from engine.

10.Remove fasteners that secure the upper radiator

1. Engine run solenoid

2. Alternator belt

Figure 12

3. Throttle cable

shroud to the lower shroud and radiator (see Radiator Removal in this section). Position coolant reservoir and bracket away from the radiator. Remove upper radiator shroud from machine.

Groundsmaster 4000--D Page 3 -- 13 Kubota Diesel Engine

Page 30

11.Remove fan hub and fan from hydraulic fan motor (Fig. 14).

A. Removehex nut(item9)and washer (item8)that secure fan hub and fan assembly to fan motor.

NOTE: The fan motor shaft is tapered. B. Usesuitablepullertoremove fanhub(with fanat-

tached) from fan motor shaft taking care to not damage fan. Remove fan hub and fan from machine.

12.Remove transport cylinder assembly from engine mount (Fig. 15). It is not necessary to remove the hydraulichose from the cylinder.Locate and remove shim plate(s) from between transport cylinder and engine mount.

IMPORTANT: The hydraulic pump assembly can remain in machine during engine removal. Toprevent pump from shifting or falling, make sure to support pump assembly before mounting fasteners are removed.

13.Support hydraulic pump assembly. Remove fasteners that secure pump assembly to engine (see Pump Assembly Removal in the Service and Repairs section of Chapter 4 -- Hydraulic System).

14.Make sure all cable ties securingthewiringharness, fuellines or hydraulic hoses to the engine are removed.

15.Connect hoist or lift to the lift tabs on engine.

16.Remove flange nuts, rebound washers and cap screws securing the engine mounts to the engine supports.

1. Lock nut

2. Flat washer

3. Throttle lever

4. Lock nut

5. Flange head screw

6. Cap screw

27 to 33 ft--lb

(37to44N--m)

Figure 13

7. Flange head screw

8. Spring washer (2 used)

9. Ball joint

10. Cap screw (2 used)

11. Throttle cable

12. Cable support

CAUTION

One person should operate lift or hoist while another person guides the engine out of the machine.

IMPORTANT: Make sure not to damage the engine, fuel and hydraulic lines, electrical harness or other components while removing the engine.

17.Carefully remove engine assembly from the machine.

18.Ifnecessary,removeengine mountsfromthe engine using Figure 9 as a guide.

Engine Installation (Fig. 9)

1. Ifremoved,installengine mountstothe engineusing Figure 9 as a guide.

2. Connect hoist or lift to the engine lift tabs.

1. Fan motor

2. Cap screw (2 used)

3. Flat washer (2 used)

4. Fan motor bracket

5. Lock nut (2 used)

6. Washer (4 used)

12 to 14 ft--lb

(17to18N--m)

Figure 14

7. Cap screw (4 used)

8. Hex nut

9. Washer

10. Fan hub

11. Fan

Groundsmaster 4000--DPage 3 -- 14Kubota Diesel Engine

Page 31

CAUTION

One person should operate lift or hoist while another person guides the engine into the machine.

IMPORTANT: Make sure not to damage the engine, fuel and hydraulic lines, electrical harness or other parts while installing the engine.

3. Carefully lower engine into the machine.

12.Install aircleanerassembly totheengine (seeAirFilter System Installation in this section).

13.Installexhaustsystemtomachine(seeExhaustSystem Installation in this section).

14.Connect coolant hosestotheradiator.Makesureradiator drain is shut. Fill radiator and reservoir with coolant.

15.Check position of wires, fuel lines, hydraulic hoses andcables for proper clearance with rotating, high temperature and moving components.

4. Align engine to the engine supports and hydraulic pumpinputshaft.Secureenginetoenginesupportswith cap screws, rebound washers and flange nuts.

5. Secure hydraulic pump assembly to engine (see Pump Assembly Installation in the Service and Repairs section of Chapter 4 -- Hydraulic System).

6. Thoroughly clean tapered surfaces of fan motor shaft and fan hub. Position fan hub (with fan attached) onto motor shaft and secure with washer and hex nut (Fig.14). Torquenutfrom27to33ft--lb (37 to 44 N--m).

7. Positionupper radiator shroudandcoolantreservoir withbrackettotheradiator.Secureshroudandreservoir bracket to the radiator and lower radiator bracket with removedfasteners (seeRadiatorInstallationin this section).Make sure thatclearancebetweenshroud and fan is at least 0.180” (4.6 mm) at all points.

8. Connectthrottle cable tothespeedcontrollever with washer and lock nut (Fig. 13). Secure cable to cable support. Adjust throttle cable.

9. Connect fuel line to the injection pump.

10.Install transportcylinderassemblyto engine adapter plate (Fig. 15). Make sure that removed shim(s) are positioned between transport cylinder and engine mount.

11.Connect wires and/or electrical connections to the following electrical components:

A. Thedual temperature switch, temperature sender and alternator (Fig 10).

16.Position battery to machine. Connect positive battery cable first and then negative battery cable. Secure battery to machine with strap and cover.

17.Check and adjust engine oil as needed.

18.Check and adjust hydraulic oil as needed.

19.Bleed fuel system.

20.Start engine and operate hydraulic controls to properlyfill hydraulic system(see Charge Hydraulic System in Chapter 4 -- Hydraulic System).

21.Close and secure hood.

RIGHT FRONT

Figure 15

1. Carriage screw (2 used)

2. Shim

3. Transport cylinder

4. Lock nut (2 used)

5. Piston

6. Backup ring (2 used)

7. O--ring (2 used)

8. Retaining ring

9. Seal

10. O--ring

11. Fitting

12. O--ring

13. Hydraulic hose

14. Engine mount

Kubota

Diesel Engine

B. The glow plug (Fig. 11). C. The engine run solenoid (Fig. 12). D. Battery,frameandwireharness groundtotheen-

gine block. E. The starter and low oil pressure switch (near

starter).

Groundsmaster 4000--D Page 3 -- 15 Kubota Diesel Engine

Page 32

Spring Coupler

RIGHT

FRONT

1. Spring coupler

2. Washer (14 used)

3. Cap screw (6 used)

4. Flywheel plate

5. Cap screw (4 used)

6. LH engine mount

7. Cap screw (2 used)

8. Carriage screw (2 used)

9. Cylinder shim

10. Transport cylinder

11. Lock nut (2 used)

12. Cylinder piston

13. O--ring (2 used)

14. Backup ring (2 used)

Figure 16

28 to 32 ft--lb

(38to43N--m)

15. Retaining ring

16. Seal

17. O--ring

18. Hydraulic fitting

19. O--ring

20. Hydraulic hose

21. RH engine mount

Loctite #242

29 to 33 ft--lb

(40to44N--m)

Groundsmaster 4000--DPage 3 -- 16Kubota Diesel Engine

Page 33

Coupler Removal (Fig. 16) NOTE: The hydraulic pump assembly needs to be re-

moved from engine before coupler can be removed.

1. Ifengine is in machine,supportenginefrom below to prevent it from shifting while removing hydraulic pump assembly (see Piston (Traction) Pump Removal in the Service and Repairs section of Chapter 4 -- Hydraulic System), transport cylinder assembly, flywheel plate, engine mounts and spring coupler.

2. Remove flywheel plate and spring coupler from engine using Figure 16 as a guide.

Coupler Installation (Fig. 16)

1. Position spring coupler to engine flywheel and align mounting holes. Make sure that coupling hub is away from engine flywheel (Fig. 17).

2. Apply Loctite #242 (or equivalent) to threads of cap screws (item 3). Secure coupler to flywheel with six (6) capscrews and washers. Torquecapscrewsin a crossing pattern from 29 to 33 ft--lb (40 to 44 N--m).

Engine Side Hydraulic

Pump Side

Figure 17

1. Coupler 2. Engine flywheel

Kubota

Diesel Engine

3. Positionflywheelplate toengineandenginemounts. Secure flywheel plate and mounts with cap screws (items 5 and 7) and washers using a crossing pattern tightening procedure. Torque cap screws in a crossing pattern from 28 to 32 ft--lb (38 to 43 N--m).

4. Install transport cylinder assembly to engine mount.

5. If engine is in machine, install hydraulic pump assembly (see Piston (Traction) Pump Installation in the Service and Repairs section of Chapter 4 -- Hydraulic System).

Groundsmaster 4000--D Page 3 -- 17 Kubota Diesel Engine

Page 34

This page is intentionally blank.

Groundsmaster 4000--DPage 3 -- 18Kubota Diesel Engine

Page 35

Table of Contents

Chapter 4

Hydraulic System

SPECIFICATIONS 2.............................

GENERAL INFORMATION 3.....................

Operator’s Manual 3..........................

Towing Traction Unit 3.........................

Check Hydraulic Fluid 3.......................

Hydraulic Hoses 4............................

Hydraulic Hose and Tube Installation 5..........

Hydraulic Fitting Installation 6...................

HYDRAULIC SCHEMATIC 8.....................

HYDRAULIC FLOW DIAGRAMS 10...............

Traction Circuit: 4WD (Mow) 10.................

Traction Circuit: Transport (2WD) 12.............

Lower Cutting Deck 14........................

Raise Cutting Deck 16.........................

Mow 18......................................

PTO Mow Circuit Cutting Deck Blade Braking 20..

Steering Circuit 22............................

Engine Cooling Fan Circuit 24..................

SPECIAL TOOLS 26............................

Hydraulic Pressure Test Kit 26..................

Hydraulic Tester (Pressure and Flow) 26.........

Hydraulic Test Fitting Kit 27.....................

Measuring Container 27.......................

TROUBLESHOOTING 28........................

TESTING 31...................................

Traction Circuit Charge Pressure 32.............

Traction Circuit Relief Pressure 34..............

Counterbalance Pressure 36...................

Rear Traction Circuit (RV) Relief Pressure 38.....

Traction Circuit Reducing Valve (PR) Pressure 40.

Cutting Deck Circuit Pressure 42................

PTO Relief Pressure 44........................

Cutting Deck Motor Case Drain Leakage 46......

Cutting Deck Gear Pump Flow 48...............

Steering Circuit Relief Pressure 50..............

Lift/Lower Circuit Relief Pressure 52.............

Steering and Lift/Lower Gear Pump Flow 54......

Engine Cooling Fan Circuit 56..................

Engine Cooling Fan Circuit Gear Pump Flow 58...

ADJUSTMENTS 60.............................

Adjust Front Cutting Deck Lift Flow Control 60....

SERVICE AND REPAIRS 61.....................

General Precautions for Removing and

Installing Hydraulic System Components 61....

Check Hydraulic Lines and Hoses 61............

Flush Hydraulic System 62.....................

Charge Hydraulic System 63...................

Hydraulic Reservoir 64........................

Hydraulic Oil Cooler 66........................

Gear Pump 68................................

Gear Pump Service 70.........................

Traction Circuit 72.............................

Piston

Piston (Traction) Pump Service 76..............

Rear Axle Motor 78...........................

Front Wheel Motor 80.........................

Rear Axle and Front Wheel Motor Service 82.....

4WD Manifold 84.............................

4WD Manifold Service 86......................

Traction (Flow Divider) Manifold 88..............

Traction (Flow Divider) Manifold Service 90.......

Filter Manifold 92.............................

Filter Manifold Service 94......................

Steering and Cooling Fan Circuits 96............

Steering Valve 98.............................

Steering Valve Service 100.....................

Steering Cylinder 102..........................

Steering Cylinder Service 104..................

Engine Cooling Fan Motor 106..................

Engine Cooling Fan Motor Service 108...........

Fan Drive Manifold 112........................

Fan Drive Manifold Service 114.................

PTO Circuit 116...............................

Cutting Deck Motor 117........................

Cutting Deck Motor Service 118.................

PTO Manifold 122.............................

PTO Manifold Service 124......................

Lift/Lower Circuit 126..........................

Lift/Lower Control Valve 128....................

Lift/Lower Control Valve Service 130.............

Side Deck Lift Cylinder 132.....................

Front Deck Lift Cylinder 134....................

Lift Cylinder Service 136.......................

Counterbalance Manifold 138...................

Counterbalance Manifold Service 140............

EATON MODEL 72400 SERVO CONTROLLED PIS-

TON PUMP REPAIR INFORMATION

EATON MODEL 74318 and 74348 PISTON MOTORS:

FIXED DISPLACEMENT, VALVE PLA TE DESIGN REPAIR INFORMATION

(Traction) Pump 74......................

System

Hydraulic

Groundsmaster 4000--D Hydraulic SystemPage 4 -- 1

Page 36

Specifications

Item Description

Piston (Traction) Pump Eaton Variable Displacement Piston Pump

System Relief Pressure: Forward 4000 PSI (274 bar) System Relief Pressure: Reverse 5000PSI (343 bar) Charge Pressure 250 PSI (17 bar)

Front Wheel Motors Eaton Fixed Displacement Piston Motors

Rear Axle Motor Eaton Fixed Displacement Piston Motor

Gear Pump Casappa 4 Section, Positive Displacement Gear pump

Section P1/P2 Displacement (per revolution) 1.16 Cubic Inches (19.09 cc) Section P3/P4 Displacement (per revolution) 0.56 Cubic Inches (9.16 cc)

Steering Control Valve Eaton Steering Unit, Series 5

Steering Circuit Relief Pressure 1350 PSI (93 bar)

Lift/Lower Circuit Relief Pressure 1500 PSI (103 bar)

Cutting Deck Motors Sauer Danfoss Gear Motor

PTO Circuit Relief Pressure

Front and Left Side 3000 PSI (207 bar) Right Side 2000 PSI (137 bar)

(Model 72400)

(Model 74318)

(Model 74315)

Engine Cooling Fan Motor Casappa Gear Motor

Displacement (per revolution) 0.50 Cubic Inches (8.3 cc)

Engine Cooling Fan Circuit Relief Pressure 3000 PSI (207 bar)

Hydraulic Filters Spin--on Cartridge Type

In--line Suction Strainer 100 Mesh (In Reservoir)

Hydraulic Reservoir 8 U.S. Gallons (30.3 Liters)

Hydraulic Oil See Operator’s Manual

Groundsmaster 4000--DHydraulic System Page 4 -- 2

Page 37

General Information

Operator’s Manual

Towing Traction Unit

IMPORTANT: If towing limits are exceeded, severe damage to the piston pump may occur.

