Toro 4014-D, 4000-D User Manual

Part No. 10176SL (Rev. A)

Service Manual

(Models 30448 and 30446)

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 30448) and 4010--D (Model 30446).

REFER TOTHEOPERATOR’SMANUALFOROPERATING, 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 & 4010--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 importantinstructionswhichmustbefollowed to prevent damage to systems or components on the machine.

Groundsmaster4000--D

E The Toro Company -- 2010, 2012

Groundsmaster4010--D

This page is intentionally blank.

Groundsmaster 4000--D/4010--D

Chapter 1 -- Safety

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

Jacking Instructions 1 -- 5.........................

Safety and Instruction Decals 1 -- 6................

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 -- 9........................

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

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

Troubleshooting 4 -- 30...........................

Testing 4 - - 36...................................

Adjustments 4 -- 70..............................

Service and Repairs 4 -- 72.......................

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 -- 6............................

Adjustments 5 -- 17..............................

Electrical System Quick Checks 5 -- 18.............

Component Testing 5 -- 20........................

Service and Repairs 5 -- 47.......................

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........................

SafetyProduct Records

and Maintenance

Kubota

Diesel Engine

System

Hydraulic

System

Electrical

Groundsmaster 4000--D/4010--D

Axles, Planetaries

Chassis

Cutting

and Brakes

Decks

This page is intentionally blank.

Groundsmaster 4000--D/4010--D

Table Of Contents (Continued)

Chapter 9 -- Operator Cab

General Information 9 -- 2........................

Service and Repairs 9 -- 3........................

SANDEN SD COMPRESSOR SERVICE GUIDE

Chapter 10 -- Foldout Drawings

Hydraulic Schematic 10 -- 3.......................

Electrical Schematics 10 -- 4......................

Wire Harness Drawings 10 -- 9....................

Cab

OperatorFoldout

Drawings

Groundsmaster 4000--D/4010--D

This page is intentionally blank.

Groundsmaster 4000--D/4010--D

Chapter 1

Safety

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

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

While Operating 3.............................

Maintenance and Service 4....................

JACKING INSTRUCTIONS 5.....................

SAFETY AND INSTRUCTION DECALS 6..........

Safety

Groundsmaster 4000--D/4010--D Page 1 -- 1 Safety

General Safety Instructions

TheGroundsmaster4000-Dand4010--Daretestedand certified by Toro for compliance with existing safety standards and specifications. Although hazard control and accident prevention partially are dependent upon the design and configuration of the machine, these factors are also dependent upon the awareness, concern and proper training of the personnel involved in the operation, transport, maintenance and storage of the machine.Improper use or maintenance ofthemachinecan resultin injury or death. Toreducethepotentialforinjury or death, 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. Keep all shields, safety devices 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.

4. Since diesel 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.

Groundsmaster 4000--D/4010--DPage 1 -- 2Safety

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.

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.

5. Before getting off the seat: A. Ensure that traction pedal is in neutral. B. Apply the parking brake.

Safety

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 hydraulic pressurefrom the lift circuit and eliminates the risk of the cutting decks unexpectedly lowering to the ground.

F. Do notpark ons lopes unlesswheelsarechocked or blocked.

Groundsmaster 4000--D/4010--D Page 1 -- 3 Safety

Maintenance and Service

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

2. Make sure machine is in safe operating condition by keeping all nuts, bolts and screws tight.

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

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

5. Keepbodyandhandsawayfrompinholeleaksinhydrauliclinesthateject 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. Before disconnecting or performing any work on the hydraulic system, all pressure in system must be relievedbyloweringcutting decks to the ground andstopping engine.

7. If major repairs areever needed orassistance 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. Ifenginemust be running to perform maintenanceor an adjustment, keep hands, feet, clothing and other parts of the body away from cutting decks and other moving parts. Keep bystanders away.

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

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.

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).

17.When welding on machine, disconnect all battery cables to prevent damage to machine electronic equipment. Disconnect negative battery cable first and positivecablelast.Also,disconnectwire harness connector fromboth of the TEC controllers and disconnect the terminal connector from the alternator. Attach welder ground cable no more than two (2) feet (0.61 meters) from the welding location.

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

Groundsmaster 4000--D/4010--DPage 1 -- 4Safety

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 securely under the frame,justtotheinside of the front tire. Jack front wheel off the ground.

1. Front jacking point 2. Front tire

Figure 1

Safety

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

Groundsmaster 4000--D/4010--D Page 1 -- 5 Safety

Safety and Instruction Decals

Numerous safety and instruction decals are affixed to your Groundsmaster machine. If any decal becomes illegibleor damaged,installanew decal.Decalpartnumbers are listed in your Parts Catalog.

Groundsmaster 4000--D/4010--DPage 1 -- 6Safety

Product Records and Maintenance

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 installedto your machine, insert the Installation Instructions, Operator’s Manuals and Parts Catalogs for those options at the end of this chapter.

Maintenance

Maintenanceprocedures andrecommendedservice intervalsforyourGroundsmasterarecoveredintheOperator’sManual.Refertothatpublicationwhenperforming regular equipment maintenance.

Groundsmaster 4000--D/4010--D Page 2 -- 1 Product Records and Maintenance

Equivalents and Conversions

0.09375

Groundsmaster 4000--D/4010--DPage 2 -- 2Product Records and Maintenance

Torque Specifications

Recommended fastener torque values are listed in the followingtables.Forcriticalapplications,as determined byToro,eitherthe recommended torque or atorquethat 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 toall fasteners which donot have a specificrequirement 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’sheadorsimilarcondition whichaffectsthe installation.

Fastener Identification

Asnoted inthefollowingtables,torquevaluesshouldbe 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. Measurethe torque required to tighten the fastener until the lines match up.

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

Useofanoffsetwrench(e.g.crowfootwrench)willaffect torquewrench calibration due to theeffectivechangeof torquewrench length. When using a torque 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”.

Themeasuredeffectivelengthofthetorquewrenchwith 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

Torque wrenchOffset wrench

The calculated torque conversion factor for this torque wrenchwiththisoffsetwrenchwouldbe 18 / 19 = 0.947.

Groundsmaster 4000--D/4010--D Page 2 -- 3 Product Records and Maintenance

Figure 3

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 + 30

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--D/4010--DPage 2 -- 4Product Records and Maintenance

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)

Class 10.9 Bolts, Screws and Studs with

Regular Height Nuts

(Class 10 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: The nominal torque values listed above are based on 75% of the minimum proof load specified in SAEJ1199.Thetoleranceisapproximately+ nominal torque value.

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.

10%ofthe

Product Records

and Maintenance

Groundsmaster 4000--D/4010--D Page 2 -- 5 Product Records and Maintenance

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 + 14 N--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--D/4010--DPage 2 -- 6Product Records and Maintenance

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

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

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

Stopping the Engine 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 13..........................

Engine Installation 15........................

Spring Coupler 18.............................

KUBOTA WORKSHOP MANUAL, DIESEL ENGINE,

03--M--E3B SERIES

Chapter 3

Kubota Diesel Engine

Kubota

Diesel Engine

Groundsmaster 4000--D/4010--D Page 3 -- 1 Kubota Diesel Engine

Specifications

Item Description

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

Bore 3.43 in (87.0 mm)

Stroke 4.031 in (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

Fuel Capacity 19 U.S. gallons (72 liters)

Fuel Injection Pump Denso PFR 4M Type Mini Pump

Injection Nozzle Denso OPD Mini Nozzle

Water Cooled, Turbocharged, Diesel Engine

Ultra Low Sulfur Content

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 U.S. quarts (9.5 liters) with Filter

Oil Pump Trochoid Type

Coolant Capacity

Groundsmaster 4000--D 13 U.S. quarts (12.3 liters) Groundsmaster 4010--D 17 U.S. quarts (16.1 liters)

Starter 12 VDC, 2.0 kW

Alternator/Regulator 12 VDC

Groundsmaster 4000--D 40 amp Groundsmaster 4010--D 90 amp

Engine Dry Weight 419 U.S. pounds (190 kg)

Groundsmaster 4000--D/4010--DPage 3 -- 2Kubota Diesel Engine

General Information

ThisChapter gives informationaboutspecificationsand repair of the diesel engine used in Groundsmaster 4000--D and 4010--D machines.

Generalmaintenance procedures are described inyour Operator’sManual.Informationonenginetroubleshooting,testing, disassembly and reassemblyis identifiedin the Kubota Workshop Manual, Diesel Engine, 03--M--E3B that is included at the end of this section.

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, Diesel Engine, 03--M--E3B. The use of some specialized test equipment is explained. However, the cost of the test equipment and the specialized nature of some repairs may dictate that the work be done at an engine 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 of your machine.

Kubota

Diesel Engine

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--D/4010--D Page 3 -- 3 Kubota Diesel Engine

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)

18. Overflow bracket

VACUATOR DIRECTION

Groundsmaster 4000--D/4010--DPage 3 -- 4Kubota Diesel Engine

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. Ifservice indicator (item 4) and adapter (item 15) 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). Torqueindicator 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

B. When securing air cleaner in air cleaner strap, tighten cap screws (item 14) only enough to prevent air cleaner from rotating in strap.

2. Wheninstallingair cleaner hose (item 1) betweenair 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. Muffler bracket

Figure 3

3. Adapter

Figure 4

3. Air cleaner strap

4. Air cleaner slots

Groundsmaster 4000--D/4010--D Page 3 -- 5 Kubota Diesel Engine

Exhaust System

16 to 22 ft--lb

(21to29N--m)

RIGHT

FRONT

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--D/4010--DPage 3 -- 6Kubota Diesel Engine

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.

Figure 6

Kubota

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

C. Torque flange nuts that secure muffler t o muffler bracket 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 thatsecure exhaust m ount to engine to 1 3 f t -- l b ( 1 7 . 6 N -- m ) .

3. Tailpipeshouldhaveequalclearancebetweenframe and engine after installation.

4. Lower and secure hood. Rev. AGroundsmaster 4000--D/4010--D Page 3 -- 7 Kubota Diesel Engine

Fuel System

25 24

RIGHT

FRONT

1. Fuel tank

2. Fuel tank bracket

3. ROPS assembly

4. Washer head screw (3 used)

5. Tank support assembly

6. Insulated clip (3 used)

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)

135 to 165 ft--lb

(183 to 223 N--m)

28. Phillips head screw (5 used)

29. Vent hose

30. Hose clamp

31. Elbow fitting (2 used)

32. Fuel cap

33. Locking flange nut (2 used)

34. Speed nut (4 used)

35. Tank cover (2 used)

36. Phillips head screw (4 used)

37. Vent tube

38. Overflow hose

39. Hose clamp

40. Fuel supply hose

Groundsmaster 4000--D/4010--DPage 3 -- 8Kubota Diesel Engine

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.

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.

1. Install fuel tank using Figure 7 as a guide. A. Torque two(2)flange nuts(item7) thatsecurethe

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 supply hose to the standpipe and vent

andoverflow hoses to theelbow fittings (Fig. 8). Secure hoses with clamps.

4. Connect wire harness connections to the fuel send-

er.

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--overgrease to the wire terminal connections.

Kubota

Diesel Engine

CAUTION

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

5. Positionbatteryinmachine.Connectpositivebattery

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

6. Lower and secure operator seat and hood.

7. Fill fuel tank.

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

4. Useafueltransferpump toremove fuel from the fuel tank and into a suitable container.

5. Disconnect wire harness connections from the fuel sender (item 26).

6. Disconnect fuel supply hose from standpipe and ventandoverflowhoses fromelbowfittingsintop oftank (Fig. 8).

7. Remove phillips head screws that secure two (2) tank covers (item 35) to ROPS assembly.Remove tank covers.

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

Groundsmaster 4000--D/4010--D Page 3 -- 9 Kubota Diesel Engine

1. Fuel supply hose

2. Vent hose

Figure 8

3. Overflow hose

4. Fuel sender

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 9

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--D/4010--DPage 3 -- 10Kubota Diesel Engine

Removal (Fig. 9)

Installation (Fig. 9)

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. Disconnect upper and lower radiator hoses from the 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. Iftemperaturesender(item8)wasremovedfromradiator,install new O--ring on sender and thread sender into radiator. Torque sender from 9to11ft--lb(12.3to

14.9 N--m). Reconnect wire harness connector to sender.

4. Positionlower radiator shroud andfanmotorbracket assembly to the radiator.

5. Secure fan motor bracket to radiator with six (6) flangehead screws and flangenuts.Positionbracketas far as possible from radiator to maximize distance between radiator and fan motor location.

