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Part No. 13202SL Service Manual (Models 30603, 30605, 30607 and 30609) GroundsmasterR 4000--D & 4010--D Preface The purpose of this publication is to provide the service technician with information for troubleshooting, testing and repair of major systems and components on the Groundsmaster 4000--D (Models 30605 and 30609) and Groundsmaster 4010--D (Models 30603 and 30607). REFER TO THE OPERATOR’S MANUAL FOR OPERATING, MAINTENANCE AND ADJUSTMENT INSTRUCTIONS. For reference, insert a copy of the Operator’s Manual and Parts 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. The Toro Company reserves the right to change product specifications or this publication without notice. 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: A NOTE will give general information about the correct operation, maintenance, service, testing or repair of the machine. IMPORTANT: The IMPORTANT notice will give important instructions which must be followed to prevent damage to systems or components on the machine. Groundsmaster 4000--D E The Toro Company - 2014 This page is intentionally blank. Groundsmaster 4000--D/4010--D General Safety Instructions . . . . . . . . . . . . . . . . . . 1 -- 2 Jacking Instructions . . . . . . . . . . . . . . . . . . . . . . . . . 1 -- 5 Safety and Instruction Decals . . . . . . . . . . . . . . . . 1 -- 6 General Information . . . . . . . . . . . . . . . . . . . . . . . . 5 -- 2 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 -- 6 InfoCenter Display . . . . . . . . . . . . . . . . . . . . . . . . . . 5 -- 8 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 -- 15 Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 -- 25 Electrical System Quick Checks . . . . . . . . . . . . . 5 -- 29 Component Testing . . . . . . . . . . . . . . . . . . . . . . . . 5 -- 30 Service and Repairs . . . . . . . . . . . . . . . . . . . . . . . 5 -- 63 1 1 2 3 Chapter 3 -- Yanmar Diesel Engine Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 -- 2 General Information . . . . . . . . . . . . . . . . . . . . . . . . 3 -- 5 Service and Repairs . . . . . . . . . . . . . . . . . . . . . . . 3 -- 10 YANMAR TNV (Tier 4i) SERIES SERVICE MANUAL YANMAR TNV (Tier 4i) SERIES TROUBLE-SHOOTING MANUAL YANMAR TNV (Tier 4) SERIES SERVICE MANUAL YANMAR TNV (Tier 4) SERIES TROUBLESHOOTING MANUAL Chapter 4 -- Hydraulic System Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . General Information . . . . . . . . . . . . . . . . . . . . . . . . Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Service and Repairs . . . . . . . . . . . . . . . . . . . . . . . . 6 -6 -6 -6 -- 2 3 4 6 Chapter 7 -- Chassis General Information . . . . . . . . . . . . . . . . . . . . . . . . 7 -- 1 Service and Repairs . . . . . . . . . . . . . . . . . . . . . . . . 7 -- 2 Chapter 8 -- Cutting Decks Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . General Information . . . . . . . . . . . . . . . . . . . . . . . . Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . Service and Repairs . . . . . . . . . . . . . . . . . . . . . . . . 8 -8 -8 -8 -- 2 3 4 6 Cutting Decks Chassis Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 -- 2 General Information . . . . . . . . . . . . . . . . . . . . . . . . 4 -- 4 Hydraulic Schematic . . . . . . . . . . . . . . . . . . . . . . . 4 -- 10 Hydraulic Flow Diagrams . . . . . . . . . . . . . . . . . . . 4 -- 12 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 -- 28 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 -- 33 Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 -- 40 Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 -- 70 Service and Repairs . . . . . . . . . . . . . . . . . . . . . . . 4 -- 71 SAUER--DANFOSS H1 CLOSED CIRCUIT AXIAL PISTON PUMPS SERVICE MANUAL SAUER--DANFOSS K and L FRAME VARIABLE MOTORS SERVICE MANUAL EATON PARTS AND REPAIR INFORMATION: 5 SERIES STEERING CONTROL UNITS Chapter 6 -- Axles, Planetaries and Brakes Hydraulic System 2 -2 -2 -2 -- Electrical System Product Records . . . . . . . . . . . . . . . . . . . . . . . . . . . Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Equivalents and Conversions . . . . . . . . . . . . . . . . Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . Axles, Planetaries and Brakes Chapter 2 -- Product Records and Maintenance Product Records and Maintenance Chapter 5 -- Electrical System Yanmar Diesel Engine Chapter 1 -- Safety Safety Table Of Contents Groundsmaster 4000--D/4010--D This page is intentionally blank. Groundsmaster 4000--D/4010--D Table Of Contents (Continued) Chapter 10 -- Foldout Drawings Electrical Drawing Designations . . . . . . . . . . . . . 10 -Hydraulic Schematic . . . . . . . . . . . . . . . . . . . . . . . 10 -Electrical Schematics . . . . . . . . . . . . . . . . . . . . . . 10 -Wire Harness Drawings . . . . . . . . . . . . . . . . . . . . 10 -- Groundsmaster 4000--D/4010--D 2 3 4 9 Foldout Drawings General Information . . . . . . . . . . . . . . . . . . . . . . . . 9 -- 2 Service and Repairs . . . . . . . . . . . . . . . . . . . . . . . . 9 -- 3 SANDEN SD COMPRESSOR SERVICE GUIDE Operator Cab Chapter 9 -- Operator Cab This page is intentionally blank. Groundsmaster 4000--D/4010--D Safety Table of Contents GENERAL SAFETY INSTRUCTIONS . . . . . . . . . . . . Before Operating . . . . . . . . . . . . . . . . . . . . . . . . . . . . While Operating . . . . . . . . . . . . . . . . . . . . . . . . . . . . Maintenance and Service . . . . . . . . . . . . . . . . . . . . JACKING INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . SAFETY AND INSTRUCTION DECALS . . . . . . . . . . Groundsmaster 4000--D/4010--D 2 2 3 4 5 6 Page 1 -- 1 Safety Safety Chapter 1 General Safety Instructions The Groundsmaster 4000-D and 4010--D are tested and certified by Toro for compliance with existing safety standards and specifications. Although hazard control and accident prevention partially are dependent upon the design and configuration of the machine, these factors are also dependent upon the awareness, concern and proper training of the personnel involved in the operation, transport, maintenance and storage of the machine. Improper use or maintenance of the machine can result in injury or death. To reduce the potential for injury or death, comply with the following safety instructions. WARNING To reduce the potential for injury or death, comply with the following safety instructions. Before Operating 1. Review and understand the contents of the Operator’s Manual and Operator’s DVD before starting and operating the vehicle. Become familiar with the controls and know how to stop the vehicle and engine quickly. Additional copies of the Operator’s Manual are available on the internet at www.Toro.com. 4. Since diesel fuel is flammable, handle it carefully: 2. Keep all shields, safety devices and decals in place. If a shield, safety device or decal is defective, illegible or damaged, repair or replace it before operating the machine. Also tighten any loose nuts, bolts or screws to ensure machine is in safe operating condition. A. Use an approved fuel container. B. Do not remove fuel tank cap while engine is hot or running. C. Do not smoke while handling fuel. D. Fill fuel tank outdoors and only to within an inch of the top of the tank, not the filler neck. Do not overfill. E. Wipe up any spilled fuel. 3. Assure interlock switches are adjusted correctly so engine cannot be started unless traction pedal is in NEUTRAL and cutting decks are DISENGAGED. Safety Page 1 -- 2 Groundsmaster 4000--D/4010--D While Operating 6. Before getting off the seat: A. Ensure that traction pedal is in neutral. 2. Before starting the engine: B. Fully lower and disengage cutting decks. Wait for blades to stop. A. Apply the parking brake. B. Make sure traction pedal is in neutral and the PTO switch is OFF (disengaged). 3. After engine is started, release parking brake and keep foot off traction pedal. Machine must not move. If movement is evident, there may be a problem with traction pedal calibration or the piston (traction) pump that needs to be corrected before using the machine. 4. Do not run engine in a confined area without adequate ventilation. Exhaust fumes are hazardous and could possibly be deadly. C. Apply the parking brake. D. Stop engine and remove key from switch. 7. Toro recommends that anytime the machine is parked (short or long term), the cutting decks should be lowered to the ground. This relieves hydraulic pressure from the deck lift circuit and eliminates the risk of the cutting decks unexpectedly lowering to the ground. 8. Do not park on slopes unless wheels are chocked or blocked. 5. Do not touch engine, radiator or exhaust system while engine is running or soon after it is stopped. These areas could be hot enough to cause burns. Groundsmaster 4000--D/4010--D Page 1 -- 3 Safety Safety 1. Sit on the seat when starting and operating the machine. Maintenance and Service 1. Before servicing or making adjustments, lower decks, stop engine, apply parking brake and remove key from the ignition switch. 2. Make sure machine is in safe operating condition by keeping all nuts, bolts and screws tight. 3. Never store the machine or fuel container inside where there is an open flame, such as near a water heater or furnace. 4. Make sure all hydraulic connectors are tight and all hydraulic hoses and lines are in good condition before applying pressure to the hydraulic system. 5. Keep body and hands away from pin hole leaks in hydraulic lines that eject 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 must be 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 relieved by lowering cutting decks to the ground and stopping engine. 7. If major repairs are ever needed or assistance is desired, contact an Authorized Toro Distributor. 8. To reduce potential fire hazard, keep engine area free of excessive grease, grass, leaves and dirt. Clean protective screen on machine frequently. 9. If engine must be running to perform maintenance or an adjustment, keep hands, feet, clothing and other parts of the body away from cutting decks and other moving parts. Keep bystanders away. 10.To assure safety and accuracy, check maximum engine speed. 11. Shut engine off before checking or adding oil to the crankcase. Safety 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, temporarily connect the battery. Reconnect positive cable first and negative cable last. 13.Battery acid is poisonous and can cause burns. Avoid contact 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 to the safety standards for riding mowers. To assure optimum performance and continued safety certification of the machine, use genuine Toro replacement parts and accessories. Replacement parts and accessories made 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 supports, hoists and jacks. Make sure machine is parked on a solid level surface such as a concrete floor. Prior to raising the machine, 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, which may result in personal injury (see Jacking 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 positive cable last. Also, disconnect wire harness connector from both of the TEC controllers, disconnect and remove the engine ECM and disconnect the terminal connector from the alternator. Attach welder ground cable no more than two (2) feet (0.6 meters) from the welding location. 18.Make sure to dispose of potentially harmful waste (e.g. fuel, oil, engine coolant, filters, battery) in an environmentally safe manner. Follow all local codes and regulations when recycling or disposing of waste. Page 1 -- 4 Groundsmaster 4000--D/4010--D Jacking Instructions When changing attachments, tires or performing other service, use correct jacks and supports. Make sure machine is parked on a solid, level surface such as a concrete floor. Prior to raising machine, remove any attachments that may interfere with the safe and proper raising of the machine. Always chock or block wheels. Use jack stands to support the raised machine. If the machine is not properly supported by jack stands, the machine may move or fall, which may result in personal injury. Safety CAUTION 1 2 1 2 Figure 1 1. Front jacking point 2. Front tire Jacking the Front End (Fig. 1) 1. Set parking brake and chock both rear tires to prevent the machine from moving. 