If it becomes necessary to tow (or push) the machine, tow (or push) in a forward direction only and at a speed below 3 mph. The piston (traction) pump is equipped with a by--pass valve that needs to be turned

(one quarter turn) for towing. Refer to your Opera-

90 tor’s Manual for additional towing instructions.

System

Hydraulic

Check Hydraulic Fluid

The Groundsmaster 4000--D hydraulic system is designed to operate on anti--wear hydraulic fluid. The reservoir holds about 8 gallons (30.3 liters) of hydraulic fluid. Check level of hydraulic fluid daily. See Operator’s Manual for fluid level checking procedure and oil recommendations.

Figure 1

1. By--pass valve location

Figure 2

1. Hydraulic reservoir cap

Groundsmaster 4000--D Hydraulic SystemPage 4 -- 3

Page 38

Hydraulic Hoses

Hydraulichoses are subject to extremeconditions such aspressuredifferentialsduring operationandexposure to weather, sun, chemicals, very warm storage conditionsormishandlingduring operationandmaintenance. These conditions can cause hose damage and deterioration. Some hoses are more susceptible to these conditions than others. Inspect all machine hydraulic hoses frequently for signs of deterioration or damage:

WARNING

Beforedisconnectingorperformingany work on hydraulic system, relieve all pressure in system. Operate all hydraulic controls to relieve system pressure.

Hard, cracked, cut, abraded, charred, leaking or otherwise damaged hose.

Kinked, crushed, flattened or twisted hose. Blistered, soft, degraded or loose hose cover. Cracked, damaged or badly corroded hose fittings.

When replacing a hydraulic hose, be sure that the hose is straight (not twisted) before tightening the fittings. This can be done by observing the imprint (layline) on thehose. Usetwo wrenches; hold the hose straight with one wrench and tighten the hose swivel nut onto the fitting with the other wrench ( See Hydraulic Hose and Tube Installation in this section). If the hose has an elbowat oneend,tightenthe swivelnutonthat endbefore tightening the nut on the straight end of the hose.

For additional hydraulic hose information, refer to Toro Service Training Book, Hydraulic Hose Servicing (Part Number 94813SL).

Keepbodyand handsaway frompinholeleaksor 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 withthis typeofinjury.Gangrenemayresult from such an injury.

Groundsmaster 4000--DHydraulic System Page 4 -- 4

Page 39

Hydraulic Hose and Tube Installation (O--Ring Face Seal Fitting)

1. Makesure threads and sealing surfaces of the hose/ tube and the fitting are free of burrs, nicks, scratches or any foreign material.

2. Asa preventative measure against leakage, it is recommended that the face seal O--ring be replaced any time the connection is opened. Make sure the O--ring is installedandproperly seatedinthefittinggroove.Lightly lubricate the O--ring with clean hydraulic oil.

3. Place the hose/tube against the fitting body so that theflatfaceofthehose/tube sleevefullycontactstheO-ring in the fitting.

4. Thread the swivel nut onto the fitting by hand. While holding the hose/tube with a wrench, use a torque wrench to tighten the swivel nut to the recommended installation torque shown in Figure 5. This tightening process will require the use of an offset wrench (e.g. crowfoot wrench). Use of an offset wrench will affect torque wrench calibration due to the effective length change of the torque wrench. Tightening torque when usingatorquewrenchwithanoffsetwrenchwillbelower than the listed installation torque (see Using a Torque Wrench with an Offset Wrench in the Torque Specificationssection of Chapter 2 --Product Records and Maintenance).

C. Useasecondwrench totightenthenut tothecorrect Flats From Wrench Resistance (F.F.W.R.).The markingsonthe nutandfittingbodywillverifythatthe connection has been properly tightened.

Siz e F.F.W.R.

4 (1/4 in. nominal hose or tubing) 1/2 to 3/4 6 (3/8 in.) 1/2 to 3/4 8 (1/2 in.) 1/2 to 3/4 10 (5/8 in.) 1/2 to 3/4 12 (3/4 in.) 1/3 to 1/2 16 (1 in.) 1/3 to 1/2

Swivel Nut

Tube or Hose

O--ring

Fitting Body

Figure 3

System

Hydraulic

5. If a torque wrench is not available or if space at the swivelnut prevents use of a torquewrench,analternate method of assembly is the Flats From Wrench Resist-

Mark Nut

and Fitting

Body

Final

Position

ance (F.F.W.R.) method (Fig. 2).

A. Usingawrench,tighten the swivelnutonto thefittinguntillightwrench resistanceisreached (approximately 30 in--lb).

B. Mark the swivel nut and fitting body. Hold the hose/tube with a wrench to prevent it from turning.

AT WRENCH RESISTANCE

Extend Line

Figure 4

Fitting Dash Size Hose/Tube Side Thread Size Installation Torque

4 9/16 -- 18 18to22ft--lb(25to29N--m) 6 11/16 - - 16 27to33ft--lb(37to44N--m)

8 13/16 -- 16 37to47ft--lb(51to63N--m) 10 1--14 60 to 74 ft--lb (82 to 100 N--m) 12 13/16--12 85 to 105 ft--lb (116 to 142 N--m) 16 17/16--12 110 to 136 ft--lb (150 to 184 N--m)

Initial Position

AFTER TIGHTENING

20 1 11/16 -- 12 140 to 172 ft--lb (190 to 233 N--m)

Figure 5

Groundsmaster 4000--D Hydraulic SystemPage 4 -- 5

Page 40

Hydraulic Fitting Installation (SAE Straight Thread O--Ring Fitting into Component Port)

Non--Adjustable Fitting (Fig. 6)

1. Make sure all threads and sealing surfaces of fitting and component port are free of burrs, nicks, scratches or any foreign material.

2. Asa preventative measure against leakage, it is recommended that the O--ring be replaced any time the connection is opened.

3. Lightly lubricate the O--ring with clean hydraulic oil. Fittingthreadsshouldbecleanwith nolubricantapplied.

IMPORTANT: Before installing fitting into port, determine port material. If fitting is to be installed into an aluminum port, installation torque is reduced.

4. Install the fitting into the port. Then, use a torque wrench and socket to tighten the fitting to the recommended installation torque shown in Figure 7.

NOTE: Useof an offset wrench (e.g. crowfoot wrench) will affect torque wrench calibration due to the effective length change of the torque wrench. Tightening torque when using a torque wrench with an offset wrench will be less than the recommended installation torque. See Using a Torque Wrench with an Offset Wrench in the Torque Specifications section of Chapter 2 -- Product Recordsand Maintenancetodetermine necessary conversion information.

5. If a torque wrench is not available, or if space at the portpreventsuseof atorquewrench, analternatemethod of assembly is the Flats From Finger Tight (F.F.F.T.) method.

A. Install the fitting into the port and tighten it down full length until finger tight.

B. If port material is steel, tighten the fitting to the listed F.F.F.T.If port material is aluminum, tighten fitting to 60% of listed F.F.F.T.

Siz e F.F.F.T.

4 (1/4 in. nominal hose or tubing) 1.00 + 6(3/8in.) 1.50+ 8(1/2in.) 1.50+ 10 (5/8 in.) 1.50 + 12 (3/4 in.) 1.50 + 16 (1 in.) 1.50 +

Fitting

O--ring

0.25

Figure 6

Fitting

Dash Size

Fitting Port Side

Thread Size

Installation Torque Into

Steel Port

Installation Torque Into

Aluminum Port

4 7/16 -- 20 15to19ft--lb(21to25N--m) 9to11ft--lb(13to15N--m) 5 1/2 -- 20 18to22ft--lb(25to29N--m) 11to15ft--lb(15to20N--m) 6 9/16 -- 18 34to42ft--lb(47to56N--m) 20to26ft--lb(28to35N--m)

8 3/4 -- 16 58to72ft--lb(79to97N--m) 35to43ft--lb(48to58N--m) 10 7/8 -- 14 99 to 121 ft--lb (135 to 164 N--m) 60 to 74 ft--lb (82 to 100 N--m) 12 11/16--12 134 to 164 ft--lb (182 to 222 N--m) 81 to 99 ft--lb (110 to 134 N--m) 14 13/16--12 160 to 196 ft--lb (217 to 265 N--m) 96 to 118 ft--lb (131 to 160 N--m) 16 15/16--12 202 to 248 ft--lb (274 to 336 N--m) 121 to 149 ft--lb (165 to 202 N--m) 20 15/8--12 247 to 303 ft--lb (335 to 410 N--m) 149 to 183 ft--lb (202 to 248 N--m)

Figure 7

Groundsmaster 4000--DHydraulic System Page 4 -- 6

Page 41

Adjustable Fitting (Fig. 8)

1. Make sure all threads and sealing surfaces of fitting and component port are free of burrs, nicks, scratches or any foreign material.

2. Asa preventative measure against leakage, it is recommended that the O--ring be replaced any time the connection is opened.

3. Lightly lubricate the O--ring with clean hydraulic oil. Fittingthreadsshouldbecleanwith nolubricantapplied.

4. Turnback the lock nut as far as possible. Make sure the back up washer is not loose andis pushed up as far as possible (Step 1 in Figure 9).

IMPORTANT: Before installing fitting into port, determine port material. If fitting is to be installed into an aluminum port, installation torque is reduced.

Lock Nut

Back--up Washer

O--ring

Figure 8

5. Install the fitting into the port and tighten finger tight until the washer contacts the face of the port (Step 2).

6. Toput the fitting in the desired position,unscrew itby the required amount, but no more than one full turn (Step 3).

7. Hold the fitting in the desired position with a wrench and use a torque wrench to tighten the fitting to the recommended installation torque shown in Figure 7. This tightening process will require the use of an offset wrench (e.g. crowfoot wrench). Use of an offset wrench will affect torque wrench calibration due to the effective length change of the torque wrench. Tightening torque when using a torque wrench with an offset wrench will be lower than the listed installation torque (see Using a Torque Wrench with an Offset Wrench in the Torque Specifications section of Chapter 2 -- Product Records and Maintenance).

8. If a torque wrench is not available, or if space at the portpreventsuseof atorquewrench, analternatemethod of assembly is the Flats From Finger Tight (F.F.F.T.) method. Hold the fitting in the desired position with a wrench and, if port material is steel, tighten the lock nut witha secondwrenchtothe listedF.F.F.T(Step 4).Ifport material is aluminum, tighten fitting to 60% of listed F.F.F.T.

Step 3Step 1

Step 2 Step 4

Figure 9

System

Hydraulic

Siz e F.F.F.T.

4 (1/4 in. nominal hose or tubing) 1.00 + 6(3/8in.) 1.50+ 8(1/2in.) 1.50+ 10 (5/8 in.) 1.50 + 12 (3/4 in.) 1.50 + 16 (1 in.) 1.50 +

0.25

Groundsmaster 4000--D Hydraulic SystemPage 4 -- 7

Page 42

Hydraulic Schematic

COUNTERBALANCE

MANIFOLD

TRACTION

4WD

MANIFOLD

FILTER

MANIFOLD

VALVE

BYPASS

NOTE: A larger hydraulic schematic is

included in Chapter 9: Foldout Drawings

MANIFOLD

FAN DRIVE

M1 M2 ST L

LC1

RV1

MANIFOLD

RV2

FRONT PTO

LC2

LC1

RV1

LH PTO

MANIFOLD

RV2

LC2

RV1

RH PTO

RV2

MANIFOLD

P1 P2T

LC1

LC2

Groundsmaster 4000--DHydraulic System Page 4 -- 8

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System

Hydraulic

Groundsmaster 4000--D Hydraulic SystemPage 4 -- 9

Page 44

Hydraulic Flow Diagrams

COUNTERBALANCE

MANIFOLD

4WD

MANIFOLD

TRACTION

Traction Circuit (4WD Forward Shown)

Groundsmaster 4000--D

Working Pressure

Low Pressure (Charge)

Flow

Return or Suction

MANIFOLD

FAN DRIVE

M1 M2 ST L

LC1

RV1

MANIFOLD

RV2

FRONT PTO

LC2

LC1

RV1

LH PTO

MANIFOLD

RV2

LC2

RV1

RH PTO

MANIFOLD

RV2

P1 P2T

LC1

LC2

Groundsmaster 4000--DHydraulic System Page 4 -- 10

Page 45

Traction Circuit: 4WD (Mow)

The traction circuit piston pump is a variable displacement pump that is directly coupled to the engine flywheel. Pushing the traction pedal engages a hydraulic servo valve which controls the variable displacement piston pump swash plate to create a flow of oil. This oil isdirectedtothefrontwheeland rearaxlemotors.Operating pressure on the high pressure side of the closed traction circuit loop is determined by the amount of load developedatthefixeddisplacementwheelandaxlemotors. As the load increases, circuit pressure can increase to relief valve settings: 4000 PSI (274 bar) in forward and 5000 PSI (343 bar) in reverse. If pressure exceeds the relief setting, oil flows through the relief valveto the low pressure side of the closed loop traction circuit. The traction circuit provides operation in either 4WD (mow) or transport (2WD).

Traction circuit pressure (forward and reverse) can be measured at test ports on the sides of the machine.

The traction circuit pump and motors use a small amount of hydraulic fluid for internal lubrication. Fluid is designed to leak across traction pump and motor components into the case drain. This leakage results in the lossofhydraulicfluidfromtheclosedloop tractioncircuit thatmust be replaced. Thecharge circuit is designed to replace this traction circuit leakage.

The gear pump section that supplies oil to the steering andlift/lower circuits alsoprovides oil forthe charge circuit. This gear pump is driven directly off the traction pump. It provides a constant supply of charge oil to make up for oil that is lost due to internal leakage in the traction pump and motors.