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

7. 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.

Kubota

Diesel Engine

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

8. Removefastenersthatsecurelower radiator shroud 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.Disconnect wire harness connector from temperature sender (item 8).

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

13.Plug all radiator and hose openings to prevent contamination.

8. Connect reservoir hose to the vent tube near the radiator cap.

9. Connectupper andlowerradiator hosestothe radiator.

10.Reinstall air cleaner hose (item 61).

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

12.Close and secure hood.

Groundsmaster 4000--D/4010--D Page 3 -- 11 Kubota Diesel Engine

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)

10. Rebound washer (4 used)

28 to 32 ft--lb

(38to43N--m)

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)

19. LH engine mount

Figure 10

29 to 33 ft--lb

(40to44N--m)

Loctite #242

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

28. Ground harness

Groundsmaster 4000--D/4010--DPage 3 -- 12Kubota Diesel Engine

Engine Removal (Fig. 10)

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

2. Remove battery from machine (see Battery Service intheService andRepairs sectionof Chapter5 --Electrical System).

3. Raise and support hood.

CAUTION

Do not open radiator cap or drain coolant if the radiator or engine is hot. Pressurized, hot coolant can escape and cause burns.

Ethylene--glycol antifreeze is poisonous. 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.

Figure 11

1. Alternator 2. Temperature sender

Kubota

Diesel Engine

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. Remove air cleaner systemfrom 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 temperature sender and alternator (Fig 11). B. The glow plugs (Fig. 12). C. The engine run solenoid. D. Battery,frameandwireharness groundattheen-

gine block. E. The electric starter and low oil pressure switch

(near electric starter).

1. Glow plug wire

2. Glow plug lead

1. Cable swivel

2. Cable stop

3. Throttle cable

Figure 12

3. Cylinder #4 glow plug

Figure 13

4. Cable clamp

5. Fuel supply hose

F. The air conditioning compressor (Groundsmaster 4010--D machines).

Groundsmaster 4000--D/4010--D Page 3 -- 13 Kubota Diesel Engine

8. Disconnect fuel supply hose from injection pump (Fig. 13).

9. Removethrottle cablefromengine (Figs.13and 14): A. Removelock nut thatsecuresthrottlecableswiv-

el to speed control lever. B. Loosen cable clamp and remove throttle cable

from under clamp. C. Position throttle cable away from the engine.

IMPORTANT: Thehydraulic 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.

14.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).

10.Remove fasteners that secure the upper radiator

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.

11.Remove cooling fan motor and fan assembly (Fig.

15). A. To prevent contamination of hydraulic system,

thoroughly clean exterior of fan motor and fittings. B. Disconnecthydraulic hoses fromcoolingfanmo-

tor.Putcaps orplugsonfittings and hosestoprevent contamination. Label hydraulic lines for proper assembly.

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

D. Carefullyremovefanmotor,fan and motorbracket assembly from machine.

12.Remove transport cylinder assembly from engine

mount (Fig. 16). It is not necessary to remove the hydraulichose from thecylinder.Locateandremove cylinder spacer from between transport cylinder and engine mount.

13.On Groundsmaster 4010--D machines:

1. Lock nut

2. Throttle cable

3. Cable support

4. Lock nut

5. Washer head screw

6. Cap screw (2 used)

Figure 14

7. Cable clamp

8. Spring washer (2 used)

9. Lock nut

10. Cable swivel

11. Cable stop

A. Removewindshield washer reservoir from reservoir mount on engine (Fig. 17). Position reservoir away from engine. Do not remove reservoir mount from engine.

B. Removeair conditioningcompressorfrombrackets (see Air Conditioning Compressor Removal in theServiceandRepairssectionofChapter9 --Operator Cab). Position compressor away from engine taking care to not damage compressor or hoses. Support compressor to make sure it willnot fall during engine removal.

C. Disconnect coolant hose from fitting on engine water flange.

1. Fan

2. Fan motor bracket

3. Fan motor

Figure 15

4. Cap screw (6 used)

5. Flange nut (6 used)

6. Radiator

Groundsmaster 4000--D/4010--DPage 3 -- 14Kubota Diesel Engine

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

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

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

RIGHT FRONT

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.

18.Carefully remove engine assembly from machine.

19.Ifnecessary,removeengine mountsfromthe engine using Figure 10 as a guide.

Engine Installation (Fig. 10)

1. Make sure that all parts removed from the engine duringmaintenance or rebuilding are installedtotheengine.

2. Ifremoved, installenginemounts totheengine using Figure 10 as a guide.

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

CAUTION

Figure 16

1. Carriage screw (2 used)

2. Cylinder spacer

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. RH engine mount

15. Jam nut

16. Cap screw

Kubota

Diesel Engine

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.

4. Carefully lower engine into the machine. Figure 17

5. Align engine to the engine supports and hydraulic

pumpinputshaft.Secureenginetoenginesupportswith cap screws, rebound washers and flange nuts.

1. Reservoir

2. Mount

3. Carriage screw (3 used)

4. Washer (3 used)

5. Nut (3 used)

6. Flange head screw

7. Exhaust mount

6. Secure hydraulic pump assembly to engine (see

Pump Assembly Installation in the Service and Repairs section of Chapter 4 -- Hydraulic System).

Groundsmaster 4000--D/4010--D Page 3 -- 15 Kubota Diesel Engine

7. Install fan motor and fan assembly (Fig. 15). A. Carefullypositionfanmotor,fanand motorbrack-

et assembly to radiator.

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

A. The temperature sender and alternator (Fig 11).

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

C. Remove caps and plugs placed in hoses and fittings during removal to prevent contamination.

D. Connect hydraulic hoses to cooling fan motor (see Hydraulic Hose and Tube Installation in the GeneralInformationsectionofChapter4 -- Hydraulic System).

8. Positionupperradiator shroud and coolant reservoir

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.

9. Connectthrottlecabletoinjectorpump(Figs.13and

14): A. Secure throttle cable swivel to speed control le-

ver with lock nut. B. Place throttle cable under cable clamp. C. Adjust throttle cable position in cable clamp so

that engine governor lever contacts the high speed stop bolt at the same time that the throttle lever contacts the end of the slot in the control console.

D. Tighten cable clamp to secure throttle cable.

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

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

starter). F. The air conditioning compressor (Groundsmas-

ter 4010--D machines).

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

15.Installexhaustsystemtomachine(seeExhaustSystem Installation in this section).

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

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

18.Install battery tomachine (see Battery Service in the Service and Repairs section of Chapter 5 -- Electrical System). Make sure to connect positive battery cable first and then negative battery cable. Secure battery to machine with strap and cover.

10.Connect fuel line to the injection pump (Fig. 13).

11.Installtransportcylinder assembly to engineadapter

plate (Fig. 16). Make sure that cylinder spacer is positioned between transport cylinder and engine mount.

12.On Groundsmaster 4010--D machines: A. Position windshield washer reservoir to bracket

onengine (Fig. 17). Secure with removed fasteners. B. Install air conditioning compressor to brackets

(see Air Conditioning Compressor Installation in the Serviceand Repairs section of Chapter9 -- Operator Cab).Makesurethatdrivebeltisproperly tensioned.

C. Connect coolant hose to fitting on engine water flange.

19.Check and adjust engine oil as needed.

20.Check and adjust hydraulic oil as needed.

21.Bleed fuel system.

22.Start engine and operate hydraulic controls to properlyfill hydraulic system(see Charge Hydraulic System in the Service and Repairs section of Chapter 4 -- Hydraulic System).

23.Close and secure hood.

Groundsmaster 4000--D/4010--DPage 3 -- 16Kubota Diesel Engine

This page is intentionally blank.

Kubota

Diesel Engine

Groundsmaster 4000--D/4010--D Page 3 -- 17 Kubota Diesel Engine

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 spacer

Loctite #242

29 to 33 ft--lb

(40to44N--m)

Loctite #242 28 to 32 ft--lb

(38to43N--m)

Figure 18

10. Transport cylinder

11. Lock nut (2 used)

12. Cylinder piston

13. O--ring (2 used)

14. Backup ring (2 used)

15. Retaining ring

16. Seal

17. O--ring

18. Hydraulic fitting

19. O--ring

20. Hydraulic hose

21. RH engine mount

22. Cap screw

23. Jam nut

24. Lock washer (2 used)

25. Cap screw (2 used)

Groundsmaster 4000--D/4010--DPage 3 -- 18Kubota Diesel Engine

Coupler Removal (Fig. 18) NOTE: The hydraulic pump assembly needs to be re-

moved from engine before coupler can be removed.

1. Ifengineis in machine, support enginefrombelowto prevent it from shifting. Remove the following:

A. Removehydraulicpumpassembly frommachine (seePiston (Traction) Pump Removal in the Service and Repairs section of Chapter 4 -- Hydraulic System).

B. Removetransportcylinderassemblyfromengine mount. It is not necessary to remove the hydraulic hose from the cylinder. Locate and remove cylinder spacer from between transport cylinder and engine mount.

2. Remove flywheel plate and spring coupler from engine using Figure 18 as a guide.

Coupler Installation (Fig. 18)

1. Position spring coupler to engine flywheel and align mounting holes. Make sure that coupling hub is away from engine flywheel (Fig. 19).

Engine Side Hydraulic

Pump Side

Figure 19

1. Coupler 2. Engine flywheel

Kubota

Diesel Engine

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) .

3. Apply Loctite #242 (or equivalent) to threads of cap screws (items 5 and 7) used to secure flywheel plate to engine. Position flywheel plate to engine and engine mounts. 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. If engine is in machine, install the following: A. Install transport cylinder assembly to engine

mount. Make sure that cylinder spacer is placed between transport cylinder and engine mount. Check transport cylinder adjustment (see Transport Cylinderin the ServiceandRepairssection of Chapter 4 -Hydraulic System).

B. Installhydraulic pump assembly tomachine(see Piston (Traction) Pump Installation in the Service and Repairs section of Chapter 4 -- Hydraulic System).

Groundsmaster 4000--D/4010--D Page 3 -- 19 Kubota Diesel Engine

This page is intentionally blank.

Groundsmaster 4000--D/4010--DPage 3 -- 20Kubota Diesel Engine

Chapter 4

Hydraulic System

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

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

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

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

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

Relieving Hydraulic System Pressure 4..........

Traction Circuit Component Failure 4............

Hydraulic Hoses 5............................

Hydraulic Hose and Tube Installation 6..........

Hydraulic Fitting Installation 7..................

HYDRAULIC SCHEMATIC 9.....................

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

Traction Circuit: Low Speed (4WD) 10...........

Traction Circuit: Hi Speed (2WD) 12.............

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

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

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

Mow Circuit Cutting Deck Blade Braking 20......

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

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

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

TROUBLESHOOTING 30........................

TESTING 36...................................

Traction Circuit Charge Pressure 38.............

Traction Circuit Relief Pressure 40..............

Counterbalance Pressure 42...................

Traction Circuit Reducing Valve (PR) Pressure 44.

Rear Traction Circuit (RV) Relief Pressure 46.....

Piston (Traction) Pump Flow 48.................

Cutting Deck Circuit Pressure 50................

PTO Relief Pressure 52........................

Cutting Deck Motor Case Drain Leakage 54......

Cutting Deck Gear Pump Flow 56...............

Lift/Lower Circuit Relief Pressure 58.............

Steering Circuit Relief Pressure 60..............

Steering Cylinder Internal Leakage 62...........

Steering and Lift/Lower Gear Pump Flow 64......

Engine Cooling Fan Circuit 66..................

Engine Cooling Fan Circuit Gear Pump Flow 68..

ADJUSTMENTS 70.............................

Traction Linkage Adjustment 70.................

SERVICE AND REPAIRS 72.....................

General Precautions for Removing and

Installing Hydraulic System Components 72....

Check Hydraulic Lines and Hoses 72............

Flush Hydraulic System 73.....................

Filtering Closed--Loop Traction Circuit 74........

Charge Hydraulic System 75...................

Hydraulic Reservoir 76........................

Hydraulic Oil Cooler 78........................

Gear Pump 80.....

Gear Pump Service 82........................

Traction Circuit 84............................

Transport Cylinder 85.........................

Piston (Traction) Pump 86.....................

Piston (Traction) Pump Service 88..............