2. Position jack securely under the frame, just to the inside of the front tire. Jack front wheel off the ground. 3. Once the machine is raised, position jack stand under the frame as close to the wheel as possible to support the machine. 2 Jacking the Rear End (Fig. 2) 2 1 Figure 2 1. Set parking brake and chock both front tires to prevent the machine from moving. 1. Rear axle jacking point 2. Rear tire 2. Place jack securely under the center of rear axle. Jack rear of machine off the ground. 3. Once the machine is raised, use jack stands under the axle to support the machine. 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 illegible or damaged, install a new decal. Decal part numbers are listed in your Parts Catalog. Safety Page 1 -- 6 Groundsmaster 4000--D/4010--D Chapter 2 Product Records and Maintenance Table of Contents 1 1 2 2 2 3 3 3 Product Records and Maintenance PRODUCT RECORDS . . . . . . . . . . . . . . . . . . . . . . . . . MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EQUIVALENTS AND CONVERSIONS . . . . . . . . . . . Decimal and Millimeter Equivalents . . . . . . . . . . . . U.S. to Metric 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) . . . . . . . . . . . . . . . . . . . . Other Torque Specifications . . . . . . . . . . . . . . . . . . Conversion Factors . . . . . . . . . . . . . . . . . . . . . . . . . 4 5 6 6 Product Records Insert Operator’s Manuals and Parts Catalogs for your Groundsmaster at the end of this chapter. Additionally, if any optional equipment or accessories have been installed to your machine, insert the Installation Instructions, Operator’s Manuals and Parts Catalogs for those options at the end of this chapter. Maintenance Maintenance procedures and recommended service intervals for your Groundsmaster are covered in the Operator’s Manual. Refer to that publication when performing regular equipment maintenance. Groundsmaster 4000--D/4010--D Page 2 -- 1 Product Records and Maintenance Equivalents and Conversions 0.09375 Product Records and Maintenance Page 2 -- 2 Groundsmaster 4000--D/4010--D Torque Specifications These Torque Specifications for the installation and tightening of fasteners shall apply to all fasteners which do not have a specific requirement identified in this Service Manual. The following factors shall be considered when applying torque: cleanliness of the fastener, use of a thread sealant (e.g. Loctite), degree of lubrication on the fastener, presence of a prevailing torque feature (e.g. Nylock nut), hardness of the surface underneath the fastener’s head or similar condition which affects the installation. As noted in the following tables, torque values should be reduced by 25% for lubricated fasteners to achieve the similar stress as a dry fastener. Torque values may also have to be reduced when the fastener is threaded into aluminum or brass. The specific torque value should be determined based on the aluminum or brass material strength, fastener size, length of thread engagement, etc. The standard method of verifying torque shall be performed by marking a line on the fastener (head or nut) and mating part, then back off fastener 1/4 of a turn. Measure the torque required to tighten the fastener until the lines match up. Fastener Identification Grade 1 Grade 5 Grade 8 Class 8.8 Inch Series Bolts and Screws Class 10.9 Metric Bolts and Screws Figure 1 Figure 2 Using a Torque Wrench with an Offset Wrench Use of an offset wrench (e.g. crowfoot wrench) will affect torque wrench calibration due to the effective change of torque wrench 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. 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. Offset wrench 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”. The measured effective length of the torque wrench with the offset wrench installed (distance from the center of the handle to the center of the offset wrench) is 19”. The calculated torque conversion factor for this torque wrench with this offset wrench would be 18 / 19 = 0.947. Groundsmaster 4000--D/4010--D Page 2 -- 3 (effective length of torque wrench) A Torque wrench B (effective length of torque wrench + offset wrench) TORQUE CONVERSION FACTOR = A / B Figure 3 Product Records and Maintenance Product Records and Maintenance Recommended fastener torque values are listed in the following tables. For critical applications, as determined by Toro, either the recommended torque or a torque that is unique to the application is clearly identified and specified in this Service Manual. Standard Torque for Dry, Zinc Plated and Steel Fasteners (Inch Series) Thread Size # 6 -- 32 UNC Grade 1, 5 & 8 with Thin Height Nuts SAE Grade 1 Bolts, Screws, Studs & Sems with Regular Height Nuts (SAE J995 Grade 2 or Stronger Nuts) in--lb in--lb N--cm 10 + 2 13 + 2 147 + 23 # 6 -- 40 UNF # 8 -- 32 UNC 13 + 2 25 + 5 282 + 30 # 8 -- 36 UNF # 10 -- 24 UNC 18 + 2 30 + 5 339 + 56 # 10 -- 32 UNF SAE Grade 5 Bolts, Screws, Studs & Sems with Regular Height Nuts (SAE J995 Grade 2 or Stronger Nuts) SAE Grade 8 Bolts, Screws, Studs & Sems with Regular Height Nuts (SAE J995 Grade 5 or Stronger Nuts) in--lb N--cm in--lb N--cm 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 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 ft--lb ft--lb N--m ft--lb N--m ft--lb N--m 3/8 -- 16 UNC 16 + 2 16 + 2 22 + 3 30 + 3 41 + 4 43 + 5 58 + 7 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: 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. Product Records and Maintenance NOTE: The nominal torque values listed above for Grade 5 and 8 fasteners are based on 75% of the minimum proof load specified in SAE J429. The tolerance is approximately + 10% of the nominal torque value. Thin height nuts include jam nuts. Page 2 -- 4 Groundsmaster 4000--D/4010--D Standard Torque for Dry, Zinc Plated and Steel Fasteners (Metric Series) Class 8.8 Bolts, Screws and Studs with 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 + 6 in--lb 644 + 68 N--cm 78 + 8 in--lb 881 + 90 N--cm M6 X 1.0 96 + 10 in--lb 1085 + 113 N--cm 133 + 14 in--lb 1503 + 158 N--cm M8 X 1.25 19 + 2 ft--lb 26 + 3 N--m 28 + 3 ft--lb 38 + 4 N--m M10 X 1.5 38 + 4 ft--lb 52 + 5 N--m 54 + 6 ft--lb 73 + 8 N--m M12 X 1.75 66 + 7 ft--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: 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 are based on 75% of the minimum proof load specified in SAE J1199. The tolerance is approximately + 10% of the 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. Groundsmaster 4000--D/4010--D Page 2 -- 5 Product Records and Maintenance Product Records and Maintenance Thread Size Other Torque Specifications SAE Grade 8 Steel Set Screws Wheel Bolts and Lug Nuts Recommended Torque Thread Size Thread Size Square Head Hex Socket 1/4 -- 20 UNC 140 + 20 in--lb 73 + 12 in--lb 5/16 -- 18 UNC 215 + 35 in--lb 145 + 20 in--lb 3/8 -- 16 UNC 35 + 10 ft--lb 18 + 3 ft--lb 1/2 -- 13 UNC 75 + 15 ft--lb 50 + 10 ft--lb Recommended Torque** 7/16 -- 20 UNF Grade 5 65 + 10 ft--lb 88 + 14 N--m 1/2 -- 20 UNF Grade 5 80 + 10 ft--lb 108 + 14 N--m M12 X 1.25 Class 8.8 80 + 10 ft--lb 108 + 14 N--m M12 X 1.5 Class 8.8 80 + 10 ft--lb 108 + 14 N--m ** For steel wheels and non--lubricated fasteners. Thread Cutting Screws (Zinc Plated Steel) Type 1, Type 23 or Type F Thread Size Baseline Torque* No. 6 -- 32 UNC 20 + 5 in--lb No. 8 -- 32 UNC Thread Cutting Screws (Zinc Plated Steel) Thread Size Threads per Inch Baseline Torque* Type A Type B No. 6 18 20 20 + 5 in--lb 30 + 5 in--lb No. 8 15 18 30 + 5 in--lb No. 10 -- 24 UNC 38 + 7 in--lb No. 10 12 16 38 + 7 in--lb 1/4 -- 20 UNC 85 + 15 in--lb No. 12 11 14 85 + 15 in--lb 5/16 -- 18 UNC 110 + 20 in--lb 3/8 -- 16 UNC 200 + 100 in--lb * Hole size, material strength, material thickness and finish must be considered when determining specific torque values. All torque values are based on non--lubricated fasteners. Conversion Factors in--lb X 11.2985 = N--cm ft--lb X 1.3558 = N--m Product Records and Maintenance N--cm X 0.08851 = in--lb N--m X 0.7376 = ft--lb Page 2 -- 6 Groundsmaster 4000--D/4010--D Chapter 3 Yanmar Diesel Engine Table of Contents Groundsmaster 4000--D/4010--D Page 3 -- 1 Yanmar Diesel Engine SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Models 30603 and 30605 . . . . . . . . . . . . . . . . . . . . 2 Models 30607 and 30609 . . . . . . . . . . . . . . . . . . . . 3 GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . 5 Operator’s Manuals . . . . . . . . . . . . . . . . . . . . . . . . . 5 Yanmar Service and Troubleshooting Manuals . . 5 Stopping the Engine . . . . . . . . . . . . . . . . . . . . . . . . . 5 Engine Electronic Control Unit (ECU) . . . . . . . . . . 6 Yanmar Engine: Models 30603 and 30605 . . . . . 7 Yanmar Engine: Models 30607 and 30609 . . . . . 8 SERVICE AND REPAIRS . . . . . . . . . . . . . . . . . . . . . 10 Air Cleaner System . . . . . . . . . . . . . . . . . . . . . . . . . 10 Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Check Fuel Lines and Connections . . . . . . . . . 13 Empty and Clean Fuel Tank . . . . . . . . . . . . . . . . 13 Priming the Fuel System . . . . . . . . . . . . . . . . . . . 13 Fuel Tank Removal . . . . . . . . . . . . . . . . . . . . . . . 13 Fuel Tank Installation . . . . . . . . . . . . . . . . . . . . . . 13 Radiator and Oil Cooler Assembly . . . . . . . . . . . . 14 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Engine Removal . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Engine Installation . . . . . . . . . . . . . . . . . . . . . . . . 21 Spring Coupler . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Exhaust System (Models 30607 and 30609) . . . 26 YANMAR TNV (Tier 4i) SERIES SERVICE MANUAL YANMAR TNV (Tier 4i) SERIES TROUBLESHOOTING MANUAL YANMAR TNV (Tier 4) SERIES SERVICE MANUAL YANMAR TNV (Tier 4) SERIES TROUBLESHOOTING MANUAL Yanmar Diesel Engine Specifications (Models 30603 and 30605) Item Description Make / Designation Yanmar Model 4TNV84T--ZMTR: 4--Cycle, 4 Cylinder, Water Cooled, Turbocharged, Tier 4i Diesel Engine Bore 3.307 in (84 mm) Stroke 3.543 in (90 mm) 121.7 in3 (1995 cc) Total Displacement Firing Order 1 (closest to flywheel end) -- 3 -- 4 (farthest from flywheel) -- 2 Direction of Rotation Counterclockwise (viewed from flywheel) Fuel Diesel or Biodiesel (up to B20) Fuel with Low or Ultra Low Sulfur Content Fuel Tank Capacity 21 U.S. gallons (79.5 liters) Fuel Injection Pump Yanmar MP2 Distributor Type Pump Fuel Injection Type Direct Injection Starting Aid Intake Air Heater Governor Electronic All Speed Low Idle (no load) 1200 RPM High Idle (no load) 2600 RPM Engine Oil API CH--4, CI--4 or higher Engine Oil Viscosity See Operator’s Manual Crankcase Oil Capacity 6 U.S. quarts (5.7 liters) with Filter Oil Pump Trochoid Type Coolant Capacity Groundsmaster 4000--D (Model 30605) Groundsmaster 4010--D (Model 30603) 9 U.S. quarts (8.5 liters) 14.5 U.S. quarts (13.7 liters) Alternator/Regulator 12 VDC, 80 amp Engine Weight (Dry) 375 U.S. pounds (170 kg) Yanmar Diesel Engine Page 3 -- 2 Groundsmaster 4000--D/4010--D Specifications (Models 30607 and 30609) Item Description Make / Designation Yanmar Model 4TNV86CT--DTR: 4--Cycle, 4 Cylinder, Water Cooled, Turbocharged, Tier 4 Diesel Engine Bore 3.386 in (86 mm) Stroke 3.543 in (90 mm) 127.5 in3 (2090 cc) Total Displacement Firing Order 1 (closest to flywheel end) -- 3 -- 4 (farthest from flywheel) -- 2 Counterclockwise (viewed from flywheel) Fuel Diesel or Biodiesel (up to B7) Fuel with Ultra Low Sulfur Content Fuel Capacity 21 U.S. gallons (79.5 liters) Fuel Pump Yanmar Supply Pump Fuel Injection Type Common Rail with Direct Injection Governor Electronic All Speed Low Idle (no load) 1000 RPM High Idle (no load) 2700 RPM Engine Oil API CJ--4 or higher Engine Oil Viscosity See Operator’s Manual Crankcase Oil Capacity 6 U.S. quarts (5.7 liters) with Filter Oil Pump Trochoid Type Coolant Capacity Groundsmaster 4000--D (Model 30609) Groundsmaster 4010--D (Model 30607) 9 U.S. quarts (8.5 liters) 14.5 U.S. quarts (13.7 liters) Alternator/Regulator (see NOTE below) 12 VDC, 80 Amp Engine Weight (Dry) 496 U.S. pounds (225 kg) NOTE: Groundsmaster 4000--D (Model 30609) machines with serial numbers below 314000000 are equipped with a 40 amp alternator. Groundsmaster 4000--D/4010--D Page 3 -- 3 Yanmar Diesel Engine Yanmar Diesel Engine Direction of Rotation This page is intentionally blank. Yanmar Diesel Engine Page 3 -- 4 Groundsmaster 4000--D/4010--D General Information This Chapter gives information about specifications and repair of the diesel engine used in Groundsmaster 4000--D and 4010--D machines. General maintenance procedures are described in your Operator’s Manual. Information on engine troubleshooting, testing, disassembly and reassembly is identified in the Yanmar Service Manual. Most repairs and adjustments require tools which are commonly available in many service shops. Special tools are described in the Yanmar Service Manual. 