Pump flow for the charge circuit is directed through the oil filter and to the low pressure side of the closed loop traction circuit. A filter bypass valve allows charge oil flow to the closed loop if the filter becomes plugged. Chargepressure is limitedto 250 PSI (17 bar) by a relief valve located in the oil filter manifold. Charge pressure canbe measured at thechargecircuitpressuretestport on the oil filter manifold.

Aflowdividerisincorporatedintothetractioncircuitand islocated in the tractionmanifold. When in 4WD (mow), the operator can momentarily engage this flow divider when low traction situations could lead to wheel spin. Depressing the flow divider switch energizes the solenoid valve in the traction manifold. This energized solenoid valve causes traction pump hydraulic flow to split between the front wheel motors (approximately 45%) and rear axle motor (approximately 55%) to reduce the chance that excessive flow goes to a spinning wheel.

Forward Direction

When the transport/4WD switch is in the 4WD (mow) position and the traction pedal is pushed in the forward direction, oil from the piston pump passes through the tractionmanifold. Oil flow from traction manifold portM1 drives the front wheel motors in the forward direction and then returns to the hydrostat. Oil flow from traction manifold port M2 is routed to the P1 port of the 4WD manifoldwhereitisdirectedtothePD1cartridgeandout ofthe manifoldtodrivethe rearaxlemotorin theforward direction.Oil returning fromtherear motor re--entersthe 4WD manifold at the M2 port. Flow passes through the PD2cartridge,throughtheCVcheck valve,outmanifold port P2 and back to the hydrostat.

When going down a hill, the tractor becomes an over-running load that drives the wheel and axle motors. In this condition, the rear axle motor could lock up as the oil pumped from the motor increases pressure as it returnsto the hydrostat. Toprevent rear wheel lock up, an adjustable relief valve (RV) in the 4WD manifold reducesrear axle motor pressure created indown hill, dynamic braking conditions.

Reverse Direction

The traction circuit operates essentially the same in reverse 4WD (mow) as it does in the forward direction. However,theflowthroughthecircuitisreversed.Oilflow from the hydrostat is directed to the front wheel motors and also to the 4WD manifold. The oil to the front wheel motorsdrives them in the reverse direction and then returnstothehydrostatthroughthe traction manifold. The oil to the 4WD manifold enters the manifold at port P2 and flows through pressure reducing valve (PR) which limits the down stream pressure to the rear axle motor to 650 PSI (45 bar) so the rear wheels will not scuff the turf during reverse operation. This reduced pressure flows through the PD2 cartridge and out port M2 to the rearaxle motor.Return oil fromtherearmotor re--enters the4WDmanifoldat portM1,flowsthroughthePD1cartridge,exitsthemanifold atportP1andreturns tothehydrostat.

System

Hydraulic

Groundsmaster 4000--D Hydraulic SystemPage 4 -- 11

Page 46

COUNTERBALANCE

MANIFOLD

(shifted)

(energized)

(extended)

4WD

MANIFOLD

TRACTION

Traction Circuit (Transport Forward Shown)

Groundsmaster 4000--D

Working Pressure

Low Pressure (Charge)

Flow

Return or Suction

MANIFOLD

FAN DRIVE

M1 M2 ST L

LC1

RV1

MANIFOLD

RV2

FRONT PTO

LC2

LC1

RV1

LH PTO

MANIFOLD

RV2

LC2

RV1

RH PTO

MANIFOLD

RV2

P1 P2T

LC1

LC2

Groundsmaster 4000--DHydraulic System Page 4 -- 12

Page 47

Traction Circuit: Transport (2WD)

Traction circuit pressure (forward and reverse) can be measured at test ports on the sides of the machine.

The gear pump section that supplies oil to the steering and lift/lower circuits also provides charge oil for the traction circuit. This gear pump is driven directly off the tractionpump.Itprovidesaconstantsupplyof chargeoil to the traction circuit to make up for oil that is lost due to internal leakage in the traction pump and motors.

Chargepumpflowisdirected through the oil filter and to the low pressure side of the closed loop traction circuit. A filter bypass valve allows charge oil flow to the closed loopif thefilter becomesplugged.Chargepressureislimited to 250 PSI (17 bar) by a relief valve located in the oil filter manifold. Charge pressure can be measured at thechargecircuit pressure test port on theoilfiltermanifold.

Forward Direction

Withthe transport/4WD switch in the transport position, solenoidvalve (SV) in the 4WD control manifold is energized. The solenoid valve spool shifts to direct charge pressure that shifts the PD1 and PD2 control valve spools. The shifted PD1 valve prevents hydraulic flow from the piston pump to the rear axle motor. With flow blocked to the rear axle motor,all pump flow is directed to the front wheel motors to allow a higher transport speed in the forward direction.

Without flow to the rear axle motor, the rotating rear wheels drive the axle motor so it acts like a pump. Inlet oilto the axle motor isprovided by a checkvalve that allows charge oil into the rear axle motor circuit. Oil leaving the axle motor enters the 4WD control manifold at port M2 and is directed back to the axle motor through theshifted PD1 cartridge and manifold portM1.Toallow forrearwheelloopcoolingwheninforward transportoperation, a small amount of oil exits through the shifted PD1 and PD2 cartridges that returns to the reservoir.

A transport cylinder is included in the traction circuit to reduce traction control arm movement on the piston pumpwhen operating intransport (2WD). This reduced armmovement limitsswashplaterotation to preventexcessive transport speed.

Thetraction manifoldflowdividercannot beengagedby the operator during transport (2WD) operation.

Reverse Direction

The traction circuit operates essentially the same in reversetransport(2WD)asitdoesintheforwarddirection. However, the flow through the circuit is reversed. The shifted solenoid valve (SV) and directional valves PD1 and PD2 in the 4WD manifold prevent oil flow from the rear axle motor.Oil flow from the hydrostat is therefore directed to only the front wheel motors. This oil drives the front wheel motors in the reverse direction and then returns to the hydrostat. Oil circulation through the rear axle motor loop is the same as in the transport (2WD) forward direction.

System

Hydraulic

Groundsmaster 4000--D Hydraulic SystemPage 4 -- 13

Page 48

COUNTERBALANCE

MANIFOLD

4WD

MANIFOLD

TRACTION

Groundsmaster 4000--D

Working Pressure

Low Pressure (Charge)

Lower Cutting Unit (LH Deck Shown)

Flow

Return or Suction

MANIFOLD

FAN DRIVE

M1 M2 ST L

LC1

RV1

MANIFOLD

RV2

FRONT PTO

LC2

LC1

RV1

LH PTO

MANIFOLD

RV2

LC2

RV1

RH PTO

MANIFOLD

RV2

P1 P2T

LC1

LC2

Groundsmaster 4000--DHydraulic System Page 4 -- 14

Page 49

Lower Cutting Deck

A four section gear pump is coupled to the piston (traction) pump. The third gear pump section supplies hydraulic flow to both the lift/lower control valve and the steering control valve. Hydraulic flow from this pump section is delivered to the steering and lift/lower circuits through a proportional flow divider that is located in the fan drive manifold. This pump section takes its suction from the hydraulic reservoir.

Whenthecutting decks are in a stationaryposition,flow from the gear pump is by--passed through the lift/lower control valve, counterbalance manifold, oil filter and traction charge circuit.

Tolower a side cuttingdeck, the appropriate liftlever on the lift/lower control valve is pushed to allow valve shift in the lift/lower control valve. This valve change causes a valve shift in the counterbalance manifold and oil flow to the rod end of the lift cylinder.Higher hydraulic pressureagainsttherodend ofthecylinder causes thecylinder shaft to retract, and lower the cutting deck. Oil from the piston end of the cylinder returns to the traction chargecircuit. When the liftlever is released, the lift cylinder and side cutting deck are held in position.

Tolower the frontcuttingdeck,the center lift lever onthe lift/lowercontrolvalveispushedtoallowvalveshiftinthe lift/lowercontrol.Thisvalvechangeallowsapassagefor oil flow from the rod end of the front deck lift cylinders. The weight of the cutting deck causes the lift cylinders to extend, and lower the cutting deck. Oil from the rod end of the cylinders is allowed to return to the traction chargecircuit. When the liftlever is released, the lift cylinders and cutting deck are held in position.

The drop speed of the front cutting deck is regulated by anadjustableflow control valve that is locatedin the hydraulic lines between the lift/lower control valve and the front deck lift cylinders.

Anadjustablecounterbalancevalve(CB)inthecounterbalance manifold maintains back pressure on the deck lift cylinders to allow some of the cutting deck weight to be transferred to the traction unit to improve traction. A reliefvalve locatedinthelift/lower controlvalvelimitslift/ lowercircuitpressure to 1500 PSI (103 bar). Excess circuit flow is routed to the oil filter and then to the traction charge circuit.

System

Hydraulic

Groundsmaster 4000--D Hydraulic SystemPage 4 -- 15

Page 50

COUNTERBALANCE

MANIFOLD

4WD

MANIFOLD

TRACTION

Groundsmaster 4000--D

Working Pressure

Low Pressure (Charge)

Raise Cutting Unit (LH Deck Shown)

Flow

Return or Suction

MANIFOLD

FAN DRIVE

P1 P2T

M1 M2 ST L

LC1

RV1

MANIFOLD

RV2

FRONT PTO

LC2

LC1

RV1

LH PTO

MANIFOLD

RV2

LC2

LC1

RV1

RH PTO

MANIFOLD

RV2

LC2

Groundsmaster 4000--DHydraulic System Page 4 -- 16

Page 51

Raise Cutting Deck

A four section gear pump is coupled to the piston (traction) pump. The third gear pump section supplies hydraulicflowtothelift/lowercontrolvalveandthesteering control valve. Hydraulic flow from this pump section is delivered to the two circuits through a proportional flow divider. The gear pump takes its suction from the hydraulic reservoir.

Whenthecutting decks are in a stationaryposition,flow from the gear pump is by--passed through the lift/lower control valve, counterbalance manifold, oil filter and traction charge circuit.

To raise a side cutting deck, the appropriate lift lever on thelift/lower control valve is pulled to allow valveshift in thelift/lowercontrol valve. This valve changeallows hydraulic pressure to the piston end of the lift cylinder and causes the cylinder shaft to extend, raising the cutting deck. Oil from the rod end of the cylinder flows to the tractionchargecircuit.Whentheliftleverisreleased,the lift cylinder and cutting deck are held in position.

Toraisethe front cutting deck, the centerliftleveron the lift/lower control valve is pulled to allow valve shiftin the lift/lower control valve. This valve change allows hydraulicpressuretotherod end of the front deck lift cylinders, causing the cylinders to retract. As the cylinders retract, the front deck raises. Oil from the piston end of the cylinders returns to the hydraulic reservoir. When theliftleverisreleased,theliftcylinders andcuttingdeck are held in position.

System

Hydraulic

Groundsmaster 4000--D Hydraulic SystemPage 4 -- 17

Page 52

COUNTERBALANCE

MANIFOLD

4WD

MANIFOLD

TRACTION

Mow (Front Deck Shown)

Groundsmaster 4000--D

Working Pressure

Low Pressure (Charge)

Flow

Return or Suction

MANIFOLD

FAN DRIVE

M1 M2 ST L

LC1

RV1

MANIFOLD

RV2

FRONT PTO

LC2

LC1

RV1

LH PTO

MANIFOLD

RV2

LC2

RV1

RH PTO

MANIFOLD

RV2

P1 P2T

LC1

LC2

Groundsmaster 4000--DHydraulic System Page 4 -- 18

Page 53

Mow

Hydraulicflow for themowcircuitis supplied by twosections of the gear pump. The gear pump section closest to the piston (traction) pump supplies hydraulic flow to theside 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 solenoid control valve (S), bypass cartridge (LC1), brake cartridge (LC2) and relief cartridge (RV1).Whenthethedeck solenoidvalve(S)is not energized (PTO switch OFF), hydraulic flow by--passes the deck motor through the bypass cartridge (LC1). When the PTO switch is turned ON, the solenoid valve (S) energizes, causing a shift of the by--pass cartridge (LC1) andallowinghydraulicflowtothe deckmotor.Brakecartridge (LC2) and relief cartridge (RV2) control the stoppingrate of theblade when thesolenoid control valveis de--energized as the PTO switch is turned OFF.

Returnoilfromthedeckmotorsisdirectedtotheoilcooler and oil filter. Deck motor case drain leakage returns to the hydraulic reservoir.

Maximum mow circuit pressure is limited at each deck by a relief valve (RV1) in the hydraulic manifold. The front and left deck relief valves are setat 3000 PSI (207 bar)andtherightdeckreliefvalveissetat2000PSI(137 bar).

Circuit pressure can be measured at port (G) of the hydraulic manifold for each cutting deck.

System

Hydraulic

Groundsmaster 4000--D Hydraulic SystemPage 4 -- 19

Page 54

PTO Mow Circuit Cutting Deck Blade Braking

WhentheoperatorturnsthePTOswitchOFForifadeck is raised with the PTO switch ON, PTO control manifold solenoid valve (S) is de--energized causing logic cartridge(LC1)toshift(refertoinformationinPTOMowCircuit in this section). This shifted cartridge allows oil return out manifold port P2. At the same time, solenoid valve (S) in its neutral position prevents any sense line flow through the spool which causes the logic cartridge LC2 to shift to its neutral position blocking return flow fromthe deck motor andslowingthecuttingblades (Fig.

10). Theinertiaofthe rotatingcuttingblades,however,effec-

tively turns the deck motor into a pump causing an increasein pressure as theflow from the motor comesup againsttheclosed logiccartridge(LC2).Whenthispressure builds to approximately 600 PSI (41 bar), relief valve (RV2) opens which allows a small amount of hydraulic flow to return to tank througha manifold sensing line (Fig. 11). This flow causes a pressure increase that shifts logic cartridge LC2 to once again allow oil flow from the motor (Fig. 12). When return pressure drops below 600 PSI (41 bar), relief valve (RV2) reseats and causesLC2 to close again blocking return flow from the deckmotortofurther slowthecuttingblades.This action of the brake relief valveopening and the logic cartridge shifting occurs several times in a very short time frame as the blades finally come to a stop. Once the blades havestopped, logiccartridgeLC2remains in theneutral position to keep the deck motor from rotating.