Rear Axle Motor 90...........................

Front Wheel Motor 92.........................

Rear Axle and Front Wheel Motor Service 94.....

4WD Manifold 96.............................

4WD Manifold Service 98......................

Traction (Flow Divider) Manifold 100.............

Traction (Flow Divider) M anifold Service 102.....

Filter Manifold 104............................

Filter Manifold Service 106.....................

Steering and Engine Cooling Fan Circuits 108....

Steering Control Valve 110.....................

Steering Control Valve Service 112..............

Steering Cylinder 114.........................

Steering Cylinder Service 116..................

Engine Cooling Fan Motor 118..................

Engine Cooling Fan Motor Service 120..........

Fan Drive Manifold 124........................

Fan Drive Manifold Service 126.................

PTO Circuit 128...............................

Cutting Deck Motor 129........................

Cutting Deck Motor Service 130................

PTO Manifold 134.............................

PTO Manifold Service 136.....................

Cutting Deck Lift/Lower Circuit 138..............

Lift/Lower Manifold 140........................

Lift/Lower Manifold Service 142.................

Side Deck Lift Cylinder 144.....................

Front Deck Lift Cylinder 146....................

Lift Cylinder Service 148.......................

EA TON MODEL 72400 SERVO CONTROLLED

PISTON PUMP REPAIR INFORMATION

EATON MODEL 74318 and 74348 PISTON MOTORS:

FIXED DISPLACEMENT, VALVE PLATE DESIGN REPAIR INFORMATION

.......

....................

System

Hydraulic

Rev. AGroundsmaster 4000--D/4010--D Hydraulic SystemPage 4 -- 1

Specifications

Item Description

Piston (Traction) Pump Eaton Variable Displacement Piston Pump

Maximum Displacement (per revolution) 2.48 in 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

Displacement (per revolution) 2.48 in

Rear Axle Motor Eaton Fixed Displacement Piston Motor

Displacement (per revolution) 2.01 in

Gear Pump Casappa 4 Section, Positive Displacement Gear pump

Section P1/P2 Displacement (per revolution) 1.16 in Section P3/P4 Displacement (per revolution) 0.56 in

Steering Control Valve Eaton Steering Unit, Series 5

Displacement (per revolution) 6.1 in

Steering Circuit Relief Pressure 1350 PSI (93 bar)

Lift/Lower Circuit Relief Pressure 1600 PSI (110bar)

Cutting Deck Motors Sauer Danfoss Gear Motor

Displacement (per revolution) 1.17 in

(Model 72400)

(40.6 cc)

(Model 74318)

(40.6 cc)

(Model 74315)

(32.9 cc)

(19.09 cc)

(9.16 cc)

(100 cc)

(19.2 cc)

PTO Circuit Relief Pressure

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

Engine Cooling Fan Motor Casappa Gear Motor

Displacement (per revolution) 0.50 in

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

(8.3 cc)

Groundsmaster 4000--D/4010--DHydraulic System Page 4 -- 2

General Information

Operator’s Manual

Check Hydraulic Fluid

TheGroundsmasterhydraulicsystemisdesignedtooperate on anti--wear hydraulic fluid. The hydraulic reservoir located beneath the operator seat holds approximately 8 U.S. 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.

Towing Traction Unit

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

If it becomes necessary to tow (or push) the machine, tow (or push) in a forward direction only and at a speedbelow 3 mph (5 kph). Thepiston(traction)pump isequippedwith aby--passvalvethatneedstobeturned

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

90 tor’s Manual for additional towing instructions.

IMPORTANT: Do not turn by--pass valve when en gine is running.

Figure 1

1. Hydraulic reservoir cap 2. Operator seat

Figure 2

1. Bypass valve location 2. Operator seat

System

Hydraulic

Groundsmaster 4000--D/4010--D Hydraulic SystemPage 4 -- 3

Relieving Hydraulic System Pressure

Beforedisconnectingor performing any work onthehydraulic system, all pressure in the hydraulic system mustberelieved.Parkmachineonalevelsurface,make sure that PTO switch is OFF, lower cutting decks fully, stopengine and engage parking brake.Waitfor all moving parts to come to a complete stop.

To relieve hydraulic pressure in traction circuit, move tractionpedal to both forward and reverse directions. To relieve hydraulic pressure in steering circuit, rotate steering wheel in both directions.

Traction Circuit Component Failure

The traction circuit on Groundsmaster 4000--D and 4010--Dmachines is a closedloop system that includes the piston (traction) pump, two (2) front wheel motors and the rear axle motor. If a component in the traction circuit should fail, debris and contamination from the failed component will circulate throughout the traction circuit. This contamination can damage other components in the circuit so it must be removed to prevent additional component failure.

The recommended method of removing traction circuit contamination would be to temporarily install the Toro high flow hydraulic filter (see Special Toolsin this chapter) into the circuit. This filter should be used when connecting hydraulic test gauges in order to test traction circuitcomponentsorafter replacingafailedtractioncircuit component (e.g. traction (piston) pump or wheel motor). The filter will ensure that contaminates are removedfromthe closedloopandthus,donotcauseadditional component damage.

To relieve hydraulic pressure in lift circuit, start engine andfully lowerthecuttingdecks.Turnkeyswitch toOFF and remove key from the ignition switch.

System pressure in mow circuit is relieved when the PTO switch is disengaged.

Once the Toro high flow hydraulic filter kit has been placedin the circuit, raise andsupport the machine with all wheels off the ground. Then, operate the traction circuit to allow oil flow throughout the circuit.The filter will remove contamination from the traction circuit during operation. Because the Toro high flow filter is bi--directional,the tractioncircuitcan be operatedinboththe forward and reverse direction. The filter should be removed from the machine after contamination has been removed from the traction circuit. See Filtering Closed--LoopTractionCircuitintheServiceandRepairs section of this chapter for additional information on using the Toro high flow hydraulic filter.

Thealternative tousingthe Torohigh flowhydraulicfilter kit after a traction circuit component failure would be to disassemble, drain and thoroughly clean all components, tubes and hoses in the traction circuit. If any debris remains in the traction circuit and the machine is operated,thedebriscancauseadditionalcircuitcomponent failure.

Groundsmaster 4000--D/4010--DHydraulic System Page 4 -- 4

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 (seeRelievingHydraulicSystemPressure in this section).

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 the hose. Use two wrenches when tightening a hose; hold the hose straight with one wrench and tighten the hose swivel nut onto the fitting with the second wrench (see Hydraulic Hose and Tube Installation in this section). If the hose has an elbow at one end, tighten the swivel nut on that end before tightening the nut on the straight end of the hose.

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

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.

System

Hydraulic

Groundsmaster 4000--D/4010--D Hydraulic SystemPage 4 -- 5

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

1. Makesurethreadsandsealingsurfacesofthehose/ tube and the fitting are free of burrs, nicks, scratches or any foreign material.

2. Asapreventativemeasureagainstleakage,itis recommended that the face seal O--ring be replaced any time the connection is opened. Make sure the O--ringis 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

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/4010--DHydraulic System Page 4 -- 6

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. Asapreventativemeasureagainstleakage,itis 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

System

Hydraulic

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--D/4010--D Hydraulic SystemPage 4 -- 7

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. Asapreventativemeasureagainstleakage,itis 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 in Figure 9). Make sure that the fitting does not bottom in the port during installation.

6. Toputthe fitting in the desired position, unscrew it by the required amount to align fitting with incoming hose or tube, but no more than one full turn (Step 3 in Figure

9).

7. Hold the fitting in the desired position with a wrench and use a torque wrench to tighten the lock nut 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 second wrench tothe listed F.F.F.T (Step 4 in Figure9).If port material is aluminum, tighten fittingto60% of listed F.F.F.T.

Step 3Step 1

Step 2 Step 4

Figure 9

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/4010--DHydraulic System Page 4 -- 8

Hydraulic Schematic

4WD

MANIFOLD

TRACTION

FILTER

MANIFOLD

VALVE

BYPASS

.070

.035

S5 S7

S2 S3

RV2

RV1

MANIFOLD

LIFT/LOWER

MANIFOLD

FAN DRIVE

TP1 P2

M1 M2 ST L

System

Hydraulic

MANIFOLD

FRONT PTO

NOTE: A larger hydraulic schematic is

included in Chapter 10: Foldout Drawings

LH PTO

MANIFOLD

RH PTO

MANIFOLD

Rev. AGroundsmaster 4000--D/4010--D Hydraulic SystemPage 4 -- 9

Hydraulic Flow Diagrams

4WD

MANIFOLD

TRACTION

FILTER

MANIFOLD

VALVE

BYPASS

.035

.070

S5 S7

S2 S3

RV2

RV1

MANIFOLD

LIFT/LOWER

MANIFOLD

FAN DRIVE

TP1 P2

M1 M2 ST L

Working Pressure

Low Pressure (Charge)

Traction Circuit: Low Speed (4WD) (Forward Shown)

Flow

Return or Suction

MANIFOLD

FRONT PTO

LH PTO

MANIFOLD

RH PTO

MANIFOLD

Rev. A Groundsmaster 4000--D/4010--DHydraulic System Page 4 -- 10

Traction Circuit: Low Speed (4WD)

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 isdirected tothefrontwheel andrearaxle motors.Operating pressure on the high pressure side of the closed traction circuitloop is determined by the amountof load developedatthefixed displacementwheel andaxlemotors. 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 piston pump relief valve to the low pressure side of the closed loop traction circuit. The traction circuit provides operation in either Hi speed (2WD) or Low speed (4WD).

Traction circuit pressure (forward and reverse) can be measured at test ports in hydraulic tubes. The forward tractionport is on theleftside of themachineand the reverse traction port is on the right side 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 lossof hydraulic fluid from the closedlooptractioncircuit that must be replaced. The charge circuit is designedto replace this traction circuit leakage.

The gear pump section that supplies oil to the steering and lift/lower circuits also provides oil for the 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 t he 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. Chargepressureislimitedto250PSI(17bar)by a relief valve located in the oil filter manifold. Charge pressure canbemeasuredat the charge circuit pressure test port on the oil filter manifold.

Forward Direction

Whenthe Hi/LowswitchisintheLow speed(4WD)positionandthetractionpedalispushedin theforwarddirection, 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 piston pump. Oil flow from tractionmanifoldport M2 is routed tothe P1 port of the 4WD manifoldwhereitisdirectedtothePD1cartridgeandout ofthemanifoldtodrivetherearaxlemotorintheforward direction.Oil returningfromtherearmotorre--entersthe 4WD manifold at the M2 port. Flow passes through the PD2cartridge,throughthe CVcheckvalve, outmanifold port P2 and back to the piston pump.

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 returns to the piston pump. To prevent rear wheel lock up, an adjustable relief valve (RV) in the 4WD manifold reduces rear axle motor pressure created in down hill, dynamic braking conditions.

Reverse Direction

The traction circuit operates essentially the same in reverse Low speed (4WD) as it does in the forward direction. However, the flow through the circuit is reversed. Oil flow from the piston pump is directed to the front wheel motors and also to the 4WD manifold. The oil to the front wheel motors drives them in the reverse direction and then returns to the piston pump through the tractionmanifold. Theoilto the 4WDmanifoldentersthe manifoldat portP2andflows through pressurereducing valve(PR) which limits thedown stream pressure tothe rear axle motor to 650 PSI (45 bar) so the rear wheels will not scuff the turf during reverse operation. This reducedpressure flows throughthePD2cartridge and out port M2 to the rear axle motor. Return oil from the rear motor re--enters the 4WD manifold at port M1, flows throughthePD1cartridge,exitsthemanifoldatportP1 and returns to the piston pump.

System

Hydraulic

Aflow divider is incorporated intothe traction circuit and is located in the traction manifold. When in Low speed (4WD), 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 circuit flow goes to a spinning wheel.