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 Yanmar engines are supplied through your Authorized Toro Distributor. If no parts list is available, be prepared to provide your distributor with the Toro model and serial number of your machine. Operator’s Manuals Yanmar Diesel Engine The Operator’s Manual provides information regarding the operation, general maintenance and maintenance intervals for your Groundsmaster machine. The Yanmar Operator’s Manual includes information specific to the engine used in your Groundsmaster. Refer to these publications for additional information when servicing the machine. Yanmar Service and Troubleshooting Manuals The engine that powers your Groundsmaster machine is either a Yanmar model 4TNV84T--Z (used on Groundsmaster models 30603 and 30605) (Tier 4i) or a Yanmar model 4TNV86CT (used on Groundsmaster models 30607 and 30609) (Tier 4). Both the Yanmar Service Manual and Yanmar Troubleshooting Manual are available for these engines. Make sure that the correct engine manuals are used when servicing the engine on your Groundsmaster. Stopping the Engine IMPORTANT: After mowing or full load operation on machines with a turbo--charged engine, cool the turbo-charger by allowing the engine to run at low idle speed for five (5) minutes before stopping the engine. Failure to do so may lead to turbo-charger trouble. Groundsmaster 4000--D/4010--D Page 3 -- 5 Yanmar Diesel Engine Engine Electronic Control Unit (ECU) The Yanmar engine that powers your Groundsmaster uses an electronic control unit (ECU) for engine management and also to communicate with the machine TEC controllers and the operator Info Center display on the machine. All wire harness electrical connectors should be plugged into the engine ECU before the machine ignition switch is moved from the OFF position to either the ON or START position. 2 1 NOTE: On models 30607 and 30609, a ground wire is used to ground the engine ECU to the machine frame. The ground wire is connected to the ECU with one of the mounting screws and is connected to the frame at the engine mount. The engine electrical components (e.g. engine ECU, fuel injectors, EGR, exhaust DPF) are identified and matched in the engine ECU program. If engine electrical components are replaced on the engine, the Yanmar electronic tool must be used to update the engine ECU program which will ensure correct engine operation. If the engine ECU identifies that an engine problem exists, the engine speed may be reduced or the engine might stop. The Yanmar electronic tool and troubleshooting manual should be used to provide assistance in identifying the cause of the problem and the repairs that are necessary. Contact your Toro distributor for assistance in Yanmar engine troubleshooting. Figure 1 1. Electronic control unit (30603 / 30605) 2. Alternator 1 2 IMPORTANT: Do not plug or unplug the engine ECU for a period of thirty (30) seconds after the machine key switch is turned OFF. The ECU may remain energized even though the ignition switch is OFF. If the engine ECU is to be disconnected for any reason, make sure that the ignition switch is in the OFF position with the key removed before disconnecting the engine ECU. Also, to prevent possible ECU damage when welding on the machine, disconnect and remove the engine ECU from the machine before welding. Yanmar Diesel Engine Page 3 -- 6 Figure 2 1. Electronic control unit (30607 / 30609) 2. Alternator Groundsmaster 4000--D/4010--D Yanmar Engine: Models 30603 and 30605 During machine operation, if an engine fault occurs, the machine InfoCenter display can be used to identify the fault. Also, the Yanmar SMARTASSIST--Direct electronic control diagnostics service system is available to confirm real--time engine running status and to offer timely technical services. Figure 3 Groundsmaster 4000--D/4010--D Page 3 -- 7 Yanmar Diesel Engine Yanmar Diesel Engine The engine used on Groundsmaster models 30603 and 30605 is a Yanmar TNV Series, turbocharged, diesel engine that complies with EPA interim Tier 4 emission regulations. Engine features include an electronic control unit (ECU) controlled direct fuel injection and electronic governor. An air heater in the intake system is used to assist starting the engine. Numerous engine sensors are used to allow the engine electronic control unit (ECU) to monitor and control engine operation for optimum engine performance. Yanmar Engine: Models 30607 and 30609 The engine used on Groundsmaster models 30607 and 30609 is a Yanmar TNV Series, turbocharged, diesel engine that complies with EPA Tier 4 emission regulations. Engine features include an electronic control unit (ECU) that controls a common rail fuel injection system with direct injection, water--cooled exhaust gas recirculation (EGR), an electronic governor, an exhaust system diesel oxidation catalyst (DOC) and an exhaust diesel particulate filter (DPF) with active regeneration. Glow plugs are used to assist starting the engine. Numerous engine sensors are used to allow the engine ECU to monitor and control engine operation for optimum engine performance. During machine operation, if an engine fault occurs, the machine InfoCenter display can be used to identify the fault. Also, the Yanmar SMARTASSIST--Direct electronic control diagnostics service system is available to confirm the real--time engine running status and to offer timely technical services. The exhaust system DPF has four (4) modes for maintenance: passive regeneration, assist regeneration, reset regeneration and stationary regeneration. Figure 4 Passive regeneration is the primary mode regeneration that occurs during normal operation. When the engine is running at normal loads, the exhaust temperature will keep the DPF above the minimum temperature for regeneration so normal particulate matter (PM) accumulation in the DPF is expected. ASSIST OR RESET REGENERATION ICON Assist regeneration occurs if the engine ECU senses that the DPF backpressure has increased to its maximum threshold. During assist regeneration, the intake throttle valve limits the air flow into the engine while the injectors add additional fuel. This process increases the DPF temperature which allows accumulated particulate to burn off, without changing the load on the engine. Burning of the accumulated PM decreases the pressure across the DPF. The assist regeneration is completed automatically when necessary. A small icon will be displayed on the InfoCenter during assist regeneration (Fig. 5) to inform the operator. The machine can continue to be used during an assist regeneration. Reset regeneration takes place at a time interval (every 100 hours) to reset the baseline sensor readings in the DPF. The reset regeneration ensures that the engine is running at peak efficiency. During this mode, post injection is the means of increasing the DPF temperature. The reset regeneration is completed automatically when necessary. A small icon will be displayed on the InfoCenter during reset regeneration (Fig. 5) to inform the operator. The machine can continue to be used during a reset regeneration. Yanmar Diesel Engine STATIONARY REGENERATION REQUEST ICON STATIONARY REGENERATION IN PROCESS ICON Figure 5 NOTE: If the engine is turned off during an assist or reset regeneration process, the regeneration will resume once the engine is restarted and required temperature level is reached. Page 3 -- 8 Groundsmaster 4000--D/4010--D When the regeneration process is completed, the InfoCenter will remove the stationary regeneration icon and cease periodic regeneration messages. The engine will return to low idle speed with operator controls returned to normal. IMPORTANT: A stationary regeneration should ONLY be initiated if an InfoCenter display advisory requests that this be done. IMPORTANT: During a stationary regeneration, make sure that the machine is parked on a hard, level surface in a well ventilated area. This process runs the machine at a higher exhaust temperature for a period of approximately thirty (30) minutes to burn off collected particulate in the DPF. Yanmar Diesel Engine Stationary regeneration is requested by the engine ECU if the assist and reset regenerations do not return the DPF particulate level to an acceptable level. During the stationary regeneration, the engine ECU controls engine speed, load and air/fuel mixture to perform a controlled burn of the particulate collected in the DPF. This type of regeneration is not a normal condition and may indicate that the DPF will require service soon, that an engine problem exists (e.g. incorrect engine fuel or oil) or that a DPF pressure sensor is failing. If a stationary regeneration is necessary, an advisory will occur on the InfoCenter and the necessary steps will be listed. A large icon will be displayed on the InfoCenter instead of the temperature gauge during stationary regeneration (Fig. 5). During the stationary regeneration process, the InfoCenter display will identify the percent completed during the process. The machine cannot be used during a stationary regeneration. Groundsmaster 4000--D/4010--D Page 3 -- 9 Yanmar Diesel Engine Service and Repairs Air Cleaner System RIGHT 8 9 6 10 14 11 13 12 FRONT 15 3 4 2 7 6 5 1 VACUATOR DIRECTION 14 16 16 14 18 17 MODELS 30603 and 30605 MODELS 30607 and 30609 Figure 6 1. 2. 3. 4. 5. 6. Air cleaner assembly Tank support Indicator Adapter Air cleaner strap Flat washer (4 used) Yanmar Diesel Engine 7. 8. 9. 10. 11. 12. Cap screw (2 used) Lock nut (2 used) Flat washer (2 used) Lock nut (2 used) Spring (2 used) Flat washer (2 used) Page 3 -- 10 13. 14. 15. 16. 17. 18. Socket head screw (2 used) Hose clamp Air cleaner inlet hose Hose clamp Air cleaner outlet hose (tier 4) Air cleaner outlet hose (tier 4i) Groundsmaster 4000--D/4010--D Removal (Fig. 6) 1. Park machine on a level surface, lower cutting decks, stop engine, apply parking brake and remove key from the ignition switch. 2 4 2. Raise and support hood. 1 3. Remove air cleaner components as needed using Figure 6 as a guide. Installation (Fig. 6) 3 IMPORTANT: Any leaks in the air cleaner system will cause serious engine damage. Make sure that all air cleaner components are in good condition and are properly secured during assembly. Figure 7 1. Air cleaner housing 2. Safety filter element 3. Air filter element A. If service indicator (item 4 in Fig. 6) and adapter (item 15 in Fig. 6) were removed from air cleaner housing, apply thread sealant to adapter threads before installing adapter and indicator to housing. Install adapter so that grooves in adapter hex and adapter filter element are installed toward service indicator (shown in Fig. 8). Torque indicator from 12 to 15 in--lb (1.4 to 1.6 N--m). 