DECK MOTOR

PTO MANIFOLD

RV2

PTO MANIFOLD

RV2

RV1

LC2

Figure 10

RV1

LC2

LC1

DECK MOTOR

PTO MANIFOLD

RV2

Figure 11

RV1

LC2

Figure 12

LC1

Groundsmaster 4000--DHydraulic System Page 4 -- 20

Page 55

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System

Hydraulic

Groundsmaster 4000--D Hydraulic SystemPage 4 -- 21

Page 56

COUNTERBALANCE

MANIFOLD

4WD

MANIFOLD

TRACTION

Groundsmaster 4000--D

Working Pressure

Low Pressure (Charge)

Steering Circuit (Left Turn Shown)

Flow

Return or Suction

MANIFOLD

FAN DRIVE

M1 M2 ST L

LC1

RV1

MANIFOLD

RV2

FRONT PTO

LC2

LC1

RV1

LH PTO

MANIFOLD

RV2

LC2

RV1

RH PTO

MANIFOLD

RV2

P1 P2T

LC1

LC2

Groundsmaster 4000--DHydraulic System Page 4 -- 22

Page 57

Steering Circuit

A four section gear pump is coupled to the piston (traction) pump. The third gear pump section supplies hydraulicflowtothesteeringcontrolvalveandthelift/lower controlvalve.Pumphydraulicflowisdelivered tothe two circuitsthroughaproportionalflow dividerlocated in the fandrive manifold.Thegearpump takesitssuctionfrom thehydraulicreservoir.Steering circuit pressure is limited to 1350 PSI (93 bar) by a relief valve located in the steering control.

With the steering wheel in the neutral position and the enginerunning, flow enters thesteering control valve at the P port and goes through the steering control spool valve, by--passing the rotary meter (V1) and steering cylinder. Flow leaves the control valve through the PB port to the oil filter and traction charge circuit.

Left Turn

When a left turn is made with the engine running, the turningofthesteeringwheelpositionsthespoolvalveso thatflowgoesthroughthetopofthespool.Flowentering thesteering control valve at the P port goes throughthe spool and is routed to two places. First, most of the flow through the valve is by --passed out the PB port back to the oil filter and traction charge circuit. Second, the remainder of the flow is drawn through the rotary meter (V1) and out the L port. Pressure contracts the steering cylinder piston for a left turn. The rotary meter ensures

that the oil flow to the cylinder is proportional to the amount of the turning on the steering wheel. Fluid leavingthe cylinder flows back through the spool valvethen through the T port and to the hydraulic reservoir.

Thesteeringcontrolvalvereturnstotheneutralposition when turning is completed.

Right Turn

When a right turn is made with the engine running, the turningofthesteeringwheelpositionsthespoolvalveso thatflow goes through thebottom of the spool.Flow entering the steering control valve at the P port goes throughthe spool and is routed to twoplaces.Asinaleft turn,mostoftheflow throughthevalveis by--passed out the PB port back to the oil filter and traction charge circuit. Also like a left turn, the remainder of the flow is drawn through rotary meter (V1) but goes out port R. Pressureextends the steering cylinder piston for a right turn.The rotary meterensuresthattheoil flow to thecylinder is proportional to the amount of the turning on the steering wheel. Fluid leaving the cylinder flows back through the spool valve then through the T port and to the hydraulic reservoir.

Thesteeringcontrolvalvereturnstotheneutralposition when turning is completed.

System

Hydraulic

STEERING CYLINDER

NO PISTON MOVEMENT

NEUTRAL POSITION

1350 PSI

STEERING CONTROL

STEERING CYLINDER

PISTON MOVEMENT

LEFT TURN

1350 PSI

Figure 13

STEERING CONTROL

STEERING CYLINDER

PISTON MOVEMENT

RIGHT TURN

1350 PSI

STEERING CONTROL

Groundsmaster 4000--D Hydraulic SystemPage 4 -- 23

Page 58

COUNTERBALANCE

MANIFOLD

4WD

MANIFOLD

TRACTION

Groundsmaster 4000--D

Working Pressure

Low Pressure (Charge)

Engine Cooling Fan Circuit (Forward Direction Shown)

Flow

Return or Suction

MANIFOLD

FAN DRIVE

M1 M2 ST L

LC1

RV1

MANIFOLD

RV2

FRONT PTO

LC2

LC1

RV1

LH PTO

MANIFOLD

RV2

LC2

RV1

RH PTO

MANIFOLD

RV2

P1 P2T

LC1

LC2

Groundsmaster 4000--DHydraulic System Page 4 -- 24

Page 59

Engine Cooling Fan Circuit

A four section gear pump is coupled to the piston (traction)pump. Thegearpump sectionfarthestfrom thepiston pump supplies hydraulic flow for the fan drive manifold and hydraulic engine cooling fan motor (Fig.

14). The fan drive manifold controls the operation of the hy-

draulic motor that drives the engine cooling fan in addition to including the flow divider for the steering and lift circuits. The electronically controlled proportional relief valve(PRV)inthemanifoldcontrolstheoilflowtothefan motor.Thefandrivemanifoldcontrols the speed and direction of the fan motor based on electrical output from the TEC--5002 controller.

Oil flow from the gear pump to the cooling fan motor is controlled by the proportional relief valve (PRV) in the fan drive manifold. This valve adjusts fan circuit pressure and flow based on a PWM (Pulse Width Modulation)signalfromtheTEC--5002controller.Thecontroller uses engine coolant and hydraulic oil temperatures as inputstodeterminetheproperPWMsignalfor the(PRV) valve. The fan circuit flow determines the speed of the coolingfan motor and thus, the speed ofthecoolingfan.

If the fan motor is stalled for any reason, the manifold proportionalreliefvalve(PRV) hasasecondary function as a circuit relief to limit fan motor pressure to 3000 PSI (207 bar).

When the engine is shut off, the over--running inertia load of the fan blades keeps driving the fan motor and turnsitintoapump.Thecheckvalve(CV)inthefandrive manifold will open to keep the motor circuit full of oil so the fan motor will not cavitate.

Forward Direction Fan Operation

runsin thereversedirection. A lowerPWMsignal is sent tothe PRVvalveallowingoilflowtoreturntothe fan motor but in the reverse direction causing the motor and cooling fan to run in reverse. The controller determines the length of time that the fan should be run in reverse before fan rotation is returned to the forward direction.

Figure 14

1. Gear pump 2. Fan drive manifold

REVERSE DIRECTION SHOWN

TO RESERVOIR

TO STEERING

CIRCUIT

M1 M2 L

TO LIFT/LOWER CIRCUIT

System

Hydraulic

Oilflowfromthe gearpumpis sentthroughthede--energizedsolenoid valve(S1)to rotatethecooling fanmotor. Return flow from the motor re--enters the manifold (port M2),through the de--energizedsolenoid valve (S1), out ofthe manifold (port T) andthenisroutedthroughtheoil cooler and oil filter.

Reverse Direction Fan Operation (Fig. 15)

TheTEC--5002 controller can reverse thecoolingfanto clean debris from the radiator, oil cooler and rear intake screen. If hydraulic oil and/or engine coolant temperaturesincrease to an unsuitablelevel,ahigh PWM signal is sent to the(PRV) valve to slow the cooling fanand direct pump oil flow to the reservoir. The controller then energizes solenoid valve (S1) in the fan drive manifold to reverse cooling fan motor oil flow so that the motor

Groundsmaster 4000--D Hydraulic SystemPage 4 -- 25

P1 P2T

TO OIL COOLER

Figure 15

FAN DRIVE MANIFOLD

FROM GEAR PUMP

Page 60

Special Tools

Order these special tools from your Toro Distributor.

Hydraulic Pressure Test Kit

Use to take various pressure readings for diagnostic tests. Quick disconnect fittings provided attach directly to mating fittings on machine test ports without tools. A high pressure hose is provided for remote readings. Contains one each: 1000 PSI (70 Bar), 5000 PSI (350 Bar) and 10000 PSI (700 Bar) gauges. Use gauges as recommended in the Testing section of this chapter.

Toro Part Number: TOR47009

Figure 16

Hydraulic Tester (Pressure and Flow)

This tester requires O--ring Face Seal (ORFS) adapter fittings for use on this machine.

1. INLET HOSE: Hose connected from the system circuit to the inlet side of the hydraulic tester.

2. LOAD VALVE: A simulated working load is created in the circuit by turning the valve to restrict flow.

3. PRESSUREGAUGE:Glycerinefilled0to5000PSI gauge to provide operating circuit pressure.

4. FLOW METER: This meter measures actual oil flow in the operating circuit with a gauge rated from 1 to 15 GPM(5to55LPM).

5. OUTLET HOSE: A hose from the outlet side of the hydraulictester connects to the hydraulic system circuit.

6. FITTINGS:An assortment of hydraulicfittingsareincluded with this kit.

Toro Part Number: TOR214678

Figure 17

Rev. A

Groundsmaster 4000--DHydraulic System Page 4 -- 26

Page 61

Hydraulic Test Fitting Kit

This kit includes avariety of O--ring Face Seal fittings to enable you to connect test gauges into the system.

The kit includes: tee’s, unions, reducers, plugs, c aps and male test fittings.

Toro Part Number: TOR4079

Measuring Container

Use this container for doing hydraulic motor efficiency testing(motors with case drain lines only).Measureefficiency of a hydraulic motor by restricting the outlet flow from the motor and measuring leakage from the case drainline while themotorispressurizedby the hydraulic system.

TORO TEST FITTING KIT (NO. TOR4079)

Figure 18

System

Hydraulic

The table in Figure 20 provides gallons per minute (GPM)conversionformeasuredmilliliterorouncemotor case drain leakage.

Toro Part Number: TOR4077

Figure 19

Figure 20

Groundsmaster 4000--D Hydraulic SystemPage 4 -- 27

Page 62

Troubleshooting

The charts that follow contain suggestions to assist in troubleshooting. There may possibly be more than one cause for a machine malfunction.

Refer to the Testing section of this Chapter for precautions and specific test procedures.

Problem Possible Cause

Hydraulic system operates hot. NOTE: An indication that the hy-

draulic system is operating at excessive temperatures would be frequent reversing of the cooling fan and a normal engine coolant temperature.

Engine RPM is too low. Brakes are applied or sticking. Hydraulic reservoir oil level is low. Hydraulic oil is contaminated or the wrong type. Piston pump by--pass valve is open or damaged. Cooling system is not operating properly. Charge pressure is low. Traction circuit pressure is incorrect.

NOTE: Whentroubleshooting tractionproblems on the Groundsmaster 4000--D, if a problem exists in both 4WD and transport speeds, consider a faulty component that affects the entire traction circuit (e.g. charge circuit, relief valves, piston pump, front wheel motors). Ifthe problem exists in 4WD but not in transport,consider a problem in the 4WD traction system (e.g. rear axle motor, 4WD manifold).

Pump(s) or motor(s) are damaged.

Hydraulic oil in reservoir foams. Hydraulic reservoir oil level is low.

Wrong type of oil is in the hydraulic system. Air is leaking into a pump suction line.

Machine operates in one direction only.

Traction pedal is sluggish. Traction control linkage is stuck or binding.

Machine travels too far before stopping when the traction pedal is released.

Traction control linkage is faulty. Traction relief valve is defective.

Charge pressure is low. Piston (traction) pump servo control valve orifices are plugged or

damaged. 4WD manifold PD1 and PD2 pilot directional valves seals are leaking

or damaged. Traction linkage is out of adjustment.

Charge pressure is low. Piston (traction) pump servo control valve orifices are plugged or da-

maged. Traction pedal does not return to neutral.

Groundsmaster 4000--DHydraulic System Page 4 -- 28

Page 63

Problem Possible Causes

Traction power is lost or unit will not

Hydraulic reservoir oil level is low.

operate in either direction.

Piston pump by--pass valve is open or damaged. Charge pressure is low. Traction circuit pressure is low. Front wheel motor couplers are damaged.

Four wheel drive will not engage. Electrical problem exists (see Chapter 5 -- Electrical System).

Solenoid valve (SV) in 4WD hydraulic manifold is faulty. Cartridge valve(s) in 4WD manifold is faulty. Drive gear on rear axle motor or driven gear for rear axle is loose or

damaged. Rear axle motor is damaged.

Four wheel drive will not disengage. Electrical problem exists (see Chapter 5 -- Electrical System).

Solenoid valve (SV) in 4WD hydraulic manifold is faulty. Cartridge valve in 4WD manifold is damaged or sticking.

System

Hydraulic

No cutting decks will operate. Electrical problem exists (see Chapter 5 -- Electrical System).

Gear pump or its coupler is damaged (NOTE: other hydraulic circuits impacted as well).

One cutting deck will not operate. Electrical problem exists (see Chapter 5 -- Electrical System).

System pressure to the affected deck is low. Woodruff key on affected deck motor is damaged. Solenoid valve (S) in deck manifold is faulty. Cartridge valve in deck manifold is damaged or sticking. Deck motor or gear pump section is damaged.

All cutting decks operate slowly. Engine RPM is low.

Deck motor or gear pump sections are damaged.

Cutting deck stops under load. Relief valve in deck manifold is by--passing.

Deck motor has internal leakage (by --passing oil). Cutting deck gear pump section is inefficient.

Groundsmaster 4000--D Hydraulic SystemPage 4 -- 29

Page 64

Problem Possible Causes

Cutting decks will not raise. Engine RPM is too low.

Hydraulic oil level in reservoir is low. Lift arm pivots are binding. Relief valve in lift/lower control valve is stuck. Pilot valve in lift/lower control valve is damaged or sticking. Lift cylinder(s) is (are) damaged. Gear pump section for lift/lower control valve is inefficient.

Cutting decks raise, but will not stay

Lift circuit lines or fittings are leaking.

up.

Lift cylinder is damaged. NOTE: Lift cylinders cannot provide an absolutely perfect seal. The cut-

Detents in lift/lower control valve are worn. ting deck will eventually lower if left

in the raised position during storage. Front cutting deck drops too fast or

Flow control valve is not adjusted properly. too slow.