Groundsmaster 4000--D/4010--D Hydraulic SystemPage 4 -- 11

4WD

SHIFTED)

(PD1 ANDPD2

MANIFOLD

(EXTENDED)

(ENERGIZED)

MANIFOLD

TRACTION

FILTER

MANIFOLD

VALVE

BYPASS

.070

.035

S5 S7

S2 S3

RV2

RV1

MANIFOLD

LIFT/LOWER

MANIFOLD

FAN DRIVE

TP1 P2

M1 M2 ST L

Working Pressure

Low Pressure (Charge)

Traction Circuit: Hi Speed (2WD) (Forward Shown)

Flow

Return or Suction

MANIFOLD

FRONT PTO

LH PTO

MANIFOLD

RH PTO

MANIFOLD

Rev. A Groundsmaster 4000-- D/4010--DHydraulic System Page 4 -- 12

Traction Circuit: Hi Speed (2WD)

Forward Direction

With the Hi/Low speed switch in the Hi speed position (2WD),solenoid valve(SV)inthe4WD manifold is energized. The solenoid valve spool shifts to direct charge pressure that shifts the PD1 and PD2 control valve spools.TheshiftedPD1valvepreventspistonpumphydraulicflow from reaching the rear axlemotor.With flow blocked to the rear axle motor, all traction pump flow is directedtothe frontwheelmotorsto allowahighertransport speed in the forward direction.

Without flow to the rear axle motor, the rotating rear wheels drive the axle m otor so it acts like a pump. Inlet oilto the axle motor is provided by a check valve that allowscharge circuit oil into the rear axlemotor circuit. Oil leaving the axle motor enters the 4WD manifold at port M2 and is directed back to the axle motor through the shiftedPD1 cartridge and manifold port M1. To allow for rear wheel loop cooling when in forward transport operation, a small amount of oil exits through the shifted PD1 and PD2 cartridges that returns to the reservoir. This oil loss is replaced by charge circuit oil.

A transport cylinder is included in the traction circuit to reduce traction control arm movement on the piston pump when operating in Hi speed (2WD). This reduced armmovement limits swash plate rotation to preventexcessive transport speed.

System

Hydraulic

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.Itprovidesaconstantsupplyofcharge oil to the traction circuit to make up for oil that is lost due to internal leakage in the traction pump and motors.

Chargepumpflow is directed through theoilfilter and to the low pressure side of the closed loop traction circuit. A filter bypass valve allows charge oil flow to the closed loopifthe filter becomes plugged. Charge pressure is limited to 250 PSI (17bar) by a relief valve located in the oil filter manifold. Charge pressure can be measured at the charge circuit pressure test port on the oil filter manifold.

Thetraction manifold flow divider cannot beengagedby the operator during Hi speed (2WD) operation.

Reverse Direction

The traction circuit operates essentially the same in reverseHispeed(2WD)asitdoesintheforwarddirection. However, the flow through the circuit is reversed. The shifted solenoid valve (SV) and directional valves PD1 andPD2inthe4WD manifold prevent oil flow to the rear axlemotor.Oil flow from the pistonpumpis therefore directed to only the front wheel motors. This oil drives the front wheel motors in the reverse direction and then returnsto the piston pump.Oil circulation through the rear axlemotorloop isthe sameas intheHispeed(2WD)forward direction.

Groundsmaster 4000--D/4010--D Hydraulic SystemPage 4 -- 13

4WD

MANIFOLD

TRACTION

FILTER

MANIFOLD

VALVE

RETRACTING

BYPASS

.070

.035

S5 S7

S2 S3

RV2

RV1

ENERGIZED

SOLENIDS S1, S3 AND S4

MANIFOLD

LIFT/LOWER

MANIFOLD

FAN DRIVE

TP1 P2

M1 M2 ST L

Working Pressure

Low Pressure (Charge)

Lower Cutting Deck (LH Deck Shown)

Flow

Return or Suction

MANIFOLD

FRONT PTO

LH PTO

MANIFOLD

RH PTO

MANIFOLD

Rev. A Groundsmaster 4000-- D/4010--DHydraulic System Page 4 -- 14

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 steering and lift/lower circuits. Hydraulicflow from this pump section is delivered to the two circuits through aproportional flow divider that is located in the fan drive manifold. This flow divider splits pump flow approximately 50% for the steering circuit and 50% for the lift/lower circuit.

Arelief valve (RV1) located inthe lift/lower manifold limits lift/lower circuit pressure to 1600 PSI (110 bar). An adjustable valve (RV2) in the lift/lower manifold maintains back pressure (counterbalance) on the deck lift cylinders to allow some of the cutting deck weight to be transferred to the traction unit to improve traction.

Each of the cutting decks (center, right and left) can be loweredindependentlywiththeuse ofthree(3)switches on the armrest console. Pressing the front of a switch provides an input f or the TEC--5001 controller to lower acutting deck. The controller provideselectricaloutputs to solenoids in the lift/lower manifold to allow appropriate manifold valve shift to cause a deck t o lower.

When the cutting decks are in a stationary position, all solenoids in the lift/lower manifold are de--energized. In this position, lift/lower circuit flow bypasses the lift cylindersand isdirectedthroughthe lift/lower manifold,oilf ilter and then to the traction charge circuit.

NOTE: To lower a cutting deck, the operatormust be in the operator seat and the traction speed must be in the Low speed (4WD) position.

Lower Center Cutting Deck

To lower the center cutting deck, the front of the center console switch is depressed. The switch signal is an input to the TEC--5001controller which provides an electrical output to solenoid valve S6 in the lift/lower manifold. Energized solenoid valve S6 shifts to allow a passage for oil flow from the rod end of the center deck lift cylinders. The weight of the cutting deck causes the center deck lift cylinders to extend and lower the center cutting deck. Oil from the extending cylinders flows throughan orifice in the fitting at manifold port C2(.070) tocontrol thedropspeedofthecuttingdeck.Flowisthen directedthrough the shifted S6, valveRV2, out manifold port CH, to the oil filter and is then availablefor the traction charge circuit.

Whenthe center deck switch is released, solenoid S6 is de--energized and the lift cylinders and center cutting deck are held in position.

Lower Right Cutting Deck

Tolowertherightwingdeck,thefrontoftherightconsole switchis pushed asaninput to the TEC--5001 controller. The controller provides an electrical output to solenoid valvesS1,S8andS9in thelift/lowermanifold.Theenergized solenoid valves shift to allow a passage for circuit oil flow to the rod end of the right deck lift cylinder. ShiftedS1 prevents oil flowfrom bypassing the liftcylinders. Shifted S8 allows an oil path to the rod end of the right lift cylinder to retract the lift cylinder and lower the right cutting deck. Oil from the retracting cylinder flows through the orifice in manifold port C6 (.063) to control thedrop speed of the cutting deck. Flowis then directed through shifted S9, valve RV2, out manifold port CH, to the oil filter and then to the traction charge circuit.

When the deck switch is released, the manifold solenoids are de--energized and the lift cylinder and right cutting deck are held in position.

Lower Left Cutting Deck

To lower the left wing deck, the front of the left console switchis pushed asaninput to the TEC--5001 controller. The controller provides an electrical output to solenoid valvesS1,S3andS4in thelift/lowermanifold.Theenergized solenoid valves shift to allow a passage for circuit oilflow to the rod end of the left decklift cylinder.Shifted S1 prevents oil flow from bypassing the lift cylinders. Shifted S3 allows an oil path to the rod end of the left lift cylinder to retract the lift cylinder and lower the left cutting deck. Oil from the retracting cylinder flows through the orifice in manifold port C4 (.063) to control the drop speed of the cutting deck. Flow is then directed through the shifted S4, valve RV2, out manifold port CH, to the oil filter and then to the traction charge circuit.

When the deck switch is released, the manifold solenoids are de--energizedand the lift cylinder and left cutting deck are held in position.

Cutting Deck Float

Cutting deck float allows the fully lowered cutting decks to follow ground surface contours. Lift/lower manifold solenoid valves S4 (left deck), S6 (center deck) and S9 (right deck) are energized when the decks are fully lowered.Theseenergizedsolenoidsprovidean oilpassage toand from the liftcylinders to allow cylinderand cutting deck movement while mowing. Counterbalance pressure (RV2) will affect deck float operation.

NOTE: If a deck is already fully lowered when the ignition switch is moved from OFF to RUN, the deck will not be in float until the appropriate deck lift/lower switch is momentarily pressed to lower.

System

Hydraulic

Rev. AGroundsmaster 4000--D/4010--D Hydraulic SystemPage 4 -- 15

4WD

MANIFOLD

TRACTION

FILTER

MANIFOLD

VALVE

EXTENDING

BYPASS

.070

.035

S5 S7

S2 S3

RV2

RV1

ENERGIZED

SOLENIDS S1AND S2

MANIFOLD

LIFT/LOWER

MANIFOLD

FAN DRIVE

TP1 P2

M1 M2 ST L

Working Pressure

Low Pressure (Charge)

Raise Cutting Deck (LH Deck Shown)

Flow

Return or Suction

MANIFOLD

FRONT PTO

LH PTO

MANIFOLD

RH PTO

MANIFOLD

Rev. A Groundsmaster 4000-- D/4010--DHydraulic System Page 4 -- 16

Raise Cutting Deck

Each of the cutting decks (center, right and left) can be raised independently with the use of three (3) switches on the armrest console. Pressing the rear of a switch provides an input for the TEC--5001 controller to raise a cutting deck. The controller provides electrical outputs to solenoids in the lift/lower manifold to allow appropriatevalveshifttocauseadecktoraise.

NOTE: To raise a cutting deck, the operator must be in the operator seat.

Raise Center Cutting Deck

To raise the center cutting deck, the rear of the center console switch is depressed. The switch signal is an input to the TEC--5001controller which provides an electricaloutput tosolenoidvalvesS1 and S5 in the lift/lower manifold. The energized solenoid valves shift to allow a passage for circuit oil flow to the rod end of the center deck lift cylinders. Shifted S1 prevents oil flow from bypassing the lift cylinders.Shifted S5 allowsan oil path to therodend of the front lift cylinders causing theliftcylinders to retract and raise the center cutting deck. An orifice in manifold port C2 (.035) exists to control the raise speed of the cutting deck. Oil from the barrel end of the retracting cylinders returns to the hydraulic reservoir.

Raise Right Cutting Deck

To raise the right deck, the rear of the right console switch is depressed as an input to the TEC-- 5001 controller.The controller provides an electrical output to solenoid valves S1 and S7 in the lift/lower manifold. The energized solenoid valves shift to allow a passage for circuitoil flow to the barrel end of the right deck lift cylinder. Shifted S1 prevents oil flow from bypassing the lift cylinders. Shifted S7 allows an oil path through the orifice in manifold port C6 and to the barrel end of the right lift cylinder to extend the lift cylinder and raise the right cutting deck. Oil from the extending cylinder is directed throughS8(de--energized),out manifold port CH, to the oil filter and then to the traction charge circuit.

When the deck switch is released, the manifold solenoids are de--energized and the lift cylinder and right cutting deck are held in position.

Raise Left Cutting Deck

To raise the left deck, the rear of the left console switch is depressed as an input to the TEC--5001 controller. The controller provides an electrical output to solenoid valves S1 and S2 in the lift/lower manifold. The energized solenoid valves shift to allow a passage for circuit oil flow to the barrel end of the left deck lift cylinder. ShiftedS1 prevents oil flowfrom bypassing the liftcylinders. Shifted S2 allows an oil path through the orifice in manifoldport C4 and to the barrel end of theleft liftcylinder to extend the lift cylinder and raise the left cutting deck.Oilfrom the extending cylinder is directed through S3 (de-- e nergized), out manifold port CH, to the oil filter and then to the traction charge circuit.

When the deck switch is released, the manifold solenoids are de--energizedand the lift cylinder and left cutting deck are held in position.

System

Hydraulic

When the deck switch is released, the manifold solenoids are de--energized and the center deck lift cylinders and center cutting deck are held in position.

Rev. AGroundsmaster 4000--D/4010--D Hydraulic SystemPage 4 -- 17

4WD

MANIFOLD

TRACTION

FILTER

MANIFOLD

VALVE

BYPASS

.070

.035

S5 S7

S2 S3

RV2

RV1

MANIFOLD

LIFT/LOWER

MANIFOLD

FAN DRIVE

TP1 P2

M1 M2 ST L

Working Pressure

Low Pressure (Charge)

Mow (Front Deck Shown)

Flow

Return or Suction

MANIFOLD

FRONT PTO

LH PTO

MANIFOLD

RH PTO

MANIFOLD

Rev. A Groundsmaster 4000-- D/4010--DHydraulic System Page 4 -- 18

Mow

A four section gear pump is coupled to the piston (traction)pump. Hydraulic flowforthemowcircuitis supplied by two sections of the gear pump. The gear pump section closest to the piston (traction) pump supplies hydraulicflow to the side cuttingdecks, while thenext 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),brakecartridge(LC2)andtwo(2)reliefcartridges (RV1 and RV2). Circuit pressure can be measured at port (G) of the hydraulic manifold for each cutting deck.