2 3 12 to 15 in--lb (1.4 to 1.6 N--m) B. When installing air cleaner, orientate the vacuator valve on the air cleaner cover so that the valve is pointing in a downward position and between 5:00 to 7:00 (approximate clock position) when viewed from the end. C. When securing air cleaner in air cleaner strap, tighten cap screws (item 14) only enough to prevent air cleaner from rotating in strap. 4. Air cleaner cover 5. Vacuator valve Yanmar Diesel Engine 1. Assemble air cleaner system using Figure 6 as a guide. 5 1 Figure 8 1. Air cleaner assembly 2. Service indicator 3. Adapter D. When installing air cleaner outlet hose between air cleaner and engine, position hose to allow maximum clearance between air cleaner hose and muffler bracket. E. Make sure that air cleaner hoses do not contact the engine or exhaust system after assembly. To ensure clearance, move and/or rotate air cleaner body in air cleaner strap if necessary. 2. After all air cleaner components have been installed, lower and secure hood. Groundsmaster 4000--D/4010--D Page 3 -- 11 Yanmar Diesel Engine Fuel System 24 25 22 9 RIGHT FRONT 11 17 20 10 6 5 7 23 21 26 27 28 29 30 31 19 8 7 32 18 13 34 35 26 16 12 33 14 36 15 4 60 to 80 in--lb (7 to 9 N--m) 4 38 37 3 2 1 Figure 9 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. Carriage screw (2 used) Retaining ring (2 used) Flat washer (2 used) Flange nut (6 used) Vent hose Fuel tank Hose clamp (2 used) Elbow fitting (2 used) Stand pipe Grommet (3 used) Hose clamp Lock washer (5 used) Phillips head screw (5 used) Yanmar Diesel Engine 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. Fuel sender Gasket Fuel cap Fuel supply hose Fuel return hose RH latch bracket Tank support assembly Flange nut (2 used) Fuel tank bracket Carriage screw (2 used) Lock nut (2 used) Flat washer (2 used) Flat washer (4 used) Page 3 -- 12 27. 28. 29. 30. 31. 32. 33. 34. 35. 36. 37. 38. Lock nut (2 used) Spring (2 used) Flat washer (2 used) Socket head screw (2 used) Indicator Adapter Air cleaner assembly Air cleaner strap Cap screw (2 used) Screw (4 used) LH latch bracket Cap screw (4 used) Groundsmaster 4000--D/4010--D 4. Disconnect wire harness connections from the fuel sender (item 14). Because diesel fuel is flammable, use caution when storing or handling it. Do not smoke while filling the fuel tank. Do not fill fuel tank while engine is running, hot or when machine is in an enclosed area. Always fill fuel tank outside and wipe up any spilled diesel fuel before starting the engine. Store fuel in a clean, safety--approved container and keep cap in place. Use diesel fuel for the engine only; not for any other purpose. 5. Disconnect fuel supply, vent and return hoses from elbow fittings in top of tank (Fig. 10). 6. Remove fuel tank using Figure 9 as a guide. Tank is secured to frame with fasteners (items 1, 2, 3 and 4) on the forward side and bracket (item 22) on the rear side. Fuel Tank Installation (Fig. 9) 1. Install fuel tank using Figure 9 as a guide. When securing tank to frame, follow the following sequence: A. Loosely install fasteners on front of tank (items 1, 2, 3 and 4). Check Fuel Lines and Connections Check fuel lines and connections periodically as recommended in the Operator’s Manual. Check lines for deterioration, damage, leaking or loose connections. Replace hoses, clamps and connections as necessary. B. Install and tighten bracket (item 22) at rear of tank. C. Torque two (2) flange nuts (item 4) from 60 to 80 in--lb (7 to 9 N--m). Empty and Clean Fuel Tank Empty and clean the fuel tank periodically as recommended in the Operator’s Manual, if the fuel system becomes contaminated or if the machine is to be stored for an extended period. IMPORTANT: Follow all local codes and regulations when recycling or disposing waste fuel. To clean fuel tank, flush tank out with clean diesel fuel. Make sure tank is free of contaminates and debris. 2. Connect fuel supply hose to the standpipe and vent and return hoses to the elbow fittings (Fig. 10). Secure hoses with clamps. 3. Secure wire harness connector(s) to fuel sender. On senders with two (2) wire harness terminals, apply skin-over grease (see Special Tools in this chapter) to harness terminals after installation. 4. Lower and secure operator seat and hood. Priming the Fuel System 5. Fill fuel tank with new fuel. The fuel system needs to be primed before starting the engine for the first time, after running out of fuel or after fuel system maintenance (e.g. draining the filter/water separator, replacing a fuel hose). To prime the fuel system, make sure that the fuel tank has fuel in it. Then, turn the ignition key to the RUN position for 10 to 15 seconds which allows the fuel pump to prime the fuel system. DO NOT use the engine starter motor to crank the engine in order to prime the fuel system. 6. Prime the fuel system (see above). 7. Before returning machine to operation, make sure that no fuel leaks exist. 4 1 Fuel Tank Removal (Fig. 9) 2 1. Park machine on a level surface, lower cutting decks, stop engine, apply parking brake and remove key from the ignition switch. 2. Raise and support operator seat and hood. 3 3. Use a fuel transfer pump to remove fuel from the fuel tank and into a suitable container. Figure 10 NOTE: Fuel sender may have two (2) wire harness terminals (shown in Fig. 10) or a single harness connector. Groundsmaster 4000--D/4010--D 1. Fuel supply hose 2. Vent hose Page 3 -- 13 3. Return hose 4. Fuel sender Yanmar Diesel Engine Yanmar Diesel Engine DANGER Radiator and Oil Cooler Assembly 31 30 27 RIGHT 28 26 FRONT 3 25 32 33 2 24 4 23 6 1 29 3 21 5 34 9 8 22 10 3 16 20 19 11 35 7 Thread Sealant 12 18 17 13 36 9 4 14 15 12 3 Figure 11 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. LH radiator support Cap screw (2 used) Flange nut (12 used) Hose clamp (3 used) Hose Flange nut (6 used) Foam plug (2 used) Flange head screw (6 used) Flange head screw (9 used) Foam strip Hose bracket R--clamp (2 used) Yanmar Diesel Engine 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. Cap screw (2 used) Hose Coolant reservoir Tank mount Flat washer (7 used) Cap screw (6 used) Lower radiator hose Hose clamp (4 used) Upper radiator hose Lower radiator shroud Upper radiator shroud Hose clamp Page 3 -- 14 25. 26. 27. 28. 29. 30. 31. 32. 33. 34. 35. 36. Air cleaner inlet hose Radiator/hydraulic oil cooler Bulb seal RH radiator support Straight hydraulic fitting Intake bracket 90o hydraulic fitting Pipe plug Hex plug with O--ring Foam pad (2 used) Draincock Cap screw (2 used) Groundsmaster 4000--D/4010--D 1. Park machine on a level surface, lower cutting decks, stop engine, apply parking brake and remove key from the ignition switch. Open and support hood. MODEL 30607 (WITH TIER 4 ENGINE) 1 CAUTION RIGHT 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. FRONT 5 2 2. Drain radiator into a suitable container either by using the draincock (item 35) near the lower left side corner of the radiator or by removing the lower radiator hose from the radiator. IMPORTANT: Follow all local codes and regulations when recycling or disposing engine coolant. 3. Disconnect radiator hoses from the radiator. Groundsmaster 4010--D machines with a Tier 4 compliant engine (model 30607) use the lower radiator hose assembly shown in Figure 12. 6 3 4 Yanmar Diesel Engine Removal (Fig. 11) 3 Figure 12 1. Radiator/oil cooler 2. Lower radiator hose 3. Hose clamp RIGHT 4. Remove air cleaner inlet hose (item 25). 4. Radiator fitting 5. Hose clamp 6. Radiator hose 3 1 FRONT 5. Read the General Precautions for Removing and Installing Hydraulic System Components in the Service and Repairs section of Chapter 4 -- Hydraulic System. 4 5 6. Thoroughly clean hydraulic lines at lower radiator shroud (Fig. 13) and oil cooler ports (Fig. 14). Disconnect hydraulic lines and put caps or plugs on lines to prevent contamination. Label disconnected hydraulic lines for proper installation. 2 7. Disconnect hood rods from hood and radiator supports (see Hood in the Service and Repairs section of Chapter 7 -- Chassis). 8. Remove flange head screws (item 8) and flange nuts (item 6) that secure the radiator supports (items 1 and 28) to the frame. 9. Carefully raise radiator assembly with shrouds, fan motor assembly and supports from the machine. 10.Disassemble radiator/oil cooler assembly as needed using Figures 11 and 13 as guides. Figure 13 1. Radiator/oil cooler 2. Motor and fan assembly 3. Cap screw (6 used) 4. Flange nut (6 used) 5. Lower radiator shroud 11. If necessary, remove hydraulic fittings (items 29 and 31) from oil cooler and discard O--rings. 12.Plug all radiator and hose openings to prevent contamination. Groundsmaster 4000--D/4010--D Page 3 -- 15 Yanmar Diesel Engine Installation (Fig. 11) 4 1. Inspect seals (items 7, 10, 27 and 34) around radiator location for wear or damage. Replace seals if necessary. 1 2. Remove all plugs placed during the removal procedure. 5 3. If hydraulic fittings (items 29 and 31) were removed from oil cooler, lubricate and place new O--rings onto fittings. Install fittings into port openings and tighten fittings (see Hydraulic Fitting Installation in the General Information section of Chapter 4 -- Hydraulic System). 2 4. Assemble radiator/oil cooler using Figures 11 and 13 as guides. 3 A. If fan motor bracket was removed, position bracket as far as possible from radiator to maximize distance between radiator and fan motor location. B. Make sure that clearance between radiator shrouds and cooling fan is at least 0.180” (4.6 mm) at all points. 6 Figure 14 1. Radiator/oil cooler 2. Straight fitting 3. Hydraulic tube 4. 90o fitting 5. Hydraulic hose 6. Hydraulic tube 5. Carefully lower radiator assembly with shrouds, fan motor assembly and supports to the machine frame. 6. Secure radiator supports (items 1 and 28) to the frame with flange head screws (item 8) and flange nuts (item 6). 7. Connect hydraulic lines to fittings in oil cooler ports (Fig. 14) and at lower radiator shroud (Fig. 13) (see Hydraulic Hose and Tube Installation in the General Information section of Chapter 4 -- Hydraulic System). 8. Connect upper and lower radiator hoses to the radiator. 9. Install and secure air cleaner inlet hose (item 25). 10.Make sure radiator draincock is closed. Fill radiator with coolant. 11. Connect hood rods to radiator supports and hood (see Hood in the Service and Repairs section of Chapter 7 -- Chassis). 12.Close and secure hood. Yanmar Diesel Engine Page 3 -- 16 Groundsmaster 4000--D/4010--D Yanmar Diesel Engine This page is intentionally blank. Groundsmaster 4000--D/4010--D Page 3 -- 17 Yanmar Diesel Engine Engine 16 22 14 MODEL 30603 SHOWN 15 13 1 12 11 7 18 11 19 9 2 7 5 17 20 11 6 10 21 RIGHT 9 FRONT 5 3 4 8 4 Figure 15 1. 2. 3. 4. 5. 6. 7. 8. Engine (model 30603 shown) Cap screw (4 used) Rebound washer (4 used) Flange nut (12 used) Engine mount (4 used) Cap screw (2 used per mount) Engine mount bracket (2 used) Lock washer Yanmar Diesel Engine 9. 10. 11. 12. 13. 14. 15. Engine mount bracket (2 used) Cap screw (14 used) Lock washer (18 used) Cap screw (2 used) Exhaust bracket Cap screw (2 used) Flange nut (2 used) Page 3 -- 18 16. 17. 18. 19. 20. 21. 22. Exhaust pipe Wire harness bracket Cap screw (3 used) Wire harness bracket Lock washer (2 used) Cap screw (2 used) Clamp assembly Groundsmaster 4000--D/4010--D Engine Removal (Fig. 15) 1 1. Park machine on a level surface, lower cutting decks, stop engine, apply parking brake and remove key from the ignition switch. 2. Disconnect negative battery cable from battery terminal and then disconnect positive cable from battery (see Battery Service in the Service and Repairs section of Chapter 5 -- Electrical System). 