Cutting decks will not lower. Lift arm pivots are binding.

Counterbalance pressure is excessive.

Pilot valve in lift/lower control valve is damaged or sticking.

Lift cylinder is damaged.

Lift/lower control valve is worn or damaged.

Groundsmaster 4000--DHydraulic System Page 4 -- 30

Page 65

Testing

The most effective method for isolating problems in the hydraulic system is by using hydraulic test equipment suchaspressure gauges and flow metersin the circuits during various operational checks (See the Special Tools section in this Chapter).

Before Performing Hydraulic Tests IMPORTANT: All obvious areas such as oil supply,

filter,binding linkages, loose fasteners or improper adjustmentsmustbecheckedbeforeassuming that ahydraulic componentis the sourceof theproblem.

Precautions for Hydraulic Testing

WARNING

Before disconnecting or performing any work on the hydraulic system, all pressure in the system must be relieved and all rotating machine parts must be stopped. Stop engine; lower or support attachments.

1. Clean machine thoroughly before disconnecting or disassemblingany hydraulic components. Always keep in mind the need for cleanliness when working on hydraulic equipment. Contamination will cause excessive wear of components.

CAUTION

Failure to use gauges with recommended pressure (PSI) rating as listed in test procedures couldresult indamage to thegauge andpossible personal injury from leaking hot oil.

CAUTION

All testing should be performed by two (2) people.One personshouldbe in theseat to operate the machine, and the other should read and record test results.

CAUTION

Operate all hydraulic controls to relieve system pressure and avoid injury from pressurized hydraulic oil. Controls must be operated with the ignitionswitch in OFF. Removekeyfrom the ignition switch.

2. Put metal caps or plugs on any hydraulic lines left open or exposed during testing or removal of components.

3. Theenginemust beingoodoperatingcondition.Use a phototac when performing a hydraulic test. Engine speed can affect the accuracy of the tester readings. Check actual speed of the pump when performing flow testing.

4. When using the hydraulic tester with pressure and flow capabilities, the inlet and the outlet hoses must be properly connected and not reversed to prevent damage to the hydraulic tester or components.

5. When using the hydraulic tester with pressure and flow capabilities, completely open load valve in the tester before starting the engine to minimize the possibility of damaging components.

6. Install fittings finger tight and far enough to make sure that they are not cross--threaded before tightening them with a wrench.

7. Position tester hoses to prevent rotating machine partsfrom contacting and damaging thehosesortester.

System

Hydraulic

8. Check oil level in the hydraulic reservoir. After con-

WARNING

Keepbodyandhands awayfrom pinholeleaks ornozzles that eject hydraulic fluid under high pressure. Do not use hands to search for leaks; use paper or cardboard. Hydraulic fluid escaping under pressure can have sufficient force to penetrate the skin and cause serious injury. If fluid is injected into the skin, it must be surgically removed within a few hours by a doctor familiar with this type of injury. Gangrene may result from such an injury.

Groundsmaster 4000--D Hydraulic SystemPage 4 -- 31

necting test equipment, make sure tank is full.

9. Check control linkages for improper adjustment, binding or broken parts.

10.After installing test gauges, run engine at low speed and check for any hydraulic oil leaks.

11.All hydraulic tests should be madewiththehydraulic oil at normal operating temperature.

12.Before returningmachine to use, makesure that hydraulic reservoir has correct fluid level.

Page 66

Traction Circuit Charge Pressure (Using Pressure Gauge)

FROM COUNTERBALANCE

MANIFOLD

FROM FRONT DECK

CYLINDERS

4WD

MANIFOLD

FROM STEERING VALVEPORT PB

FROM STEERING VALVEPORT T

FROM FRONT PTO MANIFOLD

TO PTO (MOW) CIRCUIT TO PTO (MOW) CIRCUIT

TO STEERING & LIFT CIRCUITS

TO COOLING FAN CIRCUIT

TRACTION

PRESSURE

GAUGE

MANIFOLD

FILTER

MANIFOLD

FROM PTO MANIFOLDS & FAN MOTOR

FROM PTO MANIFOLDS

Groundsmaster 4000--DHydraulic System Page 4 -- 32

Page 67

ProcedureforTractionCircuitChargePressureTest

1. Make sure hydraulic oil is at normal operating temperatureby operatingthe machine for approximately 10 minutes. Make sure the hydraulic tank is full.

2. Park machine on a level surface with the cutting decks lowered and off. Make sure engine is off and the parking brake is applied.

3. Raise and support operator seat.

CAUTION

Prevent personal injury and/or damage to equipment. Read all WARNINGS, CAUTIONS and Precautions for Hydraulic Testing at the beginning of this section.

4. Connect a 1000 PSI (70 bar) pressure gauge onto charge pressure test port on filter manifold (Fig. 21).

5. Start the engine and put throttle at full engine speed (2870 RPM) with no load on the hydraulic system.

GAUGEREADINGTOBE200 to 300 PSI (13.8 to

20.6 bar).

6. Stop engine and record test results.

7. If there is no pressure or pressure is low, check for restrictioninpumpintakeline.Also,inspectchargerelief valve located in filter manifold (see Hydraulic Manifold Service: Filter Manifold in the Service and Repairs sectionofthischapter).Ifnecessary,checkforinternaldamage or worn parts in gear pump.

8. Also, with the pressure gauge still connected to the charge pressure test port, take a gauge reading while operating the machine in forward and reverse. Start the engineand put throttle atfullenginespeed (2870 RPM). Apply the brakes and push the traction pedal forward, then reverse.

Figure 21

1. Charge pressure port 2. Filter manifold

System

Hydraulic

GAUGEREADINGTOBE200 to 300 PSI (13.8 to

20.6 bar).

9. If pressure is good under no load, but consistently drops below specification when under traction load, the piston pump and/or traction motor(s) should be suspected of wear and inefficiency. When the pump and/or traction motor(s) are worn or damaged, the charge pumpis not able to keep upwithinternalleakagein traction circuit components.

10.When testing is completed, disconnect pressure gauge from test port.

Groundsmaster 4000--D Hydraulic SystemPage 4 -- 33

Page 68

Traction Circuit Relief Pressure (Using Pressure Gauge)

FORWARD TRACTION CIRCUIT RELIEF PRESSURE TEST SHOWN

FROM COUNTERBALANCE

MANIFOLD

FROM FRONT DECK

CYLINDERS

PRESSURE

GAUGE

FROM STEERING VALVEPORT PB

FROM STEERING VALVEPORT T

FROM FRONT PTO MANIFOLD

TO PTO (MOW) CIRCUIT TO PTO (MOW) CIRCUIT

TO STEERING & LIFT CIRCUITS

TO COOLING FAN CIRCUIT

TRACTION

4WD

MANIFOLD

FILTER

MANIFOLD

FROM PTO MANIFOLDS & FAN MOTOR

FROM PTO MANIFOLDS

Groundsmaster 4000--DHydraulic System Page 4 -- 34

Page 69

Procedure for Traction Circuit Relief Pressure Test

1. Make sure hydraulic oil is at normal operating temperatureby operatingthe machine for approximately 10 minutes. Make sure the hydraulic tank is full.

CAUTION

Move machine to an open area, away from people and obstructions.

2. Drivemachine to an open area, lower cutting decks, turn the engine off and apply the parking brake.

CAUTION

Prevent personal injury and/or damage to equipment. Read all WARNINGS, CAUTIONS and Precautions for Hydraulic Testing at the beginning of this section.

3. Connect a 10,000 PSI (700 bar) pressure gauge to traction circuit test port for function to be checked (Fig. 22 or 23).

Figure 22

1. Forward traction port 2. Left front wheel

Figure 23

1. Reverse traction port 2. Right front wheel

System

Hydraulic

4. Starttheengine andmovethrottle tofullspeed(2870 RPM). Release parking brake. Make sure that trans-

port/4WD switch is in the transport position.

5. Sitonseat,applybrakes fully andslowlydepress the traction pedal in the appropriate direction. While pushing traction pedal, look at pressure reading on gauge:

GAUGE READING TO BE:

Forward: 3750 to 4250 PSI (259 bar to 293 bar) Reverse: 4750 to 5250 PSI (328 to 362 bar)

6. Releasetractionpedal and stop engine. Recordtest results.

7. If traction pressure is too low,inspect traction pump reliefvalves (Fig.24).Clean orreplacevalves as necessary. These cartridge type valves are factory set, and are not adjustable. If relief valves are in good condition, traction pump or wheel motors should be suspected of wear and inefficiency.

NOTE: Seal leakage across pilot directional valves PD1 and PD2 in 4WD manifold can also cause low forward traction pressure with reverse pressure meeting specifications.

RIGHT

FRONT

1. Forward relief valve

2. Reverse relief valve

Figure 24

3. Traction pump

8. When testing is completed, disconnect pressure gauge from test port.

Groundsmaster 4000--D Hydraulic SystemPage 4 -- 35

Page 70

Counterbalance Pressure (Using Pressure Gauge)

COUNTERBALANCE

MANIFOLD

PRESSURE

GAUGE

4WD

MANIFOLD

FROM PTO MANIFOLDS

TO PTO (MOW) CIRCUIT

TRACTION

MANIFOLD

FILTER

MANIFOLD

FAN DRIVE

TO PTO (MOW) CIRCUIT

M1 M2 ST L

P1 P2T

FROM DECK MOTORS

FROM FRONT PTO MANIFOLD

CIRCUIT

MANIFOLD

FROM RH PTO

Groundsmaster 4000--DHydraulic System Page 4 -- 36

Page 71

Procedure for Counterbalance Pressure Test

1. Make sure hydraulic oil is at normal operating temperatureby operatingthe machine for approximately 10 minutes. Make sure the hydraulic tank is full.

2. Park machine on a level surface with the cutting decks lowered and off. Make sure engine is off and the parking brake is applied. Remove console cover.

CAUTION

Prevent personal injury and/or damage to equipment. Read all WARNINGS, CAUTIONS and Precautions for Hydraulic Testing at the beginning of this section.

3. Determine system charge pressure (see Traction Circuit Charge Pressure Testin this section).

4. Connect a 1000 PSI (70 bar) gauge to counterbalance test port on manifold under console (Fig. 25).

5. Start the engine and put throttle at full engine speed

(2870RPM) withnoloadon thesystem.Do not engage the cutting decks.

GAUGEREADINGTOBE220 PSI (15.2 bar) over systemcharge pressure (e.g. if charge pressure is

250PSI(17.2 bar), counterbalance pressure should be 470 PSI (32.4 bar)).

6. Stop engine and record test results.

7. Adjustment of the counterbalance valve can be performed as follows:

Figure 25

1. Counterbalance test port

2. Counterbalance valve

3. Lock nut

4. Adjusting screw

System

Hydraulic

NOTE: Do not remove the valve from the hydraulic

manifold for adjustment.

A. Loosen lock nut on counterbalance valve (Fig.

25). B. To increase pressure setting, turn the adjust-

ment screw on the valve in a clockwise direction. A 1/8turnonthescrewwillmakeameasurablechange in counterbalance pressure.

C. To decrease pressure setting, turn the adjustmentscrew onthevalve inacounterclockwisedirection.A 1/8 turn on the screw will make ameasurable change in counterbalance pressure.

D. Tighten lock nut to secure adjustment. Check counterbalance pressure and readjust as needed.

8. When testing is completed, disconnect pressure gauge from test port.

Groundsmaster 4000--D Hydraulic SystemPage 4 -- 37

Page 72

Rear Traction Circuit (RV) Relief Pressure (Using Pressure Gauge)

FROM COUNTERBALANCE

MANIFOLD

FROM FRONT DECK

CYLINDERS

4WD

MANIFOLD

PRESSURE

GAUGE

FROM STEERING VALVE PORT PB

FROM STEERING VALVE PORT T

FROM FRONT PTO MANIFOLD

TO STEERING & LIFT CIRCUITS

TO COOLING FAN CIRCUIT

MANIFOLD

TRACTION

TO PTO (MOW) CIRCUIT

FILTER

MANIFOLD

FROM PTO MANIFOLDS

FROM PTO MANIFOLDS & FAN MOTOR

Groundsmaster 4000--DHydraulic System Page 4 -- 38

Page 73

Procedurefor RearTractionCircuit (RV)Relief Pressure Test

1. Make sure hydraulic oil is at normal operating temperatureby operatingthe machine for approximately 10 minutes. Make sure the hydraulic tank is full.

2. Park machine on a level surface with the cutting decks lowered and off. Make sure engine is off and the parking brake is applied.

CAUTION

Prevent personal injury and/or damage to equipment. Read all WARNINGS, CAUTIONS and Precautions for Hydraulic Testing at the beginning of this section.

3. Connect a 1000 PSI (70 bar) gauge to test port on 4WD control manifold under radiator (Fig. 26).

4. Start the engine and put throttle at full engine speed (2870 RPM). Make sure that transport/4WD switch is in the 4WD position.

5. Operate the machine in 4WD (not transport speed) with the cutting decks lowered. Drive down a slope in a forward direction, decrease pressure on the traction pedaland monitorthepressure gauge.Pressureshould increase until the relief valve lifts.

GAUGEREADINGTOBE750PSI(52 bar) (approx-

imate).

6. Stop engine and record test results.

Figure 26

1. 4WD control manifold 2. Relief valve test port

Figure 27

1. Manifold: lower side 2. Relief valve (RV)

System

Hydraulic

7. Relief valve (RV) is located on the lower, front side ofthe4WD control manifold (Fig. 27). Adjustmentofthe relief valve (RV) can be performed as follows:

NOTE: Do not remove the valve from the hydraulic manifold for adjustment.

A. To increase relief pressure setting, remove cap onrelief valve and turn the adjustment socket on the reliefvalve in a clockwisedirection. A 1/8 turn on the socketwill make a measurable change in relief pressure (Fig. 28).

B. Todecrease pressure setting,removecaponreliefvalve and turn the adjustment socket on the relief valve in a counterclockwise direction. A 1/8 turn on the socket will make a measurable change in relief pressure (Fig. 28).