NOTE: To engage the mow circuit, the operator must be in the operator seat, the cutting deck(s)must be fully loweredandthetractionspeedmustbeintheLow speed (4WD) position.

PTO Not Engaged

WhenthePTOswitch is OFF or if the deck is raised with thePTOswitch ON,thePTOmanifoldsolenoidvalve(S) is not energized and the solenoid spool is in the neutral position. This solenoid spool in neutral allows a small amountofhydraulicflow toreturnto tankthroughamanifoldsensinglinewhichcauses a pressure increase that shifts bypass cartridge LC1. The pump flow is routed throughshiftedLC1andoutmanifoldportP2. Brakecartridge LC2 remains in the unshifted position to prevent any return flow from the deck motor to keep the motor from rotating.

Deck motor case drain leakage returns to the hydraulic reservoir.

PTO Circuit Relief

Maximum mow circuit pressure is limited for each deck by a relief valve (RV1) in the PTO manifold. The center and leftdeck relief valves are setat 3000 PSI (207bar) and the right deck relief valve is set at 2000 PSI (138 bar).

Relief valve (RV1) and bypass cartridge (LC1) work together as a two stage relief. When increased circuit resistance is met or if a cutting blade should strike an object, the pressure increase is felt at the relief valve. If the pressure should exceed the relief valve setting, the reliefvalve will open,creatinga small amount of hydraulic flow to return to tank through a manifold sensing line. This flow causes a pressure increase that shifts bypass cartridgeLC1anddiverts circuitflowawayfromthe deck motor to manifold port P2 (Fig. 10). When circuit pressure lowers, relief valve (RV1) closes which returns bypass cartridge LC1 back to its neutral position allowing flow to return to the deck motor.

System

Hydraulic

PUMP FLOW

Return flow from the front and right PTO manifolds is routedthroughtheoilcooler,oilfilterandthentothe gear pump input. Return flow from the left PTO manifold provides supply for the right deck.

PTO Engaged

When the PTO switch is turned ON and the decks are lowered, the PTO manifold solenoid valve (S) is energized by the TEC--5001controller. This shifted solenoid valve prevents any sense line flow through the valve whichallowsthebypasscartridgeLC1tobe initsneutral position.Gear pump flow enteringthemanifoldisrouted out manifoldport M1 and to the cutting deckmotor. The return flow from the deck motor re--entersmanifold port M2. The shifted solenoid valve (S) allows a small amount of this return flow to return to tank through a manifoldsensing line which causes a pressureincrease that shifts brake cartridge LC2. Hydraulic flow is routed through shifted LC2, out manifold port P2, through the oil cooler and filter and then is routed to the gear pump input. The deck motor continues to rotate as long as solenoid valve (S) is energized.

FRONT PTO

MANIFOLD

Figure 10

SOLENOIDS ENERGIZED DECK MOTOR STALLED RV1 SHIFTED LC1 SHIFTED

RETURN

Groundsmaster 4000--D/4010--D Hydraulic SystemPage 4 -- 19

Mow Circuit Cutting Deck Blade Braking

WhentheoperatorturnsthePTOswitchOFF orifadeck is raised with the PTO switch ON, PTO manifold solenoidvalve(S)isde--energizedcausingbypass cartridge (LC1) to shift (refer to information in Mow Circuit in this section).This shifted cartridge allowsoilreturnoutmanifold port P2. At the same time, solenoid valve (S) in its neutralpositionpreventsanysenseline flowthrough the spool which causes the brake cartridge (LC2) to shift to its neutral position blocking return flow from the deck motor and slowing the cutting blades (Fig. 11).

Theinertiaoftherotating cuttingblades,however,effectively turns the deck motor into a pump causing an increasein pressure as the flow from the motor comesup against the closed brake cartridge (LC2). When this pressurebuilds to approximately 600 PSI (41 bar), relief valve (RV2) opens which allows a small amount of hydraulic flow to return to tank through a manifold sensing line (Fig. 12). This flow causes a pressure increase that shifts brake cartridge (LC2) to once again allow oil flow from the motor (Fig. 13). When return pressure drops below 600 PSI (41 bar), relief valve (RV2) reseats and causes LC2 to close again blocking return flow from the deckmotortofurtherslowthecutting blades.Thisaction ofthebrake relief valve opening and the brake cartridge shifting occurs several times in a very short time frame as the blades finally come to a stop. Once the blades have stopped, brake cartridge LC2 remains in the neutral position to keep the deck motor from rotating.

PTO

MANIFOLD

PUMP FLOW

RETURN

Figure 11

PUMP FLOW

PTO

MANIFOLD

PTO

MANIFOLD

RETURN

Figure 12

PUMP FLOW

RETURN

Figure 13

Groundsmaster 4000--D/4010--DHydraulic System Page 4 -- 20

This page is intentionally blank.

System

Hydraulic

Groundsmaster 4000--D/4010--D Hydraulic SystemPage 4 -- 21

4WD

MANIFOLD

TRACTION

FILTER

MANIFOLD

VALVE

BYPASS

.035

.070

RETRACTING

S5 S7

S2 S3

RV2

RV1

MANIFOLD

LIFT/LOWER

MANIFOLD

FAN DRIVE

TP1 P2

M1 M2 ST L

Working Pressure

Steering Circuit (Left Turn Shown)

Low Pressure (Charge)

Return or Suction

Flow

MANIFOLD

FRONT PTO

LH PTO

MANIFOLD

RH PTO

MANIFOLD

Rev. A Groundsmaster 4000-- D/4010--DHydraulic System Page 4 -- 22

Steering Circuit

Steering circuit pressure is limited to 1350 PSI (93 bar) bya relief valvelocatedin the steeringcontrolvalve. Circuit pressure can be measured at a test port in the hydraulic supply tube.

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

Left Turn

When a left turn is made with the engine running, the turningofthesteeringwheelpositionsthespool valve so thatflowgoesthroughthetop ofthespool.Flowentering the steering control valveat the P port goes through the spool and is routed to two places. First,most of the flow throughthevalveisby--passedoutthePBportbackto 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 retracts 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 leaving the cylinder flows back through the spool valve then through the T port and to the hydraulic reservoir.

Thesteeringcontrolvalvereturns to the neutral position when turning is completed.

Right Turn

When a right turn is made with the engine running, the turningofthesteering wheelpositionsthespoolvalveso that flow goes throughthe bottom of the spool. Flow entering the steering control valve at the P port goes throughthe spool and is routed to two places. As in a left turn,most of the flow throughthevalveisby--passedout 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. Pressure extends the steeringcylinder piston fora right turn.The rotarymeter ensures that the oil flow to the cylinder 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.

Thesteeringcontrolvalvereturns to the neutral position when turning is completed.

System

Hydraulic

STEERING CYLINDER

NO PISTON MOVEMENT

NEUTRAL POSITION

1350 PSI

STEERING CONTROL

STEERINGCYLINDER

PISTON MOVEMENT

LEFT TURN

1350 PSI

STEERING CONTROL

Figure 14

Groundsmaster 4000--D/4010--D Hydraulic SystemPage 4 -- 23

STEERING CYLINDER

PISTONMOVEMENT

RIGHT TURN

1350 PSI

STEERING CONTROL

4WD

MANIFOLD

TRACTION

FILTER

MANIFOLD

VALVE

BYPASS

.035

.070

S5 S7

S2 S3

RV2

RV1

MANIFOLD

LIFT/LOWER

MANIFOLD

FAN DRIVE

TP1 P2

M1 M2 ST L

Working Pressure

Low Pressure (Charge)

Engine Cooling Fan Circuit (Forward Direction Shown)

Flow

Return or Suction

MANIFOLD

FRONT PTO

LH PTO

MANIFOLD

RH PTO

MANIFOLD

Rev. A Groundsmaster 4000-- D/4010--DHydraulic System Page 4 -- 24

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 engine cooling fan circuit (Fig. 15).

The fan drive manifold controls the operation of the hydraulic motor that drives the engine cooling fan in addition to including the flow divider for the steering and lift/lower circuits. The fan drive manifold controls the speedand direction of the fanmotor 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

Oilflowfromthe gearpumpis sentthroughthede--energizedfanmanifoldsolenoid valve(S1)torotate thecooling fan motor.Return flow from the motor re--entersthe manifold (port M2), through the de--energized solenoid valve(S1), outofthe manifold (portT)andthen isrouted through the oil cooler and oil filter.

ing oil flow to return to the 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 thefan should be run in reverse before fan rotation is returned to the forward direction.

Figure 15

1. Gear pump 2. Fan drive manifold

REVERSE DIRECTION SHOWN

TO RESERVOIR

TO STEERING

CIRCUIT

M1 M2 L

(ENERGIZED)

TO LIFT/LOWER CIRCUIT

System

Hydraulic

Reverse Direction Fan Operation (Fig. 16)

TheTEC--5002controller can reversethecooling fan to clean debris from the rear intake screen. If hydraulic oil and/or engine coolant temperatures increase to an unsuitable level, a high PWM signal is sent to the (PRV) valve to slow the cooling fan and direct pump oil flow to the reservoir. The controller then energizes solenoid valve(S1)in thefandrivemanifoldtoreversecoolingfan motoroil flow so that themotorrunsinthereversedirection.AlowerPWMsignalis sent to the PRV valve allow-

Groundsmaster 4000--D/4010--D Hydraulic SystemPage 4 -- 25

P1 P2T

TO OIL COOLER

Figure 16

FAN DRIVE MANIFOLD

FROM GEAR PUMP

Special Tools

Order special tools from your Toro Distributor.

Hydraulic Pressure Test Kit

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

Toro Part Number: TOR47009

15 GPM Hydraulic Tester Kit (Pressure and Flow)

Figure 17

Use to test hydraulic circuits and components for flow andpressurecapacitiesas recommendedinthe Testing sectionofthischapter.Thistesterincludes thefollowing:

1. INLET H OSE: 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. PRESSURE GAUGE: Glycerine filled 0 to 5000 PSI 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 hydraulictesterconnectsto thehydraulicsystem circuit.

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

Toro Part Number: TOR214678

Figure 18

Groundsmaster 4000--D/4010--DHydraulic System Page 4 -- 26

40 GPM Hydraulic Tester (Pressure and Flow)

Use to test hydraulic circuits and components for flow andpressurecapacitiesas recommendedinthe Testing sectionofthischapter.Thistesterincludes thefollowing:

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

2. PRESSURE GAUGE: Glycerine filled 0 to 5000 PSI gauge to provide operating circuit pressure.

3. FLOW METER: This meter measures actual oil flow in the operating circuit with a gauge rated from 4 to 40 GPM (20 to 150 LPM).

Toro Part Number: AT40002 NOTE: Thistesterdoesnotincludehoses(seeHydrau-

lic Hose Kit TOR6007 below).

Hydraulic Hose Kit

Thiskitincludesfittingsandhosesneededtoconnect40 GPM hydraulic tester (AT40002) or high flow hydraulic filterkit(TOR6011)tomachinehydraulic tractionsystem components.

Toro Part Number: TOR6007

Figure 19

Figure 20

System

Hydraulic

Groundsmaster 4000--D/4010--D Hydraulic SystemPage 4 -- 27

High Flow Hydraulic Filter Kit

The high flow hydraulic filter kit is designed with large flow (40 GPM/150 LPM) and high pressure (5000 PSI/345 bar) capabilities. This kit provides for bi--directionalfiltration which prevents filtered debris from being allowedback intothe circuit regardless of flow direction.

If a component failure occurs in the closed loop traction circuit, contamination from the failed part will remain in the circuit until removed. When connecting hydraulic test gauges in order to test traction circuit components orafterreplacing afailedtractioncircuitcomponent(e.g. hydrostat or wheel motor), the high flow hydraulic filter can be installed in the traction circuit. The filter will ensure that contaminates are removed from the closed loopandthus,donotcause additional component damage.

Toro Part Number: TOR6011 NOTE: This kit does not include hoses (see Hydraulic

Hose Kit TOR6007 above). NOTE: Replacementfilter element is Toro part number

TOR6012. Filter element cannister tightening torque is 25 ft--lb (34 N--m).

Figure 21

O --Ring Kit

The O--ring kit includes O--rings in a variety of sizes for face seal and port seal hydraulic connections. It is recommended that O--rings be replaced whenever a hydraulic connection is loosened.