2 3. Raise and support hood. 3 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 and Oil Cooler Assembly in this section). Disconnect upper and lower hoses from the radiator. Figure 16 1. Positive battery cable 2. Negative battery cable 3. Fusible link harness MODELS 30607 and 30609 2 4 6 5 1 3 5. Remove air cleaner assembly from engine (see Air Cleaner System in this section). 6. Remove exhaust pipe (item 16 in Fig. 15) and exhaust bracket (item 13 in Fig. 15 or item 6 in Fig. 20) from engine. 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: Figure 17 1. Tier 4 engine 2. Hose clamp 3. Fuel supply hose A. The engine wire harness from the machine wire harness. 4. Hose clamp 5. Fuel return hose 6. Front lift bracket MODELS 30603 and 30605 B. The positive battery cable from the engine starter motor (Fig. 16). 1 5 C. The fusible link harness from the main wire harness (Fig. 16). 3 4 D. The negative battery cable at the engine block (Fig. 16). 2 8. Carefully disconnect engine wire harness connector from engine ECU. 9. Disconnect fuel supply and return hoses from engine (Fig. 17 or 18). Position fuel hoses away from engine. 10.Remove fasteners that secure the coolant reservoir tank mount to the radiator and radiator shrouds (Fig. 19). Position and support coolant reservoir with mount away from the engine. Groundsmaster 4000--D/4010--D Page 3 -- Figure 18 1. Tier 4i engine 2. Hose clamp 3. Fuel supply hose 19 4. Hose clamp 5. Fuel return hose Yanmar Diesel Engine Yanmar Diesel Engine CAUTION 11. On machines with a Tier 4 compliant engine (models 30607 and 30609): RIGHT FRONT A. Remove fuel tank to allow engine to be raised from machine (see Fuel System in this section). 1 B. Install lift bracket to front of engine cylinder head (item 6 in Fig. 17). Front lift bracket was included with new machine or is available as a service part (refer to parts catalog for part number). 12.On Groundsmaster 4010--D machines: A. Remove air conditioning compressor from compressor mount (see Air Conditioning Compressor in the Service and Repairs section of Chapter 9 -- Operator Cab). Position compressor away from engine taking care to not damage compressor or AC hoses. Support compressor to make sure it will not fall during engine removal. B. Disconnect coolant hoses from fittings on engine water flange. On Groundsmaster 4010--D machines with a Tier 4 compliant engine (model 30607), disconnect coolant hose from fitting on lower radiator hose assembly. Label coolant hoses for proper assembly. IMPORTANT: The hydraulic pump assembly can remain in machine during engine removal. To prevent pump from shifting or falling, make sure to support pump assembly before the fasteners that secure pump assembly to engine are removed. 3 2 Figure 19 1. Radiator/oil cooler 2. Tank Mount 3. Coolant reservoir MACHINES WITH OPERATOR CAB 1 6 7 13.Support hydraulic pump assembly. Remove fasteners that secure pump assembly to engine (see Pump Assembly in the Service and Repairs section of Chapter 4 -- Hydraulic System). 2 3 9 4 10 14.Note location of all cable ties securing the wire harness, fuel lines and hydraulic hoses to the engine for assembly purposes. Remove cable ties as needed for engine removal. 5 8 11 15.Connect lift or hoist to the lift brackets on engine. 10 16.Remove flange nuts, rebound washers and cap screws that secure the engine mount brackets to the engine mounts. 12 Figure 20 1. 2. 3. 4. 5. 6. Yanmar Diesel Engine Page 3 -- 20 Exhaust pipe Flange screw (2 used) Flange nut Idler pulley Carriage screw Exhaust bracket 7. 8. 9. 10. 11. 12. Compressor mount Cap screw (2 used) Cap screw (4 used) Lock washer Cap screw (3 used) Pulley Groundsmaster 4000--D/4010--D 6. Secure hydraulic pump assembly to engine (see Pump Assembly in the Service and Repairs section of Chapter 4 -- Hydraulic System). One person should operate lift or hoist while a second person guides the engine out of the machine. 7. On machines with a Tier 4 compliant engine (models 30607 and 30609): A. Remove lift bracket from front of engine cylinder head (item 6 in Fig. 17). The bracket must be removed before fuel tank installation. Retain lift bracket and fasteners for future use. IMPORTANT: Make sure to not damage the engine, radiator assembly, fuel lines, hydraulic lines, electrical wire harness or other components while removing the engine. 17.Slowly move the engine assembly away from the hydraulic pump assembly to allow the pump input shaft to slide out of the spring coupler on the engine flywheel. Once the engine has cleared the pump input shaft, carefully remove the engine from the machine. 18.If necessary, remove engine mount brackets from the engine using Figure 15 or 20 as a guide. B. Install and secure fuel tank to machine (see Fuel System in this section). 8. Position coolant reservoir with mount to the radiator. Secure reservoir tank mount to the radiator and radiator shrouds with removed fasteners. 9. Connect fuel supply and return hoses to the engine fittings (Fig. 17 or 18). 10.On Groundsmaster 4010--D machines: Engine Installation (Fig. 15) A. Install air conditioning compressor to compressor mount (see Air Conditioning Compressor Installation in the Service and Repairs section of Chapter 9 -- Operator Cab). Make sure that drive belt is properly tensioned. 1. Make sure that all parts removed from the engine during maintenance or rebuilding are installed to the engine. 2. If removed, install engine mount brackets to the engine using Figure 15 or 20 as a guide. B. Connect coolant hoses to fittings on engine water flange. 3. Connect lift or hoist to the engine lift brackets. 11. Connect wires and/or electrical connections to engine locations. CAUTION A. The engine wire harness from the machine wire harness. One person should operate lift or hoist while a second person guides the engine into the machine. B. The positive battery cable from the engine starter motor (Fig. 16). IMPORTANT: Make sure to not damage the engine, radiator assembly, fuel lines, hydraulic lines, electrical wire harness or other components while installing the engine. 4. Carefully lower engine into the machine. Slowly move the engine assembly toward the hydraulic pump assembly to allow the pump input shaft to slide into the spring coupler on the engine flywheel. 5. Align engine to the engine mounts. Secure engine to engine mounts with cap screws, rebound washers and flange nuts. Groundsmaster 4000--D/4010--D C. The fusible link harness from the main wire harness (Fig. 16). D. The negative battery cable at the engine block (Fig. 16). 12.Carefully connect engine wire harness connector to engine ECU. 13.Install and secure exhaust bracket (item 13 in Fig. 15 or item 6 in Fig. 20) and exhaust pipe (item 16 in Fig. 15) from engine. 14.Install air cleaner assembly to the engine (see Air Cleaner System in this section). Page 3 -- 21 Yanmar Diesel Engine Yanmar Diesel Engine CAUTION 15.Connect coolant hoses to the radiator. Make sure radiator draincock is closed. Fill radiator and coolant reservoir with coolant. 16.Secure the wire harness, fuel lines and hydraulic hoses to the engine with cable ties as noted during engine removal. 17.Check position of electrical wires, fuel lines and hydraulic lines for proper clearance with rotating, high temperature and moving components. 18.Connect positive battery cable to positive battery terminal first and then connect negative cable to battery (see Battery Service in the Service and Repairs section of Chapter 5 -- Electrical System). Yanmar Diesel Engine 19.Check and adjust engine oil as needed. 20.Check and adjust oil level in hydraulic reservoir as needed. 21.Prime the fuel system (see Fuel System in this section). 22.Start engine and operate hydraulic controls to properly fill hydraulic system (see Charge Hydraulic System in the Service and Repairs section of Chapter 4 -- Hydraulic System). 23.Close and secure hood. Page 3 -- 22 Groundsmaster 4000--D/4010--D Yanmar Diesel Engine This page is intentionally blank. Groundsmaster 4000--D/4010--D Page 3 -- 23 Yanmar Diesel Engine Spring Coupler RIGHT 7 FRONT 28 to 32 ft--lb (38 to 43 N--m) 3 2 1 6 5 4 29 to 33 ft--lb (40 to 44 N--m) Figure 21 1. Cap screw (8 used) 2. Washer (8 used) 3. Flywheel plate Yanmar Diesel Engine 4. Cap screw (8 used) 5. Washer (8 used) Page 3 -- 24 6. Spring coupler 7. Engine (model 30603/30605 shown) Groundsmaster 4000--D/4010--D Coupler Removal (Fig. 21) NOTE: The hydraulic pump assembly needs to be removed from engine before coupler can be removed. Engine Side Hydraulic Pump Side 1. If engine is in machine, remove hydraulic pump assembly from machine (see Piston (Traction) Pump Removal in the Service and Repairs section of Chapter 4 -- Hydraulic System). 1 2. Remove flywheel plate and spring coupler from engine using Figure 21 as a guide. Coupler Installation (Fig. 21) 1. Position spring coupler to engine flywheel and align mounting holes. Make sure that coupling hub is away from engine flywheel (Fig. 22). 3. Position flywheel plate to engine. Secure flywheel plate with eight (8) cap screws (item 1) 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). Figure 22 1. Coupler 2. Engine flywheel 4. If engine is in machine, install hydraulic pump assembly to machine (see Piston (Traction) Pump Installation in the Service and Repairs section of Chapter 4 -Hydraulic System). Groundsmaster 4000--D/4010--D Page 3 -- 25 Yanmar Diesel Engine Yanmar Diesel Engine 2 2. Secure coupler to flywheel with eight (8) cap screws and washers. Torque cap screws in a crossing pattern from 29 to 33 ft--lb (40 to 44 N--m). Exhaust System (Models 30607 and 30609) 7 40 41 19 to 29 ft--lb (25 to 40 N--m) 39 37 8 16 22 11 35 31 18 31 29 36 38 26 17 34 25 32 10 5 28 27 30 16 20 15 25 12 34 27 33 18 4 9 16 23 18 1 18 3 14 18 23 15 44 21 23 16 13 RIGHT 42 FRONT 19 6 24 2 43 Figure 23 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. Gasket Exhaust assembly stay Exhaust assembly stay Exhaust assembly stay Exhaust assembly stay Nut DOC temp sensor (inlet) DOC temp sensor (outlet) Nut (4 used) DOC assembly Nut (3 used) DPF assembly Nut Outlet flange DPF gasket (2 used) Yanmar Diesel Engine 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. Bolt (20 used) DPF lifter DPF stiffener (5 used) DPF stiffener DPF stiffener DPF stiffener Bolt (2 used) Nut (20 used) Bolt (2 used) Pipe joint bolt (2 used) Exhaust pressure pipe (DPF inlet) Sensor gasket (4 used) Exhaust pressure pipe (DPF outlet) Exhaust hose Bolt (2 used) Page 3 -- 26 31. 32. 33. 34. 35. 36. 37. 38. 39. 40. 41. 42. 43. 44. Hose clip (2 used) Hose Bolt (3 used) Hose clip (2 used) Pressure sensor Sensor bracket Bolt (2 used) Bolt (2 used) Clip band Band Connector clip (2 used) Bolt (2 used) Bolt (2 used) Bolt (2 used) Groundsmaster 4000--D/4010--D The diesel particulate filter (DPF) is cleaned periodically through a regenerative process that is controlled by the engine ECU (see Yanmar Engine: Models 30607 and 30609 in the General Information section of this chapter). The InfoCenter display will identify the status of DPF regeneration. At recommended intervals, DPF reconditioning is necessary which will require exhaust system disassembly, DPF removal and DPF reconditioning by a company that has the necessary equipment. Once the DPF has gone through the reconditioning process, it can be re--installed in the exhaust system. Contact your Toro Distributor for information on reconditioning the DPF. Installation (Figs. 23 and 24) NOTE: Make sure that all exhaust system flanges and sealing surfaces are free of debris or damage that may prevent a tight seal. 1. Make sure to install new gaskets in place of all gaskets that were removed. Do not use any type of gasket sealant on gasket or flange surfaces. 