C. Recheck relief pressure and readjustas needed.

8. When testing is completed, disconnect pressure gauge from test port.

Groundsmaster 4000--D Hydraulic SystemPage 4 -- 39

Figure 28

1. Relief valve cap 2. Adjustment socket

Page 74

Traction Circuit Reducing Valve (PR) Pressure (Using Pressure Gauge)

FROM COUNTERBALANCE

MANIFOLD

FROM FRONT DECK

CYLINDERS

4WD

MANIFOLD

PRESSURE

GAUGE

FROM STEERING VALVE PORT PB

FROM STEERING VALVE PORT T

FROM FRONT PTO MANIFOLD

TO STEERING & LIFT CIRCUITS

TO COOLING FAN CIRCUIT

MANIFOLD

TRACTION

TO PTO (MOW) CIRCUIT

FILTER

MANIFOLD

FROM PTO MANIFOLDS

FROM PTO MANIFOLDS & FAN MOTOR

Groundsmaster 4000--DHydraulic System Page 4 -- 40

Page 75

Procedure for Traction Circuit Reducing Valve(PR) Pressure Test

1. Make sure hydraulic oil is at normal operating temperatureby operatingthe machine for approximately 10 minutes. Make sure the hydraulic tank is full.

2. Park machine on a level surface with the cutting decks lowered and off. Make sure engine is off and the parking brake is applied.

CAUTION

Prevent personal injury and/or damage to equipment. Read all WARNINGS, CAUTIONS and Precautions for Hydraulic Testing at the beginning of this section.

3. Connect a 1000 PSI (70 bar) gauge to test port on 4WD control manifold under radiator (Fig. 29).

4. Start the engine and put throttle at full engine speed (2870 RPM). Make sure that transport/4WD switch is in the 4WD position.

5. Sitonseat,applybrakes fully andslowlydepress the traction pedal in the reverse direction. While pushing traction pedal, look at pressure reading on gauge:

GAUGE READING TO BE approximately 650 PSI

(45 bar).

6. Stop engine and record test results.

7. Pressure reducing valve (PR) is located on the front side of the 4WD control manifold (Fig. 30). Adjustment of this valve can be performed as follows:

Figure 29

1. 4WD control manifold 2. Pressure test port

Figure 30

1. Manifold: front side 2. Reducing valve (PR)

System

Hydraulic

NOTE: Do not remove the pressure reducing valve

from the hydraulic manifold for adjustment.

A. To increase pressure setting, remove cap on re-

ducing valve and turn the adjustment socket on the

valveinaclockwisedirection.A1/8turnonthesock-

et will make a measurable change in pressure set-

ting.

B. Todecrease pressure setting,removecaponre-

ducing valve and turn the adjustment socket on the

valve in a counterclockwise direction. A 1/8 turn on

the socket will make a measurable change in pres-

sure setting.

C. Recheck pressure setting and readjust as need-

ed.

8. When testing is completed, disconnect pressure gauge from test port.

Groundsmaster 4000--D Hydraulic SystemPage 4 -- 41

Page 76

Cutting Deck Circuit Pressure (Using Pressure Gauge)

FRONT DECK CIRCUIT PRESSURE TEST SHOWN

TRACTION CIRCUIT FLOW

FROM FRONT WHEEL MOTORS

FROM 4WD MANIFOLD

CHARGE CIRCUIT

FROM REAR AXLE MOTOR

FILTER

MANIFOLD

PRESSURE

GAUGE

TO COOLING FAN CIRCUIT

TO STEERING & LIFT CIRCUITS

LC1

RV1

MANIFOLD

FRONT PTO

RV2

LC2

LC1

RV1

LH PTO

MANIFOLD

RV2

LC2

LC1

RV1

RH PTO

MANIFOLD

RV2

FROM COOLING

LC2

FAN CIRCUIT

Groundsmaster 4000--DHydraulic System Page 4 -- 42

Page 77

Procedure for Cutting Deck Circuit Pressure Test

1. Make sure hydraulic oil is at normal operating temperatureby operatingthe machine for approximately 10 minutes. Make sure the hydraulic tank is full.

2. Park machine on a level surface with the cutting decks lowered and off. Make sure engine is off and the parking brake is applied.

CAUTION

Prevent personal injury and/or damage to equipment. Read all WARNINGS, CAUTIONS and Precautions for Hydraulic Testing at the beginning of this section.

3. Install 5000 PSI (350 bar) pressure gauge with hydraulic hose attached to manifold test port for the deck to be tested (Figs. 31, 32 and 33).

CAUTION

Keepawayfromdecksduringtest toprevent personal injury from the cutting blades.

4. Start engine and move throttle to full speed (2870 RPM). Engage the cutting decks.

5. Watch pressure gauge carefully while mowing with the machine.

6. Cutting deck circuit pressure should be as follows and will vary depending on mowing conditions:

Figure 31

1. Front deck circuit pressure test port

Figure 32

1. Right deck circuit pressure test port

System

Hydraulic

LH Deck: 1000 to 3000 PSI (69 to 207 bar)

Front Deck: 1000 to 3000 PSI (69 to 207 bar)

RH Deck: 1000 to 2000 PSI (69 to 137 bar)

7. Disengagecutting decks.Shutoffengineandrecord test results.

8. When testing is completed, disconnect pressure gauge with hose from manifold test port.

Groundsmaster 4000--D Hydraulic SystemPage 4 -- 43

Figure 33

1. Left deck circuit pressure test port

Page 78

PTO Relief Pressure (Using Tester with Pressure Gauges and Flow Meter)

FRONT PTO RELIEF PRESSURE TEST SHOWN

FROM 4WD MANIFOLD

TRACTION CIRCUIT FLOW

FROM FRONT WHEEL MOTORS

CHARGE CIRCUIT

FROM REAR AXLE MOTOR

FILTER

MANIFOLD

FRONT PTO

TESTER

FAN CIRCUIT

FROM COOLING

LC2

TO COOLING FAN CIRCUIT

TO STEERING & LIFT CIRCUITS

LC1

RV1

RV2

LC2

LC1

RV1

LH PTO

MANIFOLD

RV2

LC2

LC1

RV1

RH PTO

MANIFOLD

RV2

Groundsmaster 4000--DHydraulic System Page 4 -- 44

Page 79

Procedure for PTO Relief Pressure Test

1. Make sure hydraulic oil is at normal operating temperatureby operatingthe machine for approximately 10 minutes. Make sure the hydraulic tank is full.

2. Park machine on a level surface with the cutting decks lowered and off. Make sure engine is off and the parking brake is applied.

CAUTION

Prevent personal injury and/or damage to equipment. Read all WARNINGS, CAUTIONS and Precautions for Hydraulic Testing at the beginning of this section.

3. Locate deck manifold to be tested (Fig. 34). Disconnect hydraulic hose at deck manifold port (M1).

NOTE: Analternativeto usingmanifoldport(M1)would beto disconnect theinlethydraulic hose to thedeckmotor.

4. Installtesterinseries withthethe disconnectedhose and hydraulic manifold port (M1) (or motor inlet if hose was disconnected at deck motor).

5. Installtesterin series with thehose and hydraulic fitting. Make sure the flow control valve on tester is fully open.

9. Disengagecutting decks.Shutoffengineandrecord testresults.Ifspecificationisnotmet,adjustorcleanreliefvalvein deck manifold port (RV1). Adjust relief valve as follows:

NOTE: Do not remove valve from the hydraulic manifold for adjustment.

A. Removecapon relief valve with anallen wrench. B. To increase pressure setting, turn the adjust-

ment screw on the valve in a clockwise direction. A 1/8turnonthescrewwillmakeameasurablechange in relief pressure.

C. To decrease pressure setting, turn the adjustmentscrew onthevalve inacounterclockwisedirection.A 1/8 turn on the screw will make ameasurable change in relief pressure.

D. Reinstall and tighten cap to secure adjustment. Recheck relief pressure and readjust as needed.

10.Disconnect tester from manifold and hose. Reconnect hydraulic hose that was disconnected for test procedure.

RIGHT FRONT

System

Hydraulic

CAUTION

Keepawayfromdecksduringtest toprevent personal injury from the cutting blades.

6. Start engine and move throttle to full speed (2870 RPM). Engage the cutting decks.

7. Watchpressure gauge carefully while slowly closing the flow control valve to fully closed.

8. As the relief valve lifts, system pressure should be approximately:

2900 to 3100 PSI (200 to 213 bar) for the front and

left decks

1900 to 2100 PSI (131 to 144 bar) for the right deck

1. Front PTO manifold

2. LH PTO manifold

FRONT PTO MANIFOLD SHOWN

1. PTO manifold

2. PTO relief valve (RV1)

Figure 34

3. RH PTO manifold

Figure 35

3. Relief valve cap

Groundsmaster 4000--D Hydraulic SystemPage 4 -- 45

Page 80

Cutting Deck Motor Case Drain Leakage (Using Tester with Pressure Gauges and Flow Meter)

FRONT CUTTING DECK MOTOR

CASE DRAIN LEAKAGE TEST SHOWN

FROM 4WD MANIFOLD

TRACTION CIRCUIT FLOW

FROM FRONT WHEEL MOTORS

CHARGE CIRCUIT

FROM REAR AXLE MOTOR

FILTER

MANIFOLD

FAN CIRCUIT

FROM COOLING

TO COOLING FAN CIRCUIT

TO STEERING & LIFT CIRCUITS

LC1

RV1

MANIFOLD

FRONT PTO

RV2

LC2

LH PTO

MANIFOLD

LC1

RV1

RV2

LC2

LC1

RV1

RH PTO

MANIFOLD

RV2

LC2

TESTER

CAP

MEASURING

CONTAINER

Groundsmaster 4000--DHydraulic System Page 4 -- 46

Page 81

Procedure for Cutting Deck Motor Case Drain Leakage Test

5. Sit on seat and start the engine. Move throttle to full speed (2870 RPM). Move PTO switch to ON.

NOTE: Overa periodoftime,a deck motor can wearinternally. 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, causedamage to sealsandothercomponentsinthehydraulic system and affect quality of cut.

NOTE: Onemethodtofindafailingormalfunctioning deck motor is to have another person observe the machine while mowing in dense turf. A bad motor will run slower, producefewerclippingsand may cause a different appearance on the turf.

1. Make sure hydraulic oil is at normal operating temperaturebyoperating the machine for approximately 10 minutes. Make sure the hydraulic tank is full.

2. Park machine on a level surface with the cutting decks lowered and off. Make sure engine is off and the parking brake is applied.

CAUTION

6. While watching pressure gauge, slowly close flow control valve on tester until a pressure of 1200 PSI (83

bar) is obtained. NOTE: Use a graduated container, special tool

TOR4077, to measure case drain leakage (Fig. 37).

7. Havea second person collectthe flow from thecase drain line for 15 seconds, then move the PTO switch to OFF and stop the engine. Record test results.

TEST RESULTS: Flow less than 22.4 ounces (662 ml) of hydraulic fluid in 15 seconds.

8. Ifflow is more than 22.4 ounces (662 ml),themotor isworn or damaged and should be repairedorreplaced.

9. After testing is completed, disconnect tester from motorand hose. Reconnecthosetothedeckmotor.Remove cap from tee--fitting and reconnect case drain hose.

System

Hydraulic

Prevent personal injury and/or damage to equipment. Read all WARNINGS, CAUTIONS and Precautions for Hydraulic Testing at the beginning of this section.

NOTE: The side deck motors are connected in series.

To isolate a faulty motor, both motors in the circuit may havetobetestedbystarting with the left side motor first.

3. Disconnect hose from return of the motor to be tested (Fig.36). Install flow tester in series with the motor and disconnected return hose. Make sure the flow control valve on tester is fully open. (Fig. 37).

4. Disconnect the motor case drain hose (small diameterhose)where itconnects to hydraulic manifold tee--fitting(not at the motor). Put a steel cap on thefittingatthe tee--fitting; leave the case drain hose open (Fig. 37).

CAUTION

Cutting deck blades will rotate when lowered with PTO switch in ON position. Keep away from cutting decks during test to prevent personal injuryfrom rotating blades. Do notstandinfrontof the machine.

Figure 36

1. Deck motor (RH shown)

2. Return hose

Figure 37

3. Case drain hose

Groundsmaster 4000--D Hydraulic SystemPage 4 -- 47

Rev. A

Page 82

Cutting Deck Gear Pump Flow (Using Tester with Pressure Gauges and Flow Meter)

FRONT DECK GEAR PUMP FLOW TEST SHOWN

FROM 4WD MANIFOLD

TRACTION CIRCUIT FLOW

FROM FRONT WHEEL MOTORS

CHARGE CIRCUIT

FILTER

MANIFOLD

FROM REAR AXLE MOTOR

TO COOLING FAN CIRCUIT

TO STEERING & LIFT CIRCUITS

TESTER

LC1

RV1

MANIFOLD

FRONT PTO

RV2

LC2

LC1

RV1

LH PTO

MANIFOLD

RV2

LC2

LC1

RV1

RH PTO

MANIFOLD

RV2

FROM COOLING

LC2

FAN CIRCUIT

Groundsmaster 4000--DHydraulic System Page 4 -- 48

Page 83

Procedure for Cutting Deck Gear Pump Flow Test NOTE: Overaperiod oftime,thegearsand wearplates

in the pump can wear.A worn pump will by pass oil and makethepumplessefficient.Eventually,enoughoilloss willoccurtocausethecutting deck motors to stall under heavy cutting conditions. Continued operation with a worn,inefficientpumpcan generate excessive heatand causedamage tothesealsandother components inthe hydraulic system.

1. Make sure hydraulic oil is at normal operating temperatureby operatingthe machine for approximately 10 minutes. Make sure the hydraulic tank is full.

2. Park machine on a level surface with the cutting decks lowered and off. Make sure engine is off and the parking brake is applied.

CAUTION

Prevent personal injury and/or damage to equipment. Read all WARNINGS, CAUTIONS and Precautions for Hydraulic Testing at the beginning of this section.