Toro Part Number: 117--2727

Figure 22

Groundsmaster 4000--D/4010--DHydraulic System Page 4 -- 28

Hydraulic Test Fitting Kit

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

The kit includes: tee’s, unions, reducers, plugs, caps 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.

The table in Figure 25 provides gallons per minute (GPM)conversionformeasuredmilliliterorouncemotor case drain leakage.

Toro Part Number: TOR4077

TORO TEST FITTING KIT (TOR4079)

Figure 23

System

Hydraulic

Figure 24

Figure 25

Groundsmaster 4000--D/4010--D Hydraulic SystemPage 4 -- 29

Troubleshooting

The charts that follow contain suggestions that can be used to assist in diagnosing hydraulic system performance issues. The suggestions are not all--inclusive. Also, consider that there may be more than one cause for a machine problem.

Review the hydraulic schematic and information on hydraulic system operation in the Hydraulic Flow Diagrams section of this Chapter. This information will be useful during the hydraulic troubleshooting process.

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

NOTE: When troubleshooting traction problems on your Groundsmaster, if a problem exists in both Low (4WD) and Hi (2WD) speeds, consider a faulty component that affects the entire traction circuit (e.g. charge circuit, traction relief v alves, piston pump, front wheel motors).Ifthe problem exists in Low (4WD) butnotinHi (2WD), consider a problem in the 4WD traction system (e.g. rear axle motor, 4WD manifold).

General Hydraulic System Problems

Problem Possible Cause

Hydraulic oil leaks from machine Fitting(s), hose(s) or tube(s) is (are) loose or damaged.

O--ring(s) or seal(s) is (are) missing or damaged.

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. 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.

Groundsmaster 4000--D/4010--DHydraulic System Page 4 -- 30

Traction Circuit Problems

Problem Possible Cause

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 power is lost or machine will not operate in either direction.

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

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.

Traction pedal does not return to neutral position. Charge pressure is low. Piston (traction) pump servo control valve orifices are plugged or

damaged. Hydraulic reservoir oil level is low.

Piston pump by--pass valve is open or damaged. Charge pressure is low.

System

Hydraulic

Traction circuit pressure is low. Front wheel motor couplers are damaged.

Four wheel drive will not engage. NOTE: Low (4WD) will not engage

when the cutting decks are lowered.

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

Electrical problem exists (see Chapter 5 -- Electrical System). Solenoid valve (SV) in 4WD 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.

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

Groundsmaster 4000--D/4010--D Hydraulic SystemPage 4 -- 31

Mow Circuit Problems

Problem Possible Cause

No cutting decks will operate. NOTE: To engage the mow circuit,

the seat must be occupied, the cutting deck(s) must be fully lowered, the traction speed must be in the Low (4WD) position and the PTO switch must be ON.

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

All cutting decks operate slowly. Engine RPM is low.

Electrical problem exists (see Chapter 5 -- Electrical System). Gear pump is damaged (NOTE: other hydraulic circuits impacted as

well).

System pressure to the affected deck is low. Woodruff key on affected deck motor is damaged. Solenoid valve (S) in PTO manifold for affected deck is faulty. Cartridge valve in PTO manifold for affected deck is damaged or

sticking. Deck motor or gear pump section is damaged. NOTE: If appropriate, transfer a suspected damaged motor to

another cutting deck. If problem follows the motor, motor needs repair or replacement.

Deck motor or gear pump sections are damaged.

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

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

Groundsmaster 4000--D/4010--DHydraulic System Page 4 -- 32

Lift Circuit Problems

Problem Possible Cause

Cutting decks will not raise. NOTE: Seat must be occupied in or-

der to raise cutting decks.

Cutting decks raise, but will not stay up.

NOTE: Lift cylinders cannot provide an absolutely perfect seal. The cutting deck will eventually lower if left in the raised position during storage.

Cutting decks will not lower. NOTE: To lower a cutting deck, the

seat must be occupied and the traction speed must be in the Low (4WD) position.

Engine RPM is too low. Hydraulic oil level in reservoir is low. Solenoid valve (S1) in lift/lower manifold is faulty. Electrical problem exists (see Chapter 5 -- Electrical System). Lift arm pivots are binding. Relief valve in lift/lower manifold is stuck. Lift cylinder(s) is (are) damaged. Gear pump section for lift circuit is inefficient (NOTE: steering circuit

impacted as well). Lift circuit lines or fittings are leaking.

Lift cylinder is damaged. Cartridge valve(s) in lift/lower manifold has damaged seals or is

faulty.

Lift arm pivots are binding. Electrical problem exists (see Chapter 5 -- Electrical System). Solenoid valve (S1) in lift/lower manifold is faulty. Counterbalance pressure is excessive.

System

Hydraulic

Lift cylinder is damaged.

Groundsmaster 4000--D/4010--D Hydraulic SystemPage 4 -- 33

Steering Circuit Problems

Problem Possible Cause

Steering inoperative or sluggish Steering components (e.g. tie rods, steering cylinder ends) are

worn or binding. Steering cylinder is binding. Oil level in hydraulic reservoir is low (NOTE: other hydraulic sys-

tems are affected as well). Steering relief valve in steering control valve is stuck or damaged. Steering cylinder leaks internally. Steering control valve is worn or damaged. Gear pump section is worn or damaged (NOTE: a worn or dam-

aged gear pump section will also affect the lift and traction (charge) circuits).

Engine Cooling Fan Circuit Problems

Problem Possible Cause

Cooling fan runs only in forward direction (fan does not run in reverse direction).

Cooling fan does not rotate. Fan motor is worn or damaged.

Cooling fan always rotates at slow speed.

Cooling fan always rotates at fast speed.

Fan control manifold solenoid cartridge valve (S1) is faulty. Electrical problem exists that prevents fan control manifold solenoid

valve (S1) operation (see Chapter 5 -- Electrical System).

Gear pump section for engine cooling fan circuit is worn or damaged. Fan control manifold cartridge valve seals are leaking.

Check valve in fan control manifold is not seating. Fan control manifold proportional relief valve (PRV) is stuck open. Hydraulic fan motor is worn or damaged.

Fan control manifold proportional relief valve (PRV) is faulty. Electrical problem exists that prevents fan control manifold propor-

tional relief valve (PRV) operation (see Chapter 5 -- Electrical System).

Groundsmaster 4000--D/4010--DHydraulic System Page 4 -- 34

This page is intentionally blank.

System

Hydraulic

Groundsmaster 4000--D/4010--D Hydraulic SystemPage 4 -- 35

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

CAUTION

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

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.

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

3. Theenginemustbe ingoodoperatingcondition.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 flow and pressure 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 flow and pressure capabilities, completely open flow control valve on tester before starting the engine to minimize the possibility of damaging components.

WARNING

Keepbody and hands awayfrom pin hole leaksor nozzlesthat eject hydraulic fluidunderhigh pressure. Do not use hands to search for leaks; use paper or cardboard. Hydraulicfluid 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.Gangrenemay result from such an injury.

WARNING

Before disconnecting or performing any work on the hydraulic system, all pressure in the system must be relieved. See Relieving Hydraulic SystemPressureintheGeneralInformationsection in this chapter.

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

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

8. Check oil level in the hydraulic reservoir. After connecting 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 made with thehydraulic oil at normal operating temperature.

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

CAUTION

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

Groundsmaster 4000--D/4010--DHydraulic System Page 4 -- 36

Which Hydraulic Tests Are Necessary?

Before beginning any hydraulic test, identify if the problemis related tothetractioncircuit, cutting(mow)circuit, lift circuit, steering circuit or engine cooling fan circuit. Once the faulty system has been identified, perform tests that relate to that circuit.

1. If a traction circuit problem exists, consider performing one or more of the following tests: Traction Circuit Charge Pressure, Traction Circuit Relief Pressure, Counterbalance Pressure, Rear Traction Circuit (RV) Relief Pressure, Traction Circuit Reducing Valve (PR) Pressure and/or Piston (Traction) Pump Flow Tests.

IMPORTANT: Refer to Traction Circuit Component Failure in the General Information section of this chapterfor information regarding the importanceof removing contamination from the traction circuit.

2. If a cutting (mow) circuit problem exists, consider performing one or more of the following tests: Cutting Deck Circuit Pressure, PTO Relief Pressure, Cutting Deck Motor C ase Drain Leakage and/or Cutting Deck Gear Pump Flow Tests.

3. If a lift circuit problem exists, consider performing oneor more of thefollowing tests: Lift/Lower Circuit ReliefPressure and/or Steering and Lift/Lower Gear Pump Flow Tests.

4. Ifa steering circuit problemexists,consider performing one or more of the following tests: Steering Circuit Relief Pressure, Steering Cylinder Internal Leakage and/or Steering and Lift/Lower Gear Pump Flow Tests.

5. Ifaenginecooling fan circuit problem exists, considerperforming one or moreof the following tests: Engine Cooling Fan Circuit and/or Engine Cooling Fan Circuit Gear Pump Flow Tests.

System

Hydraulic

Groundsmaster 4000--D/4010--D Hydraulic SystemPage 4 -- 37

Traction Circuit Charge Pressure (Using Pressure Gauge)

FROM LIFT CONTROL

MANIFOLD

TRACTION

4WD

MANIFOLD

FROM FRONT DECK

CYLINDERS

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

PRESSURE

GAUGE

FILTER

MANIFOLD

FROM PTO MANIFOLDS & FAN MOTOR

FROM PTO MANIFOLDS

Groundsmaster 4000--D/4010--DHydraulic System Page 4 -- 38

ProcedureforTractionCircuitChargePressureTest

1. Make sure hydraulic oil is at normal operating temperature by operating the machine under load for approximately ten (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

8. Next, with the pressure gauge still connected to the charge pressure test port, take a gauge reading while operating the machine in forward and reverse. Start the engine and put throttle at high idle speed (2870 RPM). Apply the brakes and push the traction pedal forward while monitoring the pressure gauge. Repeat for reverse direction. Stop engine and record test results.

9. If charge pressure meets specifications under no load conditions (step 5 above), but consistently drops more than 15% when under traction load, the piston (traction) pump and/or traction motor(s) should be suspected of wear and inefficiency. When the pump or motors are worn or damaged, the charge pump is not able to keep up with internal leakage in the traction system components.

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. 26).

5. Start the engine and put throttle at high idle 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 Filter Manifold Service in the Service and Repairs section of this chapter). A worn or damaged gear pump (P3) could also be considered (see Steering and Lift/Lower Gear Pump Flow Test in this section).

NOTE: Ifgear pump (P3) is worn or damaged, charge, steering and lift circuits will all be affected.

10.When testing is completed, disconnect pressure gaugefromtestport.Lowerandsecureoperator’s seat.

Figure 26

1. Charge pressure port 2. Filter manifold

System

Hydraulic

Groundsmaster 4000--D/4010--D Hydraulic SystemPage 4 -- 39

Traction Circuit Relief Pressure (Using Pressure Gauge)

FORWARD TRACTION CIRCUIT RELIEF PRESSURE TEST SHOWN

FROM LIFT CONTROL

MANIFOLD

PRESSURE

GAUGE

MANIFOLD

TRACTION

4WD

MANIFOLD

FROM FRONT DECK

CYLINDERS

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

FILTER

MANIFOLD

FROM PTO MANIFOLDS

FROM PTO MANIFOLDS & FAN MOTOR

Groundsmaster 4000--D/4010--DHydraulic System Page 4 -- 40

Procedure for Traction Circuit Relief Pressure Test

1. Make sure hydraulic oil is at normal operating temperature by operating the machine under load for approximately ten (10) minutes. Make sure the hydraulic tank is full.

CAUTION

Movemachine toan openarea,away frompeople and obstructions.

2. Drive machine 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. 27 or 28).

4. Start the engine and movethrottle to high idlespeed (2870RPM).Releaseparkingbrake.Make sure that Hi/ Low speed switch is in the Hi speed (2WD) position.

Figure 27

1. Forward traction port 2. Left front wheel

Figure 28

1. Reverse traction port 2. Right front wheel

System

Hydraulic

5. Siton seat,applybrakesfully and slowlydepressthe tractionpedal in the appropriatedirection(forwardorreverse). 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. Release traction pedal and stopengine. Record test results.

7. If traction pressure is too low, inspect traction pump relief valves (Fig. 29). Clean or replace relief valves as necessary. These cartridge type valves are factory set, andare 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 cause low forward tractionpressure withreversepressure meeting specifications.