2. Assemble all removed exhaust system components using Figure 23 and 24 as guides. A. If exhaust sensors (items 7 and 8 in Fig. 23) were removed, torque sensors from 19 to 29 ft--lb (25 to 40 N--m). B. If exhaust pressure pipes (items 26 and 28 in Fig. 23) were removed, replace sensor gaskets (item 27) on both sides of the pressure pipe fitting. C. If DPF stiffeners (items 18, 19, 20 and 21 in Fig. 23) were loosened or removed, tighten fasteners that secure stiffeners before tightening fasteners that secure exhaust system to DPF stays. The diesel oxidation catalyst (DOC) has a service life expectancy and requires replacement at recommended intervals. Replacement of the DOC will require exhaust system disassembly, removal of the existing DOC and installation of the new DOC. 6 5 Refer to the Parts Catalog to identify individual components for the exhaust system on your Groundsmaster. 4 3 2 Removal (Figs. 23 and 24) NOTE: The exhaust system DPF and DOC can be removed from the exhaust system without removing the entire exhaust from the engine. Certain engine service procedures (e.g. rocker cover removal for valve clearance adjustment) will require removal of the exhaust system assembly. 1 CAUTION The muffler and exhaust pipe may be hot. To avoid possible burns, allow the engine and exhaust system to cool before working on the exhaust system. 1. Raise and support hood to gain access to exhaust system. Allow engine and exhaust to cool before doing any disassembly of exhaust system components. Figure 24 1. Engine 2. Exhaust pipe 3. Clamp assembly 4. Flange nut (4 used) 5. Exhaust flange 6. Exhaust gasket 2. Remove exhaust system components from the engine as necessary using Figure 23 and 24 as guides. Discard all removed gaskets (items 1 and 15 in Fig. 23 or item 6 in Fig. 24). Groundsmaster 4000--D/4010--D Page 3 -- 27 Yanmar Diesel Engine Yanmar Diesel Engine Groundsmaster models that are powered by a diesel engine that complies with EPA Tier 4 emission regulations are equipped with an exhaust system that includes a diesel oxidation catalyst (DOC) and a diesel particulate filter (DPF). These exhaust components require service or component replacement at intervals identified in your Operator’s Manual. Additionally, the exhaust assembly uses two (2) temperature sensors and a pressure differential sensor which are used as inputs for the engine ECU to monitor the operation of the exhaust system. This page is intentionally blank. Yanmar Diesel Engine Page 3 -- 28 Groundsmaster 4000--D/4010--D Chapter 4 Hydraulic System SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . 4 Operator’s Manual . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Check Hydraulic Fluid . . . . . . . . . . . . . . . . . . . . . . . 4 Relieving Hydraulic System Pressure . . . . . . . . . . 4 Towing Traction Unit . . . . . . . . . . . . . . . . . . . . . . . . . 5 Traction Circuit Component Failure . . . . . . . . . . . . 5 Hydraulic Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Hydraulic Hose and Tube Installation . . . . . . . . . . 7 Hydraulic Fitting Installation . . . . . . . . . . . . . . . . . . 8 HYDRAULIC SCHEMATIC . . . . . . . . . . . . . . . . . . . . 10 HYDRAULIC FLOW DIAGRAMS . . . . . . . . . . . . . . . 12 Traction Circuit: LOW Speed (Mow) . . . . . . . . . . 12 Traction Circuit: HI Speed (Transport) . . . . . . . . . 14 Lower Cutting Deck Circuit . . . . . . . . . . . . . . . . . . 16 Raise Cutting Deck Circuit . . . . . . . . . . . . . . . . . . 18 Mow Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Mow Circuit Cutting Deck Blade Braking . . . . . . 22 Steering Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Engine Cooling Fan Circuit . . . . . . . . . . . . . . . . . . 26 SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . 33 TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 Traction Circuit Charge Pressure . . . . . . . . . . . . . 42 Traction Circuit Relief Pressure . . . . . . . . . . . . . . 44 Counterbalance Pressure . . . . . . . . . . . . . . . . . . . 46 Reverse Traction Circuit Reducing Valve (PR) Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 Rear Traction Circuit Relief Valve (RV) Pressure 50 Piston (Traction) Pump Flow . . . . . . . . . . . . . . . . . 52 Cutting Deck Circuit Pressure . . . . . . . . . . . . . . . . 54 PTO Relief Pressure . . . . . . . . . . . . . . . . . . . . . . . . 56 Cutting Deck Motor Case Drain Leakage . . . . . . 58 Lift/Lower Circuit Relief Pressure . . . . . . . . . . . . . 60 Steering Circuit Relief Pressure . . . . . . . . . . . . . . 62 Steering Cylinder Internal Leakage . . . . . . . . . . . 64 Engine Cooling Fan Circuit . . . . . . . . . . . . . . . . . . 66 Gear Pump Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 Adjust Control Manifold Relief Valves . . . . . . . . . 70 SERVICE AND REPAIRS . . . . . . . . . . . . . . . . . . . . . 71 General Precautions for Removing and Installing Hydraulic System Components . . . . 71 Groundsmaster 4000--D/4010--D Check Hydraulic Lines and Hoses . . . . . . . . . . . . 72 Priming Hydraulic Pumps . . . . . . . . . . . . . . . . . . . 72 Flush Hydraulic System . . . . . . . . . . . . . . . . . . . . . 73 Filtering Closed--Loop Traction Circuit . . . . . . . . 74 Charge Hydraulic System . . . . . . . . . . . . . . . . . . . 75 Hydraulic Reservoir . . . . . . . . . . . . . . . . . . . . . . . . 76 Radiator and Oil Cooler Assembly . . . . . . . . . . . . 78 Gear Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 Gear Pump Service . . . . . . . . . . . . . . . . . . . . . . . . 84 Piston (Traction) Pump . . . . . . . . . . . . . . . . . . . . . 86 Piston (Traction) Pump Service . . . . . . . . . . . . . . 90 Rear Axle Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . 92 Front Wheel Motors . . . . . . . . . . . . . . . . . . . . . . . . 94 Rear Axle and Front Wheel Motor Service . . . . . 96 Rear Traction Manifold . . . . . . . . . . . . . . . . . . . . . . 98 Rear Traction Manifold Service . . . . . . . . . . . . . 100 Front Traction Manifold . . . . . . . . . . . . . . . . . . . . 102 Front Traction Manifold Service . . . . . . . . . . . . . 104 Combination Manifold . . . . . . . . . . . . . . . . . . . . . 106 Combination Manifold Service . . . . . . . . . . . . . . 108 Control Manifold Cartridge Valve Service . . . . . 110 Steering Control Valve . . . . . . . . . . . . . . . . . . . . . 112 Steering Control Valve Service . . . . . . . . . . . . . . 114 Steering Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . 116 Steering Cylinder Service . . . . . . . . . . . . . . . . . . 118 Engine Cooling Fan Motor . . . . . . . . . . . . . . . . . . 120 Engine Cooling Fan Motor Service . . . . . . . . . . 124 Cutting Deck Motors . . . . . . . . . . . . . . . . . . . . . . . 127 Cutting Deck Motor Service (Sauer--Danfoss) . 128 Cutting Deck Motor Service (Casappa) . . . . . . . 132 PTO Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134 PTO Manifold Service . . . . . . . . . . . . . . . . . . . . . 136 Side Deck Lift Cylinders . . . . . . . . . . . . . . . . . . . . 138 Center Deck Lift Cylinders . . . . . . . . . . . . . . . . . . 140 Lift Cylinder Service . . . . . . . . . . . . . . . . . . . . . . . 142 SAUER--DANFOSS H1 CLOSED CIRCUIT AXIAL PISTON PUMPS SERVICE MANUAL SAUER--DANFOSS K and L FRAME VARIABLE MOTORS SERVICE MANUAL EATON PARTS AND REPAIR INFORMATION: 5 SERIES STEERING CONTROL UNITS Page 4 -- 1 Hydraulic System Hydraulic System Table of Contents This page is intentionally blank. Hydraulic System Page 4 -- 2 Groundsmaster 4000--D/4010--D Specifications Item Description Piston (Traction) Pump Maximum Displacement (per revolution) System Relief Pressure: Forward System Relief Pressure: Reverse Charge Pressure Sauer--Danfoss Variable Displacement Axial Piston Pump 2.75 in3 (45 cc) 4350 PSI (300 bar) 5000 PSI (345 bar) 250 PSI (17 bar) Front Wheel Motors Displacement (per revolution) Sauer--Danfoss 2--Position Axial Piston Motors 1.19 in3 (19.55 cc) Maximum / 0.64 in3 (10.55 cc) Minimum Rear Axle Motor Sauer--Danfoss 2--Position Axial Piston Motor with Loop Flushing Valve 2.14 in3 (35.00 cc) Maximum / 1.16 in3 (18.99 cc) Minimum Displacement (per revolution) Casappa 4 Section, Positive Displacement Gear pump 1.29 in3 (21.14 cc) 0.40 in3 (6.6 cc) 0.30 in3 (4.96 cc) Steering Control Valve Displacement (per revolution) Eaton Steering Unit, Series 5 6.1 in3 (100 cc) Steering Circuit Relief Pressure 1350 PSI (93 bar) Lift/Lower Circuit Relief Pressure 1600 PSI (110 bar) Cutting Deck Motors Displacement (per revolution) Gear Motor 1.17 in3 (19.2 cc) PTO Circuit Relief Pressure Front and Left Side Right Side 3000 PSI (207 bar) 2000 PSI (138 bar) Engine Cooling Fan Motor Displacement (per revolution) Casappa Gear Motor 0.51 in3 (8.4 cc) Engine Cooling Fan Circuit Relief Pressure 3250 PSI (224 bar) Hydraulic Filters In--line Suction Strainer Spin--on Cartridge Type 100 Mesh (In Reservoir) Hydraulic Reservoir 7.75 U.S. Gallons (29.3 Liters) Hydraulic Oil See Operator’s Manual NOTE: The pressure specifications listed above are component settings. When using pressure gauges to measure circuit pressures, values may be different than these specifications. See the Testing section of this chapter for hydraulic test procedures and expected test results. Groundsmaster 4000--D/4010--D Page 4 -- 3 Hydraulic System Hydraulic System Gear Pump Section P1/P2 Displacement (per revolution) Section P3 Displacement (per revolution) Section P4 Displacement (per revolution) General Information Operator’s Manual The Operator’s Manual provides information regarding the operation, general maintenance and maintenance intervals for your Groundsmaster machine. Refer to that publication for additional information when servicing the machine. Check Hydraulic Fluid The Groundsmaster hydraulic system is designed to operate on anti--wear hydraulic fluid. The hydraulic reservoir located beneath the operator seat holds approximately 7.75 U.S. gallons (29.3 liters) of hydraulic fluid. Check level of hydraulic fluid daily. See Operator’s Manual for fluid level checking procedure and oil recommendations. 2 1 Figure 1 1. Hydraulic reservoir 2. Reservoir cap Relieving Hydraulic System Pressure Before disconnecting or performing any work on the hydraulic system, all pressure in the hydraulic system must be relieved. Park machine on a level surface, make sure that PTO switch is OFF, lower cutting decks fully, stop engine and engage parking brake. Wait for all moving parts to come to a complete stop. System pressure in lift circuit is relieved when the cutting decks are fully lowered. System pressure in mow circuit is relieved when the PTO switch is disengaged. Hydraulic System To relieve hydraulic pressure in traction circuit, turn ignition switch to ON (engine not running) and move traction pedal to both forward and reverse directions. Turn ignition switch to OFF after relieving traction circuit pressure. To relieve hydraulic pressure in steering circuit, rotate steering wheel in both directions. After all hydraulic system pressures have been relieved, remove key from ignition switch. Page 4 -- 4 Groundsmaster 4000--D/4010--D 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 speed below 3 mph (5 kph). The piston (traction) pump relief valves (both forward and reverse) need to be loosened three (3) revolutions to allow the machine to be moved (Fig. 2). To prevent leakage from relief valves, do not loosen them more than three (3) revolutions. Refer to your Operator’s Manual for additional towing instructions. 3 IMPORTANT: Do not loosen relief valves when engine is running. Before returning machine to service, tighten both of the relief valves until seated. Then, torque relief valves to 52 ft--lb (70 N--m). 