3. Locate deck manifold for gear pump section to be tested.Disconnecthydraulichose at deck manifold port (P1) (Fig. 38).

4. Installtesterinseries withthethe disconnectedhose and hydraulic manifold port (P1).

8. Flowindicationshouldbeapproximately14GPM(53 LPM).

9. Shut off engine and record test results.

10.Disconnectflowtester fromhydraulichose andmanifold port. Reconnect hose to the manifold.

11.If a pressure of 2000 PSI (138 bar) cannot be obtained or flow was less than 11.5 GPM (44 LPM) (85% of expected flow), check for restriction in the pump intakeline. Iflineis notrestricted,considerthatgearpump is worn or damaged.

RIGHT FRONT

Figure 38

1. Front PTO manifold

2. Hyd. hose to front P1

3. LH PTO manifold

4. Hyd. hose to LH P1

System

Hydraulic

5. Makesure the flow control valve on the tester is fully open.

6. Start engine and move throttle to full speed (2870

RPM). 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. Watchpressure gauge carefully while slowly closing the flow control valve until 2000 PSI (138 bar) is obtained. Verify with a phototac that the engine speed is still 2870 RPM.

Groundsmaster 4000--D Hydraulic SystemPage 4 -- 49

Page 84

Steering Circuit Relief Pressure (Using Pressure Gauge)

FROM COUNTERBALANCE MANIFOLD

FROM FRONT DECK LIFT CYLINDERS

4WD

MANIFOLD

TRACTION

TO LIFT/LOWER CONTROL VALVE

PRESSURE

GAUGE

FROM PTO MANIFOLDS

TO PTO (MOW) CIRCUIT

FILTER

MANIFOLD

FAN DRIVE

P1 P2T

M1 M2 ST L

FROM DECK MOTORS

FROM FRONT PTO MANIFOLD

MANIFOLD

FROM RH PTO

CIRCUIT

FROM RH PTO

Groundsmaster 4000--DHydraulic System Page 4 -- 50

Page 85

Procedure for Steering Circuit Relief Pressure Test

1. Make sure hydraulic oil is at normal operating temperatureby operatingthe machine for approximately 10 minutes. Make sure the hydraulic tank is full.

2. Park machine on a level surface with the cutting decks lowered and off. Make sure engine is off and the parking brake is applied.

CAUTION

Prevent personal injury and/or damage to equipment. Read all WARNINGS, CAUTIONS and Precautions for Hydraulic Testing at the beginning of this section.

3. Connect a 5000 PSI (350 bar) pressure gauge onto steering pressure test port.

4. Start the engine and move throttle to full engine speed (2870 RPM).

IMPORTANT: Hold steering wheel at full lock only long enough to get a system pressure reading. Holding the steering wheel against the stop for an extended period can damage the steering valve.

5. Turn steering all the way in one direction and momentarily hold the steering wheel against resistance.

GAUGEREADINGTOBE1300 to 1400 PSI (90 to

96 bar).

6. Stop the engine and record test results.

7. If pressure is incorrect, inspect steering relief valve incontrol valve (Fig. 40). Ifreliefvalveisoperatingproperly and if lift/lower problems also exist, gear pump shouldbe suspected ofwearandinefficiency.Ifsteering wheel continues to turn at end of cylinder travel (with lower than normal effort), steering cylinder or steering valve should be suspected of wear or damage.

Figure 39

1. Steering circuit pressure test port

Figure 40

1. Steering tower 2. Steering relief valve

System

Hydraulic

8. When testing is completed, disconnect pressure gauge from test port.

Groundsmaster 4000--D Hydraulic SystemPage 4 -- 51

Page 86

Lift/Lower Circuit Relief Pressure (Using Pressure Gauge)

COUNTERBALANCE

MANIFOLD

4WD

MANIFOLD

PRESSURE

GAUGE

FROM PTO MANIFOLDS

TO PTO (MOW) CIRCUIT

TRACTION

MANIFOLD

FILTER

MANIFOLD

FAN DRIVE

TO PTO (MOW) CIRCUIT

M1 M2 ST L

P1 P2T

FROM DECK MOTORS

FROM FRONT PTO MANIFOLD

CIRCUIT

MANIFOLD

FROM RH PTO

Groundsmaster 4000--DHydraulic System Page 4 -- 52

Page 87

Procedure for Lift/Lower Circuit Relief Pressure Test

NOTE: Before attempting to check or adjust lift pres-

sure, make sure that counterbalance pressure is correctly adjusted.

1. Make sure hydraulic oil is at normal operating temperatureby operatingthe machine for approximately 10 minutes. Make sure the hydraulic tank is full.

2. Park machine on a level surface with the cutting decks lowered and off. Make sure engine is off and the parking brake is applied.

CAUTION

Prevent personal injury and/or damage to equipment. Read all WARNINGS, CAUTIONS and Precautions for Hydraulic Testing at the beginning of this section.

3. Raiseseatto gain access tolift circuit test port at the fan drive manifold (Fig. 41). Connect a 5,000 PSI (345 bar) gauge with hydraulic hose attached to test port. Route gauge hose to allow seat to be safely lowered.

4. Sit on the seat and start the engine. Move throttle to full speed (2870 RPM).

1. Fan drive manifold

2. Lift circuit test port

Figure 41

3. Lift control valve

4. Relief valve

System

4 5

Hydraulic

5. While sitting on the seat, pull lift lever back to raise thecutting decks. Momentarily hold the lever with the lift cylinder at full extension while looking at the gauge.

GAUGEREADING TOBE 1500 to 1600 PSI (104 to

110 bar).

6. Stop the engine and record test results.

7. Ifpressure is too high, adjust reliefvalveinliftcontrol valve by rotating counterclockwise (Figure 42). If pressure is too low, check for restriction in pump intake line. Check the lift cylinder for internal leakage. If cylinder is notleaking,adjustthe relief valve by rotatingclockwise. Repeatsteps 4 through6 after makinga relief valve adjustment. If pressure is still too low, pump or lift cylinder(s) should be suspected of wear, damage or inefficiency.

8. When testing is completed, disconnect pressure gauge from test port.

Figure 42

1. Control valve assembly

2. Relief valve assembly

3. Washers

4. Spring

5. Poppet

Groundsmaster 4000--D Hydraulic SystemPage 4 -- 53

Page 88

Steering and Lift/Lower Gear Pump Flow (Using Tester with Pressure Gauges and Flow Meter)

COUNTERBALANCE

MANIFOLD

4WD

MANIFOLD

FROM PTO MANIFOLDS

TO PTO (MOW) CIRCUIT

TRACTION

MANIFOLD

FILTER

MANIFOLD

TESTER

MANIFOLD

FAN DRIVE

TO PTO (MOW) CIRCUIT

FROM DECK MOTORS

FROM FRONT PTO MANIFOLD

Groundsmaster 4000--DHydraulic System Page 4 -- 54

MANIFOLD

FROM RH PTO

CIRCUIT

FROM RH PTO

Page 89

Procedure for Steering and Lift/Lower Gear Pump Flow Test

1. Make sure hydraulic oil is at normal operating temperatureby operatingthe machine for approximately 10 minutes. Make sure the hydraulic tank is full.

2. Park machine on a level surface with the cutting decks lowered and off. Make sure engine is off and the parking brake is applied.

CAUTION

Prevent personal injury and/or damage to equipment. Read all WARNINGS, CAUTIONS and Precautions for Hydraulic Testing at the beginning of this section.

IMPORTANT: Make sure that the oil flow indicator arrow on the flow gauge is showing that the oil will flow from the pump section, through the tester and into the hydraulic hose.

3. With the engine off and cutting decks lowered, disconnect the hydraulic hose from the 90 thirdgear pumpsection which supplies the steering and lift/lower circuits (Fig. 43).

4. Installtester in seriesbetweenthefittingand the disconnectedhose. Make sure the tester flow control valve is OPEN.

fitting in the

1. Gear pump

2. Fan drive manifold

Figure 43

3. Steering/lift hose

4. 90

fitting

System

Hydraulic

IMPORTANT: The pump is a positive displacement type. If pump flow is completely restricted or stopped, damage to the pump, tester or other components could occur.

5. Starttheengine andmovethrottle tofullspeed(2870 RPM). DO NOT engage the cutting decks.

6. While watching pressure gauges, slowly close flow control valve until 1000 PSI (69 bar) is obtained on gauge. Verifyengine speed continues to be 2870 RPM.

GAUGE READING TO BE: Flow approximately 7

GPM (26.3 LPM) at 1000 PSI (69 bar).

7. Stop engine and record test results.

8. If a pressure of 1000 PSI (69 bar) could not be obtained or flow is lower than 6GPM(22.3LPM)(85% of expectedflow),check for restriction in pump intakeline. Ifintakeline is not restricted, consider thatgear pump is worn or damaged.

9. Whentesting is complete, remove tester and reconnect hose to pump fitting.

Groundsmaster 4000--D Hydraulic SystemPage 4 -- 55

Page 90

Engine Cooling Fan Circuit (Using Pressure Gauge and Phototac)

COUNTERBALANCE

MANIFOLD

4WD

MANIFOLD

TRACTION

FROM PTO MANIFOLDS

TO PTO (MOW) CIRCUIT

FROM DECK MOTORS

FROM FRONT PTO MANIFOLD

MANIFOLD

FAN DRIVE

FILTER

MANIFOLD

CIRCUIT

MANIFOLD

FROM RH PTO

Groundsmaster 4000--DHydraulic System Page 4 -- 56

Page 91

Procedure for Engine Cooling Fan Circuit Test

1. Make sure hydraulic oil is at normal operating temperatureby operatingthe machine for approximately 10 minutes. Make sure the hydraulic tank is full.

2. Park machine on a level surface with the cutting decks lowered and off. Make sure engine is off and the parking brake is applied. Raise and support hood.

CAUTION

Prevent personal injury and/or damage to equipment. Read all WARNINGS, CAUTIONS and Precautions for Hydraulic Testing at the beginning of this section.

3. Raise seat to gain access to cooling fan circuit test port at the fan drive manifold (Fig. 44). Connect a 5,000 PSI(345 bar)gaugewithhydraulic hoseattachedtotest port on top of manifold.

1. Fan drive manifold

2. PRV solenoid

Figure 44

3. Test port

4. Start the engine. Move throttle to full speed (2870 RPM).

5. While monitoring the pressure gauge and using a phototac to identify the cooling fan speed, disconnect the wire harness connector (white/green and black wires)fromthePRVsolenoidonfandrivemanifold.Both fan speed and pressure should increase and stabilize after the solenoid is disconnected.

PRESSURE GAUGE READING TO BE approxi-

mately 3000 PSI (207 bar).

PHOTOTAC READING TO BE: fan speed approxi-

mately 2800 RPM.

6. Stop engine and record test results.

7. If pressure rises to approximately 3000 PSI (207 bar) but fan speed is low, consider that the fan motor is worn or damaged. If pressure and fan speed are both low, consider that the gear pump is worn or damaged (see Engine Cooling Circuit Gear Pump Flow Test).

NOTE: Ifpressureandfanspeed are bothlowand gear pumpflow proves tobec orrect, suspect thatsealsinfan drivemanifold are leaking or faulty(see Fan Drive Manifold Service in the Service and Repairs section of this chapter).

System

Hydraulic

8. When testing is complete, remove pressure gauge and reconnect wire harness to PRV solenoid.

Groundsmaster 4000--D Hydraulic SystemPage 4 -- 57

Page 92

Engine Cooling Fan Circuit Gear Pump Flow (Using Tester with Pressure Gauges and Flow Meter)

COUNTERBALANCE

MANIFOLD

4WD

MANIFOLD

FROM PTO MANIFOLDS

TO PTO (MOW) CIRCUIT

TRACTION

MANIFOLD

FILTER

MANIFOLD

TESTER

MANIFOLD

FAN DRIVE

TO PTO (MOW) CIRCUIT

FROM DECK MOTORS

FROM FRONT PTO MANIFOLD

Groundsmaster 4000--DHydraulic System Page 4 -- 58

MANIFOLD

FROM RH PTO

CIRCUIT

FROM RH PTO

Page 93

Procedure for Engine Cooling Fan Circuit Gear Pump Flow Test

1. Make sure hydraulic oil is at normal operating temperatureby operatingthe machine for approximately 10 minutes. Make sure the hydraulic tank is full.

2. Park machine on a level surface with the cutting decks lowered and off. Make sure engine is off and the parking brake is applied.

CAUTION

Prevent personal injury and/or damage to equipment. Read all WARNINGS, CAUTIONS and Precautions for Hydraulic Testing at the beginning of this section.

IMPORTANT: Make sure that the oil flow indicator arrow on the flow gauge is showing that the oil will flow from the pump section, through the tester and into the hydraulic hose.

3. With the engine off and cutting decks lowered, dis-

connectthe hydraulic hose from the90

fittingin the last gear pump section which supplies the engine cooling circuit (Fig. 43).

4. Installtester in seriesbetweenthefittingand the disconnectedhose. Make sure the tester flow control valve is OPEN.

IMPORTANT: The pump is a positive displacement type. If pump flow is completely restricted or stopped, damage to the pump, tester or other components could occur.

5. Starttheengine andmovethrottle tofullspeed(2870 RPM). DO NOT engage the cutting decks.

1. Gear pump

2. Fan drive manifold

Figure 45

3. Engine cooling hose

4. 90

fitting

System

Hydraulic

6. Whilewatchingtesterpressuregauges, slowlyclose flow control valve until 1000 PSI (69 bar) is obtained on gauge. Verifyengine speed continues to be 2870 RPM.

GAUGE READING TO BE: Flow approximately 7 GPM (26.3 LPM) at 1000 PSI (69 bar).