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

RIGHT

FRONT

1. Forward relief valve

2. Reverse relief valve

Figure 29

3. Traction pump

Groundsmaster 4000--D/4010--D Hydraulic SystemPage 4 -- 41

Counterbalance Pressure (Using Pressure Gauge)

4WD

MANIFOLD

TRACTION

FILTER

MANIFOLD

.035

.070

S5 S7

S2 S3

RV2

PRESSURE

RV1

LIFT

MANIFOLD

GAUGE

MANIFOLD

FAN DRIVE

FROM PTO MANIFOLDS

TO PTO (MOW) CIRCUIT

FROM DECK MOTORS

FROM FRONT PTO MANIFOLD

FROM RH PTO

MANIFOLD

CIRCUIT

FROM RH PTO

Rev. A Groundsmaster 4000-- D/4010--DHydraulic System Page 4 -- 42

Procedure for Counterbalance Pressure Test

1. Make sure hydraulic oil is at normal operating temperature by operating the machine under load for approximately ten (10) minutes. Make sure the hydraulic tank is full.

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

9. When testing is completed, disconnect pressure gauge from manifold test port. Install controller cover.

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. Remove controller cover to gain access to lift/lower manifold (Fig. 30).

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. Determine system charge pressure (see Traction Circuit Charge Pressure Test in this section).

5. Connect a 1000 PSI (70 bar) pressure gauge to counterbalance test port G2 on lift/lower manifold (Fig.

31).

6. Start the engine and put throttle at high idle speed

(2870RPM) with no loadonthesystem.Donotengage the cutting decks.

RIGHT FRONT

1. Controller cover

2. Screw (2 used)

Figure 30

3. Flat washer (2 used)

4. U--nut (2 used)

2 3

System

Hydraulic

GAUGE READING TO BE 220 PSI (15.2 bar) over systemcharge pressure (e.g. if charge pressureis

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

7. Stop engine and record test results.

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

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

A. Loosen lock nut on counterbalance valve (Fig.

31). 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 on the valve in a counterclockwisedirection. A 1/8 turn on the screw will make a measurable change in counterbalance pressure.

1. Lift/lower manifold

2. Test port G2

3. Counterbalance valve

Figure 31

4. Lock nut

5. Adjusting screw

Groundsmaster 4000--D/4010--D Hydraulic SystemPage 4 -- 43

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

FROM LIFT CONTROL

MANIFOLD

FROM FRONT DECK

CYLINDERS

PRESSURE

GAUGE

4WD

MANIFOLD

TRACTION

FROM STEERING VALVEPORT PB

FROM STEERING VALVE PORT T

FROM FRONT PTO MANIFOLD

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

TO STEERING & LIFT CIRCUITS

TO COOLING FAN CIRCUIT

FILTER

MANIFOLD

FROM PTO MANIFOLDS

FROM PTO MANIFOLDS & FAN MOTOR

Rev. A Groundsmaster 4000--D/4010--DHydraulic System Page 4 -- 44

Procedure for Traction Circuit Reducing Valve (PR) Pressure Test

1. Make sure hydraulic oil is at normal operating temperature by operating the machine under load for approximately ten (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) pressure gauge to test port on 4WD manifold under r adiator (Fig. 32).

4. Start the engine and put throttle at high idle speed (2870 RPM). Make sure that Hi/Low speed switch is in the Low speed (4WD) position.

5. Sitonseat,apply brakes fully andslowlydepressthe 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).

Figure 32

1. 4WD manifold 2. Pressure test port

Figure 33

1. 4WD manifold (front) 2. Reducing valve (PR)

System

Hydraulic

6. Stop engine and record test results.

7. Pressure reducing valve (PR) is locatedon the front side of the 4WD manifold (Fig. 33). Adjustment of this valve can be performed as follows:

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

A. To increase pressure setting, remove cap on reducing valve and turn the adjustment socket on the valveinaclockwisedirection.A1/8turnon the socket will make a measurable change in pressure setting.

B. Todecrease pressure setting, removecaponreducing 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 pressure setting.

C. Recheck reducing valve (PR) pressure setting and readjust as needed.

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

Figure 34

1. Relief valve cap 2. Adjustment socket

Rev. AGroundsmaster 4000--D/4010--D Hydraulic SystemPage 4 -- 45

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

FROM LIFT CONTROL

MANIFOLD

FROM FRONT DECK

CYLINDERS

PRESSURE

GAUGE

4WD

MANIFOLD

TRACTION

FROM STEERING VALVEPORT PB

FROM STEERING VALVE PORT T

FROM FRONT PTO MANIFOLD

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

TO STEERING & LIFT CIRCUITS

TO COOLING FAN CIRCUIT

FILTER

MANIFOLD

FROM PTO MANIFOLDS

FROM PTO MANIFOLDS & FAN MOTOR

Rev. A Groundsmaster 4000--D/4010--DHydraulic System Page 4 -- 46

Procedurefor RearTractionCircuit(RV)ReliefPressure Test

B. Toincrease reliefpressuresetting,rotate adjustment socket in a clockwise direction.

1. Make sure hydraulic oil is at normal operating temperature by operating the machine under load for approximately ten (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. Measure and record traction circuit pressure reducing valve (PR) pressure (see Traction Circuit Pressure Reducing Valve (PR) Pressure Test in this section).

4. Connect a 1000 PSI (70 bar) pressure gauge to test port on 4WD manifold under radiator. This is the same pressuregaugepositionasusedtomeasuretraction circuit pressure reducing valve (PR) pressure.

5. Start the engine and put throttle at high idle speed (2870RPM).Make sure that Hi/Low switch is in the Low (4WD) position.

C. To decrease pressure setting, rotate adjustment socket in a counterclockwise direction.

D. Recheck relief pressure and readjustas needed.

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

Figure 35

1. 4WD manifold (front) 2. Relief valve (RV)

System

Hydraulic

6. Operate the machine in Low speed (4WD) with the cutting decks lowered. Drivedownaslopeinaforward direction, decrease pressure on the traction pedal and monitor the pressure gauge. Pressure should increase until the relief valve lifts.

7. Stop engine and record test results.

8. Relief (RV) pressure should be approximately 750

PSI (52 bar) and at least 100 PSI (7 bar) higher than the traction circuit pressure reducing valve (PR) pressure(e.g.if the pressure reducingvalve (PR) pres-

sure is 650 PSI (45 bar), relief (RV) pressure should be at least 750 (52 bar) but not much higher).

9. Relief valve (RV) is located on the front side of the 4WD manifold (Fig. 35). Adjustment of the relief valve (RV)canbeperformedasfollows:

NOTE: Donot remove the relief valve from the hydraulic manifold for adjustment.

A. Remove cap on relief valve to locate the adjustment socket (Fig. 36). A 1/8 turn on the socket will makeameasurablechangeinreliefpressure.

Figure 36

1. Relief valve cap 2. Adjustment socket

Rev. AGroundsmaster 4000--D/4010--D Hydraulic SystemPage 4 -- 47

Piston (Traction) Pump Flow Test (Using Tester with Flow meter and Pressure Gauge)

FROM LIFT CONTROL

MANIFOLD

4WD

MANIFOLD

TRACTION

FROM FRONT DECK

CYLINDERS

FROM STEERING VALVEPORT PB

FROM STEERING VALVE PORT T

FROM FRONT PTO MANIFOLD

TO STEERING & LIFT CIRCUITS

TO COOLING FAN CIRCUIT

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

TESTER

FILTER

MANIFOLD

FROM PTO MANIFOLDS & FAN MOTOR

FROM PTO MANIFOLDS

Groundsmaster 4000--D/4010--DHydraulic System Page 4 -- 48

Procedure for Piston (Traction) Pump Flow

This test measures piston(traction)pump output (flow). During this test, pump load is created at the flow meter using the adjustable load valve on the tester.

IMPORTANT: Traction circuit flow for the Groundsmaster4000/4010 isapproximately 30GPM (113.5LPM).Use 40 GPMHydraulicTester#AT40002 (pressure and flow) for this test (see Special Tools in this chapter).

1. Make sure hydraulic oil is at normal operating temperature by operating the machine under load for approximately ten (10) minutes. Make sure the hydraulic tank is full.

2. Park machine on a level surface with the cutting decks raised and off. Latch wing decks in raised position. Make sure that the Hi/Low switch is in the Low speed (4WD) position. Shut off engine.

Test

CAUTION

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

3. Make sure that traction pedal is adjusted to the neutral position. Also, ensure that traction pump is at full stroke when traction pedal is pushed into fully forward position.

4. Raise and support machine so all wheels are off the ground(seeJackingInstructionsinChapter1 -- Safety).

5. Thoroughly clean junction of hydraulic hose and left side fitting on bottom of traction pump (forward port) (Fig. 37). Disconnect hose from left side pump fitting.

7. Startengineandrunatidlespeed.Check for any hydraulic leakage from tester and hose connections. Correct any leaks before proceeding.

8. Move throttle so engine is running at high idle speed (2870 RPM).

9. Slowly push traction pedal t o fully forward position. Keep pedal fully depressed in the forward position.

10.Havesecondperson watch pressuregauge on tester carefully while slowly closing the flow control valve until 1000 PSI (69 bar) is obtained. Verify with a phototac that the engine speed is still 2870 RPM.

NOTE: If engine speed drops below 2870 RPM, pump flow will decrease.

11.Observe flow gauge. Flow indication should be approximately 29 GPM (110 LPM).

12.Release traction pedal to the neutral position, open flow control valve on tester and shut off engine. Record test results.

13.If flow is less than 26 GPM (98 LPM), consider the following:

A. The traction pump swash plate is not being rotated fully (e.g. Hi/Low switch is not in Low speed (4WD), traction pedal linkage may need adjustment).

B. The hydrostat needs to be repaired or replaced as necessary.

14.Make necessaryrepairs before performinganyadditional tests.

15.When testing is complete, disconnect tester and hose kit from pump fitting and machine hydraulic hose. Reconnect hose to pump fitting. Lower machine to ground.

System

Hydraulic

6. Install tester with pressure gauge and flow meter in series between traction pump fitting and disconnected hosetoallowflowfromtractionpumptotester.Usehydraulichosekit (seeSpecial Toolsinthischapter)toconnect tester to machine. Make sure that fitting and hose connectionsare properlytightened.Also, make surethe flow control valve on tester is fully open.

CAUTION

Allwheels will beofftheground and rotatingduring this test. Make sure machine is supported so itwill notmove and accidentallyfall topreventinjuring anyone near the machine.

Groundsmaster 4000--D/4010--D Hydraulic SystemPage 4 -- 49

RIGHT

FRONT

Figure 37

1. Piston (traction) pump 2. LH fitting (forward port)

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

TRACTION CIRCUIT FLOW

FILTER

FROM REAR AXLE MOTOR

MANIFOLD

PRESSURE

GAUGE

FAN CIRCUIT

FROM COOLING

TO STEERING & LIFT CIRCUITS

TO COOLING FAN CIRCUIT

MANIFOLD

FRONT PTO

LH PTO

MANIFOLD

RH PTO

MANIFOLD

Groundsmaster 4000--D/4010--DHydraulic System Page 4 -- 50

Procedure for Cutting Deck Circuit Pressure Test

1. Make sure hydraulic oil is at normal operating temperature by operating the machine under load for approximately ten (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. 38, 39 and 40).

Figure 38

1. Front deck circuit pressure test port

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.

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

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

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

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. Disengagecuttingdecks. Shut offengineandrecord test results.

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

Figure 39

1. Right deck circuit pressure test port

Figure 40

1. Left deck circuit pressure test port

System

Hydraulic

Groundsmaster 4000--D/4010--D Hydraulic SystemPage 4 -- 51

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

FRONT PTO RELIEF PRESSURE TEST SHOWN

FROM 4WD MANIFOLD

CHARGE CIRCUIT

FROM FRONT WHEEL MOTORS

TRACTION CIRCUITFLOW

TRACTION CIRCUIT FLOW

FROM REAR AXLE MOTOR

FILTER

MANIFOLD

TESTER

FAN CIRCUIT

FROM COOLING

TO STEERING & LIFT CIRCUITS

TO COOLING FAN CIRCUIT

MANIFOLD

FRONT PTO

LH PTO

MANIFOLD

RH PTO

MANIFOLD

Groundsmaster 4000--D/4010--DHydraulic System Page 4 -- 52

Procedure for PTO Relief Pressure Test

1. Make sure hydraulic oil is at normal operating temperature by operating the machine under load for approximately ten (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

8. Fully open tester flow control valve and disengage cutting decks. Shut off engine and record test results. If specification is not met, adjust or clean relief valve in deck manifold port (RV1). Adjust relief valve as follows:

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

A. Removecap on r elief valve with an allen wrench. B. To increase pressure setting, turn the adjust-

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

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. 41). Disconnect hydraulic hose at deck manifold port (M1).