1 2 Figure 2 1. Piston pump 2. Relief valve (forward) 3. Relief valve (reverse) Hydraulic System IMPORTANT: If the machine must to be pushed or towed in reverse, the check valve in the rear traction manifold must also be bypassed. To bypass this check valve, connect a hydraulic hose assembly to the reverse traction pressure test port, located on the piston (traction) pump, and on the port located in--between ports M8 and P2 on the rear traction manifold which is located behind the front tire. Use Toro part numbers 95--8843 (hydraulic hose), 95--0985 (quantity 2) (coupler fitting) and 340--77 (quantity 2) (hydraulic fitting). Traction Circuit Component Failure The traction circuit on Groundsmaster 4000--D and 4010--D machines is a closed loop system that includes the piston (traction) pump, two (2) front wheel motors and the rear axle motor. If a component in the traction circuit should fail, debris and contamination from the failed component will circulate throughout the traction circuit. This contamination can damage other components in the circuit so it must be removed to prevent additional component failure. The recommended method of removing traction circuit contamination would be to temporarily install the Toro high flow hydraulic filter (see Special Tools in this chapter) into the circuit. This filter should be used when connecting hydraulic test gauges in order to test traction circuit components or after replacing a failed traction circuit component (e.g. traction (piston) pump or wheel motor). The filter will ensure that contaminates are removed from the closed loop and thus, do not cause additional component damage. Groundsmaster 4000--D/4010--D Once the Toro high flow hydraulic filter kit has been placed in the circuit, raise and support 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 traction circuit can be operated in both the forward and reverse direction. The filter should be removed from the machine after contamination has been removed from the traction circuit. See Filtering Closed--Loop Traction Circuit in the Service and Repairs section of this chapter for additional information on using the Toro high flow hydraulic filter. The alternative to using the Toro high flow hydraulic filter kit after a traction circuit component failure would be to disassemble, drain and thoroughly clean all components, hydraulic tubes and hydraulic hoses in the traction circuit. If any debris remains in the traction circuit and the machine is operated, the debris can cause additional circuit component failure. Page 4 -- 5 Hydraulic System Hydraulic Hoses Hydraulic hoses are subject to extreme conditions such as pressure differentials during operation and exposure to weather, sun, chemicals, very warm storage conditions or mishandling during operation and maintenance. 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: 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 (2) 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. WARNING Before disconnecting or performing any work on hydraulic system, relieve all pressure in system (see Relieving Hydraulic System Pressure in this section). Keep body and hands away from pin hole leaks or nozzles that eject hydraulic fluid under high pressure. Use paper or cardboard, not hands, to search for leaks. Hydraulic fluid escaping under pressure can have sufficient force to penetrate the skin and cause serious injury. If fluid is injected into the skin, it must be surgically removed within a few hours by a doctor familiar with this type of injury. Gangrene may result from such an injury. For additional hydraulic hose information, refer to Toro Service Training Book, Hydraulic Hose Servicing (Part Number 94813SL). Hydraulic System Page 4 -- 6 Groundsmaster 4000--D/4010--D Hydraulic Hose and Tube Installation (O--Ring Face Seal Fitting) 1. Make sure threads and sealing surfaces of the hose/ tube and the fitting are free of burrs, nicks, scratches or any foreign material. C. Use a second wrench to tighten the nut to the correct Flats From Wrench Resistance (F.F.W.R.). The markings on the nut and fitting body will verify that the connection has been properly tightened. 2. As a preventative measure against leakage, it is recommended that the face seal O--ring be replaced any time the connection is opened. Make sure the O--ring is installed and properly seated in the fitting groove. Lightly lubricate the O--ring with clean hydraulic oil. Size 4 (1/4 in. nominal hose or tubing) 6 (3/8 in.) 8 (1/2 in.) 10 (5/8 in.) 12 (3/4 in.) 16 (1 in.) 3. Place the hose/tube against the fitting body so that the flat face of the hose/tube sleeve fully contacts the O-ring in the fitting. Swivel Nut 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 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). Fitting Body O--ring Tube or Hose Mark Nut and Fitting Body Hydraulic System Figure 3 5. If a torque wrench is not available or if space at the swivel nut prevents use of a torque wrench, an alternate method of assembly is the Flats From Wrench Resistance (F.F.W.R.) method (Fig. 2). A. Using a wrench, tighten the swivel nut onto the fitting until light wrench resistance is reached (approximately 30 in--lb). F.F.W.R. 1/2 to 3/4 1/2 to 3/4 1/2 to 3/4 1/2 to 3/4 1/3 to 1/2 1/3 to 1/2 Final Position Initial Position Extend Line AT WRENCH RESISTANCE B. Mark the swivel nut and fitting body. Hold the hose/tube with a wrench to prevent it from turning. AFTER TIGHTENING Figure 4 Fitting Dash Size Hose/Tube Side Thread Size Installation Torque 4 9/16 -- 18 18 to 22 ft--lb (25 to 29 N--m) 6 11/16 -- 16 27 to 33 ft--lb (37 to 44 N--m) 8 13/16 -- 16 37 to 47 ft--lb (51 to 63 N--m) 10 1 -- 14 60 to 74 ft--lb (82 to 100 N--m) 12 1 3/16 -- 12 85 to 105 ft--lb (116 to 142 N--m) 16 1 7/16 -- 12 110 to 136 ft--lb (150 to 184 N--m) 20 1 11/16 -- 12 140 to 172 ft--lb (190 to 233 N--m) Figure 5 Groundsmaster 4000--D/4010--D Page 4 -- 7 Hydraulic System 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. 5. If a torque wrench is not available, or if space at the port prevents use of a torque wrench, an alternate method of assembly is the Flats From Finger Tight (F.F.F.T.) method. 2. As a preventative measure against leakage, it is recommended that the O--ring be replaced any time the connection is opened. 3. Lightly lubricate the O--ring with clean hydraulic oil. Fitting threads should be clean with no lubricant applied. 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. 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. Size 4 (1/4 in. nominal hose or tubing) 6 (3/8 in.) 8 (1/2 in.) 10 (5/8 in.) 12 (3/4 in.) 16 (1 in.) NOTE: Use of 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 Records and Maintenance to determine necessary conversion information. F.F.F.T. 1.00 + 0.25 1.50 + 0.25 1.50 + 0.25 1.50 + 0.25 1.50 + 0.25 1.50 + 0.25 Fitting O--ring Figure 6 Fitting Dash Size Fitting Port Side Thread Size Installation Torque Into Steel Port Installation Torque Into Aluminum Port 4 7/16 -- 20 15 to 19 ft--lb (21 to 25 N--m) 9 to 11 ft--lb (13 to 15 N--m) 5 1/2 -- 20 18 to 22 ft--lb (25 to 29 N--m) 11 to 15 ft--lb (15 to 20 N--m) 6 9/16 -- 18 34 to 42 ft--lb (47 to 56 N--m) 20 to 26 ft--lb (28 to 35 N--m) 8 3/4 -- 16 58 to 72 ft--lb (79 to 97 N--m) 35 to 43 ft--lb (48 to 58 N--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 1 1/16 -- 12 134 to 164 ft--lb (182 to 222 N--m) 81 to 99 ft--lb (110 to 134 N--m) 14 1 3/16 -- 12 160 to 196 ft--lb (217 to 265 N--m) 96 to 118 ft--lb (131 to 160 N--m) 16 1 5/16 -- 12 202 to 248 ft--lb (274 to 336 N--m) 121 to 149 ft--lb (165 to 202 N--m) 20 1 5/8 -- 12 247 to 303 ft--lb (335 to 410 N--m) 149 to 183 ft--lb (202 to 248 N--m) Figure 7 Hydraulic System Page 4 -- 8 Groundsmaster 4000--D/4010--D Adjustable Fitting (Fig. 8) 1. Make sure all threads and sealing surfaces of fitting and component port are free of burrs, nicks, scratches or any foreign material. 2. As a preventative measure against leakage, it is recommended that the O--ring be replaced any time the connection is opened. Lock Nut Back--up Washer 3. Lightly lubricate the O--ring with clean hydraulic oil. Fitting threads should be clean with no lubricant applied. O--ring 4. Turn back the lock nut as far as possible. Make sure the back up washer is not loose and is 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. 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. Figure 8 Step 1 Step 3 Step 2 Step 4 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). Hydraulic System 6. To put the 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). Figure 9 8. If a torque wrench is not available, or if space at the port prevents use of a torque wrench, an alternate method 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 with a second wrench to the listed F.F.F.T (Step 4 in Figure 9). If port material is aluminum, tighten fitting to 60% of listed F.F.F.T. Size 4 (1/4 in. nominal hose or tubing) 6 (3/8 in.) 8 (1/2 in.) 10 (5/8 in.) 12 (3/4 in.) 16 (1 in.) Groundsmaster 4000--D/4010--D F.F.F.T. 1.00 + 0.25 1.50 + 0.25 1.50 + 0.25 1.50 + 0.25 1.50 + 0.25 1.50 + 0.25 Page 4 -- 9 Hydraulic System Hydraulic System Page 4 -- 10 M2 1.17 CID M1 M2 1.17 CID M1 M2 1.17 CID M1 RV PD RV PD RV PD 600 PSI .025 600 PSI .025 CD PRV CD PRV 2000 PSI CD PRV LC1 P2 G P1 P2 G 50 PSI RIGHT DECK LC1 LEFT DECK LC1 P2 G P1 CENTER DECK 3000 PSI 3000 PSI 600 PSI .025 P1 STEERING CONTROL VALVE P L 0.4 CID G T STEERING CYLINDER 1.29 1.29 CID CID G 2.75 CID 14.3 GPM 14.3 GPM 4.4 GPM 3.3 GPM E 6.1 CID 0.3 CID R 2.00” BORE 4.20” STROKE 0.625” ROD NOTE: A larger hydraulic schematic is included in Chapter 10: Foldout Drawings .0315 G4 CF LS G2 CH4 P4 80 PSI OR1 .030” 250 PSI .0315 EC CV2 4 PSI S11 3250 PSI G G CH2 RV1 30.5 GPM CH1 5000 PSI P1 G3 P2 CV2 PR 380 PSI 13.7 GPM 16.8 GPM FRONT TRACTION MANIFOLD T M8 S5 OR9 .030 OR4 .040 CH 200 PSI M3 M1 CV4 CV 650 PSI RV CH2 OR .063 CH1 S3 OR5 .070 C2 CENTER DECK RAM CYLINDERS 1.50” BORE 3.08” STROKE 4 PSI C4 CH3 3300 PSI S2 S4 HFD Split 55--45 CV1 P3 RV3 OR2 .063 C3 REAR OR1 TRACTION .050 MANIFOLD T ENGINE 60 PSI CV3 OR3 .070 S1 PR 310 PSI LEFT DECK 2.50” BORE 6.50” STROKE 1.125” ROD 4350 PSI 1350 PSI CV1 4 PSI PRV M2 S10 G G M1 COOLING FAN MOTOR 0.51 CID S12 RV2 2.14 CID / 1.16 CID 2SP 1600 PSI S6 RIGHT DECK 2.50” BORE 6.50” STROKE 1.125” ROD OR7 .070 S7 S9 C6 S8 1.2 CID / 0.64 CID 1.2 CID / 0.64 CID COMBINATION MANIFOLD OR6 .063 C5 G1 Hydraulic Schematic Groundsmaster 4000--D/4010--D Hydraulic System This page is intentionally blank. Groundsmaster 4000--D/4010--D Page 4 -- 11 Hydraulic System Hydraulic System Page 4 -- 12 M2 1.17 CID M1 M2 1.17 CID M1 M2 1.17 CID M1 RV PD RV PD RV PD 600 PSI .025 600 PSI .025 CD PRV CD PRV 2000 PSI CD PRV LC1 P2 G P1 P2 G 50 PSI RIGHT DECK LC1 LEFT DECK LC1 P2 G P1 P1 CENTER DECK 3000 PSI 3000 PSI 600 PSI .025 Working Pressure Low Pressure (Charge) Return or Suction Flow STEERING CONTROL VALVE P G T G 1.29 CID 2.75 CID 14.3 GPM 14.3 GPM 4.4 GPM 3.3 GPM E 6.1 CID L STEERING CYLINDER 0.3 0.4 1.29 CID CID CID R 2.00” BORE 4.20” STROKE 0.625” ROD Traction Circuit: LOW Speed (Mow) (Forward Shown) .0315 G4 CF LS G2 CH4 P4 80 PSI OR1 .030” 250 PSI .0315 EC CV2 4 PSI S11 3250 PSI G G CH2 RV1 30.5 GPM CH1 5000 PSI P1 G3 P2 CV2 PR 380 PSI M8 S5 T 13.7 GPM OR9 .030 OR4 .040 200 PSI 16.8 GPM FRONT TRACTION MANIFOLD CH M3 M1 CV4 CV 650 PSI RV CH2 OR .063 CH1 S3 OR5 .070 C2 CENTER DECK RAM CYLINDERS 1.50” BORE 3.08” STROKE 4 PSI C4 CH3 3300 PSI S2 S4 HFD Split 55--45 CV1 P3 RV3 OR2 .063 C3 REAR OR1 TRACTION .050 MANIFOLD T ENGINE 60 PSI CV3 OR3 .070 S1 PR 310 PSI LEFT DECK 2.50” BORE 6.50” STROKE 1.125” ROD 4350 PSI 1350 PSI CV1 4 PSI PRV M2 S10 G G M1 0.51 CID S12 RV2 OR7 .070 2.14 CID / 1.16 CID 2SP 1600 PSI S6 RIGHT DECK 2.50” BORE 6.50” STROKE 1.125” ROD S7 S9 C6 S8 1.2 CID / 0.64 CID 1.2 CID / 0.64 CID COMBINATION MANIFOLD OR6 .063 C5 G1 Hydraulic Flow Diagrams Groundsmaster 4000--D/4010--D Traction Circuit: LOW Speed (Mow) Front wheel and rear axle motors are positive displacement, two speed variable motors that allow operation in either LOW (mow) or HI (transport) speed. The motors are spring biased to maximum displacement for LOW speed and are