7. Stop engine and record test results.

9. Whentesting is complete, remove tester and reconnect hose to pump fitting.

Groundsmaster 4000--D Hydraulic SystemPage 4 -- 59

Page 94

Adjustments

Adjust Front Cutting Deck Lift Flow Control

The front cutting deck lift circuit is equipped with an adjustable flow control valve used to adjust the rate at which the front cutting deck lowers. Adjust flow control valve as follows:

1. Runmachinetogethydraulicoilatoperatingtemperatures.Parkmachine on a level surface, shut engineoff and lower cutting decks to the ground.

2. Locateflowcontrolvalveunderfrontofmachine(Fig.

46).

3. Loosen set screw on valve and rotate valve clockwise to slow down drop rate of front cutting deck.

4. Verify adjustment by raising and lowering cutting deck several times. Readjust as required.

5. After desired drop rate is attained, tighten set screw on flow control valve to secure adjustment.

Figure 46

1. Front lift cylinder 2. Flow control valve

Groundsmaster 4000--DHydraulic System Page 4 -- 60

Page 95

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. Make sure hydraulic components, hoses connections and fittings are cleaned thoroughly. Always keep in mind the need for cleanliness when working on hydraulic equipment.

CAUTION

Operate all hydraulic controls to relieve system pressure and avoid injury from pressurized hydraulic oil.

3. Putcapsor plugsonanyhydrauliclines, hydraulicfittings and components left open or exposed to prevent contamination.

4. Put labels on disconnected hydraulic lines and hosesforproperinstallationafterrepairs arecompleted.

5. Note the position of hydraulic fittings (especially elbow fittings) on hydraulic components before removal. Markpartsifnecessarytomake suretheywillbealigned properly when installing hydraulic hoses and tubes.

After Repair or Replacement of Components

1. Checkoillevelinthehydraulic reservoirandadd correct oil if necessary. Drain and refill hydraulic system reservoir and change oil filter if component failure was severe or system is contaminated (see Flush Hydraulic System in this section).

2. Lubricate O--rings and seals with clean hydraulic oil before installing hydraulic components.

3. Make sure caps or plugs are removed from the hydraulic tubes, hydraulic fittings and components before reconnecting.

4. Use proper tightening methods when installing hydraulichoses and fittings (seeHydraulic Fitting Installation in the General Information section of this chapter).

5. After repairs, check control linkages or cables for proper adjustment, binding or broken parts.

6. After disconnecting or replacing any hydraulic components, operate machine functions slowly until air is outof system(seeChargeHydraulic System inthissection).

7. Checkforhydraulicoilleaks.Shutoffengineandcorrectleaksifnecessary.Checkoillevelin hydraulicreservoir and add correct oil if necessary.

System

Hydraulic

Check Hydraulic Lines and Hoses

IMPORTANT: Checkhydraulic lines andhoses daily

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 withthistypeof injury.Gangrenemayresultfrom such an injury.

Groundsmaster 4000--D Hydraulic SystemPage 4 -- 61

for leaks, kinked lines, loose mounting supports, wear,loose fittings or any hose deterioration. Make all necessary repairs before operating.

Page 96

Flush Hydraulic System

IMPORTANT: Flush the hydraulic system any time thereis a severe component failure orthe system is contaminated (oil appears milky, black or contains metal particles).

1. Park machine on a level surface. Lower cutting decks to the ground, stop engine and apply parking brake. Remove key from the ignition switch.

CAUTION

Operate all hydraulic controls to relieve system pressure and avoid injury from pressurized hydraulic oil.

IMPORTANT: Make sure to clean around any hydraulic connections that will be disconnected for draining.

2. Drain hydraulic reservoir.

3. Drain hydraulic system. Drain all hoses, tubes and components while the system is warm.

4. Change and replace both hydraulic oil filters.

9. Turn ignition key switch and engage starter for ten (10) seconds to prime hydraulic pumps. Repeat this step again.

10.Connect electrical connector to engine runsolenoid.

11.Start engine and let it idle at low speed (1450 RPM) for a minimum of two (2) minutes. Increase engine speed to high idle (2870 RPM) for minimum of one (1) minute under no load.

12.Raise and lower cutting decks several times. Turn steering wheel fully left and right several times.

13.Shut off engine and check for hydraulic oil leaks. Check oil level in hydraulic reservoir and add correct amount of oil if necessary.

14.Operate machine for two(2) hours under normal operating conditions.

15.Check condition of hydraulic oil. If the new fluid shows any signs of contamination, repeat steps 1 through 14 again until oil is clean.

16.Assume normaloperation and followrecommended maintenance intervals.

5. Inspectand cleanhydraulicreservoir (see Hydraulic Reservoir Inspection in this section).

6. Connect all hydraulic hoses, lines and components that were disconnected while draining system.

NOTE: Useonlyhydraulicfluids specifiedinthe Operator’s Manual. Other fluids may cause system damage.

7. Fill hydraulic reservoir with new hydraulic fluid.

8. Disconnectelectrical connector from engine run solenoid.

Groundsmaster 4000--DHydraulic System Page 4 -- 62

Page 97

Charge Hydraulic System

NOTE: Wheninitially starting the hydraulic systemwith

newor 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. Remove key from the ignition switch.

2. Makesure all hydraulic connections, lines and components are secured tightly.

3. Ifcomponentfailurewassevereorthesystemiscontaminated, flush and refill hydraulic system and tank (see Flush Hydraulic System in this section).

4. Makesure hydraulic reservoir is full. Add correct hydraulic oil if necessary.

5. Check control rod to the piston ( traction) pump for proper adjustment, binding or broken parts.

11.After the hydraulicsystem starts to showsigns of fill, actuate lift control lever until the lift cylinder rod moves in and out several times. If the cylinder rod does not moveafter10 to 15 seconds, or the pump e mits abnormal sounds, shut the engine off immediately and determine cause or problem. Inspect for the following:

A. Loose filter or suction lines. B. Blocked suction line. C. Faulty charge relief valve. D. Faulty gear pump.

12.If cylinder does move in 10 to 15 seconds, proceed to step 13.

13.Operatethetractionpedalin theforward andreverse directions. The wheels off the ground should rotate in the proper direction.

A. If the wheels rotate in the wrong direction, stop engine and check for proper hose connections at traction pump and motors. Correct as needed.

System

Hydraulic

6. Disconnect engine run solenoid lead to prevent the engine from starting.

7. Make sure traction pedal and lift control lever are in the neutral position. Turn ignition key switch and engage starter for ten (10) seconds to prime the traction and gear pumps. Repeat this step again.

8. Reconnect engine run solenoid lead.

WARNING

Beforejacking upthe machine,review andfollow Jacking Instructions in Chapter 1 -- Safety.

9. Raise one front and one rear wheel off the ground and place support blocks under the frame. Chock remaining wheels to prevent movement of the machine.

10.Make sure traction pedal and lift control lever are in neutral. Start engine and run it at low idle (1450 rpm). Thecharge pump should pick up oil andfillthehydraulic system. If there is no indication of fill in thirty (30) seconds, stop the engine and determine the cause.

B. If the wheels rotate in the proper direction, stop engine.

14.Adjust traction pedal to the neutral position.

15.Check operation of the traction interlock switch (see Check Interlock System in Chapter 5 -- Electrical System).

16.Remove blocks from frame and lower machine. Remove chocks from remaining wheels.

17.If the piston (traction) pump or a traction motor was replaced or rebuilt, run the machine so all wheels turn slowly for ten (10) minutes.

18.Operate machine by gradually increasing its work load to full over a ten (10) minute period.

19.Stop the machine. Check hydraulic reservoir and fill ifnecessary.Checkhydrauliccomponents for leaksand tighten any loose connections.

Groundsmaster 4000--D Hydraulic SystemPage 4 -- 63

Page 98

Hydraulic Reservoir

30 to 40 in--lb

(3.4 to 4.5 N--m)

(minimum)

31 28

RIGHT

FRONT

1. Hydraulic reservoir

2. Petcock

3. O--ring

4. Strap

5. Felt strap (2 used)

6. Bushing (2 used)

7. Bushing

8. Strap

9. Stand pipe (2 used)

10. Hose clamp (2 used)

11. Screen filter

Figure 47

12. Dipstick

13. O--ring

14. Reservoir cap

15. Suction hose

16. Tank strainer

17. Hose clamp

18. Hose

19. Hose clamp

20. Cap screw

21. Socket head screw (3 used)

NOTE: HYDRAULIC COMPONENTS ATTACHED TO FRONT FRAME ARE NOT SHOWN IN ILLUSTRATION

22. Lock nut (3 used)

23. Hose

24. Hose

25. Elbow fitting

26. Flange nut

27. O--ring

28. Flat washer (4 used)

29. Front frame

30. Flange nut (4 used)

31. Cap screw (4 used)

Groundsmaster 4000--DHydraulic System Page 4 -- 64

Page 99

NOTE: The front frame needs to be lowered from the

main frame to allow clearance to remove the hydraulic reservoir from the machine.

Removal (Fig. 47)

1. Park machine on a level surface, lower cutting decks, stop engine, apply parking brake and remove key from the ignition switch.

2. Remove front cutting deck (see Front Cutting Deck Removal in the Service and Repairs section of Chapter 8 -- Cutting Decks).

Inspection

1. Clean hydraulic reservoir and suction strainer with solvent.

2. Inspect reservoir for leaks, cracks or other damage.

Installation (Fig. 47)

1. Using a wrench, turn tank strainer into port at least 1--1/2 to 2 full turns beyond finger tight.

2. Position reservoir to machine.

3. Read the General Precautions for Removing and Installing Hydraulic System Components at the beginning of the Service and Repairs section of this chapter.

4. Drain reservoir into a suitable container.

5. Disconnect hydraulic hoses from reservoir. Label disconnected hydraulic lines for proper installation.

6. Removestraps(items 4 and 8)that secure reservoir tofront frame. Remove felt straps(item3)frombetween straps and reservoir.

7. To allow front frame to be lowered for reservoir removal, remove hydraulic tubes that connect hydraulic components on front frame (wheel motors, front deck PTO manifold and traction manifold) to components on main frame. Put caps or plugs on open hydraulic lines and fittings.

8. Chockrearwheelstopreventthemachinefrommoving. Use jack or hoist to raise front of machine and support machine with jackstands.

9. Support front frame to prevent it from moving.

3. Carefully raise front frame assembly to main frame. Align frame mounting holes and support front frame to prevent it from moving.

4. Secure front frame to main frame with cap screws (item 35), flat washers (item 28) and flange nuts (item

30).

5. Lower machine to ground.

6. Position felt straps (item 3) between straps and reservoir.Securereservoir to front frame with straps (items 4 and 8).

7. Removecaps and plugs from hydraulic lines and fittings that were placed during the removal process. Using labels placed during removal, connect hydraulic hoses and tubes to fittings on reservoir, wheel motors and hydraulic manifolds (see Hydraulic Hose and Tube Installation in the General Information section of this chapter).

8. Install front cutting deck (see Front Cutting Deck Installation in the Service and Repairs section of Chapter 8 -- Cutting Decks).

System

Hydraulic

10.Remove capscrews(item35), flatwashers(item 28)

9. Fill reservoir with new hydraulic fluid to proper level.

andflange nuts (item 30) thatsecurefrontframe to main frame.

10.Properly fillhydraulic system (see Charge Hydraulic System in this section).

11.Carefully lower front frame assembly to allow clearanceforreservoirremoval.Once lowered, support front frame to prevent it from shifting.

11.Stop engine and check for hydraulic oilleaks.Check hydraulic reservoir oil level.

12.Carefully remove hydraulic reservoir from machine.

Groundsmaster 4000--D Hydraulic SystemPage 4 -- 65

Page 100

Hydraulic Oil Cooler

RIGHT

FRONT

1. Radiator

2. RH radiator support

3. Top radiator support

4. Knob (2 used)

5. Oil cooler bracket

6. Retaining ring (2 used)

Figure 48

7. Carriage screw (2 used)

8. O--ring

9. 90

10. O--ring

11. Cap screw (2 used)

12. Lock washer (6 used)

hydraulic fitting (2 used)

12 ft--lb

(16 N--m)

13. Oil cooler

14. Flange nut (2 used)

15. Cap screw(2 used)

16. Oil cooler mount plate (2 used)

17. Cap screw (4 used)

18. LH radiator support

Groundsmaster 4000--DHydraulic System Page 4 -- 66

Toro 30412 User Manual

Preface

Table Of Contents

General Safety Instructions

Before Operating

While Operating

Maintenance and Service

Jacking Instructions

Safety and Instruction Decals

Product Records

Maintenance

Equivalents and Conversions

Torque Specifications

Fastener Identification

Using a Torque Wrench with an Offset Wrench

Standard Torque for Dry, Zinc Plated and Steel Fasteners (Inch Series)

Standard Torque for Dry, Zinc Plated and Steel Fasteners (Metric Series)

Other Torque Specifications

Conversion Factors

General Information

Operator’s Manual

Stopping the Engine

Specifications

Service and Repairs

Air Filter System

Exhaust System

Fuel System

Radiator

Engine

Spring Coupler

Specifications

General Information

Operator’s Manual

Towing Traction Unit

Check Hydraulic Fluid

Hydraulic Hoses

Hydraulic Schematic

Hydraulic Flow Diagrams

Special Tools

Hydraulic Pressure Test Kit

Hydraulic Tester (Pressure and Flow)

Hydraulic Test Fitting Kit

Measuring Container

Troubleshooting

Testing

Traction Circuit Charge Pressure (Using Pressure Gauge)

Traction Circuit Relief Pressure (Using Pressure Gauge)

Counterbalance Pressure (Using Pressure Gauge)

Rear Traction Circuit (RV) Relief Pressure (Using Pressure Gauge)

Traction Circuit Reducing Valve (PR) Pressure (Using Pressure Gauge)

Cutting Deck Circuit Pressure (Using Pressure Gauge)

PTO Relief Pressure (Using Tester with Pressure Gauges and Flow Meter)

Adjustments

Adjust Front Cutting Deck Lift Flow Control

Service and Repairs

General Precautions for Removing and Installing Hydraulic System Components

Check Hydraulic Lines and Hoses

Flush Hydraulic System

Charge Hydraulic System

Hydraulic Reservoir

Hydraulic Oil Cooler