NOTE: Analternativeto using manifoldport (M1) would betodisconnect the inlet hydraulichose to the deck motor.

4. Install tester (flow and pressure) in series with the disconnectedhose and hydraulicmanifold port (M1)(or motor inlet if hose was disconnected at deck motor). Make sure the flow control valve on tester is fully open.

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.

C. To decrease pressure setting, turn the adjustmentscrew on thevalve in a counterclockwise direction. A 1/8 turn on the screw will make a measurable change in relief pressure.

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

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

RIGHT

FRONT

System

Hydraulic

5. Start engine and move throttle to high idle speed (2870 RPM). Engage the cutting decks.

6. Watchp ressure gauge carefully while slowly closing the tester flow control valve to fully closed.

7. 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

Groundsmaster 4000--D/4010--D Hydraulic SystemPage 4 -- 53

1. Front PTO manifold

2. LH PTO manifold

FRONT PTO MANIFOLD SHOWN

1. PTO manifold

2. PTO relief valve (RV1)

Figure 41

3. RH PTO manifold

Figure 42

3. Relief valve cap

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

FRONT CUTTING DECK MOTOR

CASE DRAIN LEAKAGE TEST SHOWN

FROM 4WD MANIFOLD

CHARGE CIRCUIT

FROM FRONT WHEEL MOTORS

FROM REAR AXLE MOTOR

TRACTION CIRCUIT FLOW

TO STEERING & LIFT CIRCUITS

TO COOLING FAN CIRCUIT

TRACTION CIRCUIT FLOW

FILTER

MANIFOLD

FAN CIRCUIT

FROM COOLING

TESTER

MEASURING

CONTAINER

MANIFOLD

FRONT PTO

CAP

LH PTO

MANIFOLD

RH PTO

MANIFOLD

Groundsmaster 4000--D/4010--DHydraulic System Page 4 -- 54

Procedure for Cutting Deck Motor Case Drain Leakage Test

5. Sitonseatandstarttheengine.Movethrottletohigh idle speed (2870 RPM). Move PTO switch to ON.

NOTE: Overa periodoftime,a deck motor can wearinternally. A worn motor may by--passoil 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, produce fewer clippingsandmay cause a different appearance on the turf.

1. Make sure hydraulic oil is at normal operating temperature by operating the machine under load for approximately ten (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.

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. 44).

7. Have a second personcollect the flow from the case drain line for 15 seconds, then move the PTO switch to OFF and stopthe engine (Fig. 44). Record test results.

TEST RESULTS: Flow less than 22.4 ounces (662 ml) (0.7 GPM/2.6 LPM) of hydraulic fluid in 15 seconds.

8. If flow is more than 22.4 ounces (662 ml) (0.7 GPM/2.6LPM) in 15 seconds, the motor is worn or damaged and should be repaired or replaced.

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

CAUTION

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. 43). Install tester (flow and pressure) in serieswith the motor and disconnectedreturn hose. Make sure the flow control valve on tester is fully open.

4. Disconnect themotor 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.

CAUTION

Figure 43

1. Deck motor (RH shown)

2. Return hose

3. Case drain hose

System

Hydraulic

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.

Groundsmaster 4000--D/4010--D Hydraulic SystemPage 4 -- 55

Figure 44

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

FRONT DECK GEAR PUMP FLOW TEST SHOWN

FROM 4WD MANIFOLD

TRACTION CIRCUIT FLOW

FROM FRONT WHEEL MOTORS

CHARGE CIRCUIT

FROM REAR AXLE MOTOR

FILTER

MANIFOLD

TESTER

FAN CIRCUIT

FROM COOLING

TO STEERING & LIFT CIRCUITS

TO COOLING FAN CIRCUIT

MANIFOLD

FRONT PTO

LH PTO

MANIFOLD

RH PTO

MANIFOLD

Groundsmaster 4000--D/4010--DHydraulic System Page 4 -- 56

Procedure for Cutting Deck Gear Pump Flow Test NOTE: Overaperiodof time,thegears andwearplates

in the pump can wear. A worn pump will by pass oil and makethepumpless efficient.Eventually,enoughoilloss willoccur to cause the cuttingdeckmotors to stall under heavy cutting conditions. Continued operation with a worn,inefficient pump can generateexcessive heatand causedamage to the sealsandother components in the hydraulic system.

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

NOTE: If engine speed drops below 2870 RPM, pump flow will decrease.

8. Flowindicationshouldbe approximately14GPM (53 LPM).

1. Make sure hydraulic oil is at normal operating temperature by operating the machine under load for approximately ten (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. Disconnect hydraulic hose from fitting in deck manifold port (P1) (Fig. 45).

4. Install tester (flow and pressure) in series with the disconnected hose and hydraulic fitting in manifold port (P1).

5. Make sure the flow control valve on tester is fully open.

6. Start engine and move throttle to high idle speed (2870 RPM). Do not engage the cutting decks.

9. Shut off engine and record test results.

10.If a pressure of 2000 PSI (138 bar) cannot be obtained or flow was less than 12 GPM (45 LPM),check for restriction in the pump intake line. If line is not restricted, consider that gear pump section for cutting deck circuit is worn or damaged.

11.After testing is completed, disconnect flow tester fromhydraulic hose and manifold port.Reconnect hose to the manifold.

RIGHT

FRONT

Figure 45

1. Front PTO manifold

2. Hyd. hose to front P1

3. LH PTO manifold

4. Hyd. hose to LH P1

System

Hydraulic

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.

Groundsmaster 4000--D/4010--D Hydraulic SystemPage 4 -- 57

Lift/Lower Circuit Relief Pressure (Using Pressure Gauge)

4WD

MANIFOLD

TRACTION

FILTER

MANIFOLD

.035

.070

S5 S7

S2 S3

RV2

RV1

LIFT

MANIFOLD

GAUGE

PRESSURE

MANIFOLD

FAN DRIVE

FROM PTOMANIFOLDS

TO PTO (MOW) CIRCUIT

FROM DECK MOTORS

FROM FRONT PTO MANIFOLD

MANIFOLD

FROM RH PTO

CIRCUIT

FROM RH PTO

Rev. A Groundsmaster 4000-- D/4010--DHydraulic System Page 4 -- 58

Procedure for Lift/Lower Circuit Relief Pressure Test

NOTE: Before attempting to check or adjust lift/lower

circuit relief pressure, make sure that counterbalance pressure is correctly adjusted (see Counterbalance Pressure Test in this section).

1. Make sure hydraulic oil is at normal operating temperature by operating the machine under load for approximately ten (10) minutes. Make sure the hydraulic tank is full.

B. Todecreasepressuresetting,removecap on reliefvalve andturntheadjustmentsocket on the valve in a counterclockwise direction. A 1/8 turn on the socket will make a measurable change in pressure setting.

C. After relief valve adjustment, recheck pressure setting and readjust as needed.

9. Ifrelief valveadjustmentdoes notchangerelief pressure, check for restriction in pump intake line, lift cylinder(s) internal leakage or gear pump damage.

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. Remove controller cover to gain access to lift/lower manifold (Fig. 46).

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 5,000 PSI (345 bar) pressure gauge to test port G1 on lift/lower manifold (Fig. 47).

5. Sit on the seat and s tart the engine. Move throttle to high idle speed (2870 RPM).

6. While sitting on the seat, depress the rear of one of the lift switches to fully raise the cutting deck. Momentarilyholdtheswitch withthedeck fullyraisedwhile looking at the gauge.

GAUGE READING TO BE approximately 1600 PSI (110 bar).

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

2 3

RIGHT FRONT

Figure 46

1. Controller cover

2. Screw (2 used)

3. Flat washer (2 used)

4. U--nut (2 used)

System

Hydraulic

7. Release the lift switch,stoptheengineandrecord test results.

8. Reliefvalve (RV1)islocated on thetopsideof the lift/ lowermanifold (Fig. 47). Adjustment of thisvalvecanbe performed as follows:

NOTE: Donot remove the relief valve from the hydraulic manifold for adjustment.

A. To increase pressure setting, remove cap on reliefvalve andturntheadjustment socketonthevalve in a clockwise direction. A 1/8 turn on the socket will make a measurable change in pressure setting.

Groundsmaster 4000--D/4010--D Hydraulic SystemPage 4 -- 59

1. Lift/lower manifold

2. Test port G1

Figure 47

3. Relief valve RV1

Steering Circuit Relief Pressure (Using Pressure Gauge)

4WD

MANIFOLD

TRACTION

FILTER

MANIFOLD

.035

.070

S5 S7

S2 S3

RV2

RV1

LIFT

MANIFOLD

PRESSURE

GAUGE

FAN DRIVE

FROM PTOMANIFOLDS

TO PTO (MOW) CIRCUIT

FROM DECK MOTORS

FROM FRONT PTO MANIFOLD

FROM RH PTO

MANIFOLD

CIRCUIT

FROM RH PTO

Rev. A Groundsmaster 4000-- D/4010--DHydraulic System Page 4 -- 60

Procedure for Steering Circuit Relief Pressure Test

1. Make sure hydraulic oil is at normal operating temperature by operating the machine under load for approximately ten (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 steering circuit pressure test port and connecta 5000PSI(350bar) pressuregaugeonto testport.

A. On Groundsmaster 4000--D machines, the test port is located on the steering supply hydraulic tube under the front of the machine (Fig. 48).

7. If pressure is incorrect, inspect steering relief valve in steering control valve (see Steering Control Valve in the Service and Repairs sectionof this chapter). If relief valveis operatingproperlyand if lift/lower problemsalso exist, flow divider in fan manifold and/or gear pump (third section) should be suspected of wear and inefficiency.Ifsteeringwheel continuestoturnatend of cylinder travel (with lower than normal effort), steering cylinder or steering control valve should be suspected of wear or damage.

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

B. On Groundsmaster 4010--D machines, the test port is located on the steering supply hydraulic tube under the operator seat (Fig. 49).

4. Starttheengine and move throttle tohighidleengine speed (2870 RPM).

IMPORTANT: Hold steering wheel at full lock only longenough to geta systemreliefpressurereading. Holding the steering wheel against the stop for an extended period can damage the steering control valve.

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

GAUGE READING TO BE 1300 to 1400 PSI (90 to 96 bar).

6. Stop the engine and record test results.

Figure 48

1. Steering circuit pressure test port (GM4000--D)

Figure 49

1. Steering circuit pressure test port (GM4010--D)

System

Hydraulic

Groundsmaster 4000--D/4010--D Hydraulic SystemPage 4 -- 61

Steering Cylinder Internal Leakage

STEERING CYLINDER

CYLINDER FULLY

EXTENDED

LOOK FOR

LEAKAGE

STEEL CAP

STEERING WHEEL

TURNED FOR

RIGHT TURN

1350 PSI

STEERING CONTROLT

Groundsmaster 4000--D/4010--DHydraulic System Page 4 -- 62

Toro 4014-D, 4000-D User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Preface

Table Of Contents

Table of Contents

General Safety Instructions

Before Operating

While Operating

Maintenance and Service

Jacking Instructions

Safety and Instruction Decals

Table of Contents

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

Table of Contents

Specifications

General Information

Operator’s Manual

Stopping the Engine

Service and Repairs

Air Filter System

Exhaust System

Fuel System

Radiator

Engine

Spring Coupler

Table of Contents

Specifications

General Information

Operator’s Manual

Check Hydraulic Fluid

Towing Traction Unit

Relieving Hydraulic System Pressure

Traction Circuit Component Failure

Hydraulic Hoses

Hydraulic Schematic

Hydraulic Flow Diagrams

Mow Circuit Cutting Deck Blade Braking

Special Tools

Troubleshooting

General Hydraulic System Problems

Traction Circuit Problems

Mow Circuit Problems

Lift Circuit Problems

Steering Circuit Problems

Engine Cooling Fan Circuit Problems

Testing

Steering Cylinder Internal Leakage