hydraulically shifted to minimum displacement for HI speed. The rear axle motor includes a flushing valve that bleeds off a small amount of hydraulic oil for cooling of the closed loop traction circuit. The charge circuit replaces oil that is bled from the circuit by the flushing valve. The Smart PowerTM feature prevents the engine from slowing down in heavy load conditions (e.g. cutting tall grass) by automatically decreasing the traction speed if necessary. With a reduced traction speed, the cutting blades can continue to be at optimum speed. A traction circuit flow divider splits traction pump hydraulic flow between the front wheel motors (approximately 45%) and rear axle motor (approximately 55%) to prevent excessive circuit flow going to a spinning wheel. The flow divider is located in the front traction manifold mounted to the right, rear side of the front frame. Gear pump flow for the charge circuit is directed through the oil filter and to the low pressure side of the closed loop traction circuit. Charge pressure is limited to 250 PSI (17 bar) by a relief valve located in the piston pump. Forward Direction With the armrest console HI/LOW speed switch in the LOW speed (mow) position, solenoid valve (S12) in the combination manifold is not energized which keeps the front wheel motors and rear axle motor at their maximum displacement. With the motors at maximum displacement, a lower traction speed is available for mowing conditions. When the HI/LOW switch is in the LOW speed (mow) position and the traction pedal is pushed in the forward direction, oil from the piston pump passes through the front traction manifold. Oil flow for the front wheel motors leaves front traction manifold port M1 to drive the front wheel motors in the forward direction and then returns to the piston pump. Oil flow from front traction manifold port M2 is directed to drive the rear axle motor in the forward direction. Oil returning from the axle motor enters the rear traction manifold at the M8 port. Flow bypasses the PR cartridge through the CV check valve, out manifold port P2 and returns to the piston pump. When going down a hill, the tractor becomes an over-running load that drives the front wheel and rear axle motors. In this condition, the rear axle motor could lock up as the oil pumped from the motor increases pressure as it returns to the piston pump. To prevent rear wheel lock up, an adjustable relief valve (RV) in the rear traction manifold reduces rear axle motor pressure created in down hill, dynamic braking conditions. Reverse Direction The traction circuit operates essentially the same in reverse LOW speed (mow) 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 rear traction manifold. The oil to the front wheel motors drives them in the reverse direction and then returns to the piston pump through the front traction manifold. The oil to the rear traction manifold enters the manifold at port P2 and flows through pressure reducing valve (PR) which limits the down stream pressure to the rear axle motor to 380 PSI (26 bar) so the rear wheels will not scuff the turf during reverse operation. This reduced pressure flow is directed out rear traction manifold port M8 to drive the rear axle motor in reverse. Return oil from the rear motor returns to the piston pump through the front traction manifold. Traction circuit components use small amounts of hydraulic oil for internal lubrication. Fluid is designed to leak across traction pump and motor components into the case drain. This leakage results in the loss of hydraulic oil from the closed loop traction circuit that is replaced by the charge circuit. The gear pump sections that supply the steering, cooling fan and lift/lower circuits also provide charge circuit oil. Groundsmaster 4000--D/4010--D Page 4 -- 13 Hydraulic System Hydraulic System The traction circuit piston pump is a variable displacement pump that is directly coupled to the engine flywheel. This pump utilizes an integral electro--hydraulic servo piston assembly that controls the rate and direction of hydraulic flow. Pressing the traction pedal rotates a potentiometer that provides an input to the machine TEC controller. The controller in turn sends a corresponding PWM (Pulse Width Modulation) output to the electronic pump control to rotate the pump swash plate accordingly to control pump output and direction. Traction circuit oil is directed to the dual displacement front wheel and rear axle motors. Operating pressure on the high pressure side of the closed traction circuit loop is determined by the amount of load developed at the wheel and axle motors. As the traction load increases, circuit pressure can increase to relief valve settings: 4350 PSI (300 bar) in forward and 5000 PSI (345 bar) in reverse. If traction circuit pressure exceeds the relief setting, oil flows through the piston pump relief valve to the low pressure side of the closed loop traction circuit. Traction circuit pressure can be measured at test ports attached to the sides of the piston pump. The forward traction port is on the right side of the pump and the reverse traction port is on the left side. Hydraulic System Page 4 -- 14 Groundsmaster 4000--D/4010--D M2 1.17 CID M1 M2 1.17 CID M1 M2 1.17 CID M1 RV PD RV PD RV PD 600 PSI .025 600 PSI .025 CD PRV CD PRV 2000 PSI CD PRV LC1 P2 G P1 P2 G 50 PSI RIGHT DECK LC1 LEFT DECK LC1 P2 G P1 P1 CENTER DECK 3000 PSI 3000 PSI 600 PSI .025 Working Pressure Low Pressure (Charge) Return or Suction Flow STEERING CONTROL VALVE P G T G 2.75 CID 14.3 GPM 14.3 GPM 4.4 GPM 3.3 GPM E 6.1 CID L STEERING CYLINDER 0.3 0.4 1.29 1.29 CID CID CID CID R 2.00” BORE 4.20” STROKE 0.625” ROD Traction Circuit: HI Speed (Transport) (Forward Shown) .0315 G4 CF LS G2 CH4 P4 80 PSI OR1 .030” 250 PSI .0315 EC CV2 4 PSI S11 3250 PSI G G CH2 RV1 30.5 GPM CH1 5000 PSI P1 G3 P2 CV2 PR 380 PSI M8 S5 13.7 GPM 16.8 GPM FRONT TRACTION MANIFOLD T OR9 .030 OR4 .040 CH 200 PSI M3 M1 CV4 CV 650 PSI RV CH2 OR .063 CH1 S3 OR5 .070 C2 CENTER DECK RAM CYLINDERS 1.50” BORE 3.08” STROKE 4 PSI C4 CH3 3300 PSI S2 S4 HFD Split 55--45 CV1 P3 RV3 OR2 .063 C3 REAR OR1 TRACTION .050 MANIFOLD T ENGINE 60 PSI CV3 OR3 .070 S1 PR 310 PSI LEFT DECK 2.50” BORE 6.50” STROKE 1.125” ROD 4350 PSI 1350 PSI CV1 4 PSI PRV M2 M1 S10 G G 0.51 CID S12 RV2 2.14 CID / 1.16 CID 2SP 1600 PSI S6 RIGHT DECK 2.50” BORE 6.50” STROKE 1.125” ROD OR7 .070 S7 S9 C6 S8 1.2 CID / 0.64 CID 1.2 CID / 0.64 CID COMBINATION MANIFOLD OR6 .063 C5 G1 Traction Circuit: HI Speed (Transport) Front wheel and rear axle motors are positive displacement, two speed variable motors that allow operation in either LOW (mow) or HI (transport) speed. The motors are spring biased to maximum displacement for LOW speed and are hydraulically shifted to minimum displacement for HI speed. The rear axle motor includes a flushing valve that bleeds off a small amount of hydraulic oil for cooling of the closed loop traction circuit. The charge circuit replaces oil that is bled from the circuit by the flushing valve. A traction circuit flow divider splits traction pump hydraulic flow between the front wheel motors (approximately 45%) and rear axle motor (approximately 55%) to prevent excessive circuit flow going to a spinning wheel. The flow divider is located in the front traction manifold mounted to the right, rear side of the front frame. Traction circuit components use small amounts of hydraulic oil for internal lubrication. Fluid is designed to leak across traction pump and motor components into the case drain. This leakage results in the loss of hydraulic oil from the closed loop traction circuit that is replaced by the charge circuit. The gear pump sections that supply the steering, cooling fan and lift/lower circuits also provide charge circuit oil. Forward Direction With the armrest console HI/LOW speed switch in the HI speed (transport) position, solenoid valve (S12) in the combination manifold is energized. The energized solenoid valve directs charge pressure to shift the front wheel motors and rear axle motor to their minimum displacement. With the motors at their minimum displacements, a higher traction speed is available for transport. When the HI/LOW switch is in the HI speed (transport) position and the traction pedal is pushed in the forward direction, oil from the piston pump passes through the front traction manifold. Oil flow for the front wheel motors leaves front traction manifold port M1 to drive the front wheel motors in the forward direction and then returns to the piston pump. Oil flow from front traction manifold port M2 is directed to drive the rear axle motor in the forward direction. Oil returning from the axle motor enters the rear traction manifold at the M8 port. Flow bypasses the PR cartridge through the CV check valve, out manifold port P2 and returns to the piston pump. When going down a hill, the tractor becomes an over-running load that drives the front wheel and rear axle motors. In this condition, the rear axle motor could lock up as the oil pumped from the motor increases pressure as it returns to the piston pump. To prevent rear wheel lock up, an adjustable relief valve (RV) in the rear traction manifold reduces rear axle motor pressure created in down hill, dynamic braking conditions. Reverse Direction The traction circuit operates essentially the same in reverse HI speed (transport) 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 rear traction manifold. The oil to the front wheel motors drives them in the reverse direction and then returns to the piston pump through the front traction manifold. The oil to the rear traction manifold enters the rear traction manifold at port P2 and flows through pressure reducing valve (PR) which limits the down stream pressure to the rear axle motor to 380 PSI (26 bar) so the rear wheels will not scuff the turf during reverse operation. This reduced pressure flow is directed out rear traction manifold port M8 to drive the rear axle motor in reverse. Return oil from the rear motor returns to the piston pump through the front traction manifold. Gear pump flow for the charge circuit is directed through the oil filter and to the low pressure side of the closed loop traction circuit. Charge pressure is limited to 250 PSI (17 bar) by a relief valve located in the piston pump. Groundsmaster 4000--D/4010--D Page 4 -- 15 Hydraulic System Hydraulic System The traction circuit piston pump is a variable displacement pump that is directly coupled to the engine flywheel. This pump utilizes an integral electro--hydraulic servo piston assembly that controls the rate and direction of hydraulic flow. Pressing the traction pedal rotates a potentiometer that provides an input to the machine TEC controller. The controller in turn sends a corresponding PWM (Pulse Width Modulation) output to the electronic pump control to rotate the pump swash plate accordingly to control pump output and direction. Traction circuit oil is directed to the dual displacement front wheel and rear axle motors. Operating pressure on the high pressure side of the closed traction circuit loop is determined by the amount of load developed at the wheel and axle motors. As the traction load increases, circuit pressure can increase to relief valve settings: 4350 PSI (300 bar) in forward and 5000 PSI (345 bar) in reverse. If traction circuit pressure exceeds the relief setting, oil flows through the piston pump relief valve to the low pressure side of the closed loop traction circuit. Traction circuit pressure can be measured at test ports attached to the sides of the piston pump. The forward traction port is on the right side of the pump and the reverse traction port is on the left side. Hydraulic System Page 4 -- 16 Groundsmaster 4000--D/4010--D M2 1.17 CID M1 M2 1.17 CID M1 M2 1.17 CID M1 RV PD RV PD RV PD 600 PSI .025 600 PSI .025 CD PRV CD PRV 2000 PSI CD PRV LC1 P2 G P1 P2 G 50 PSI RIGHT DECK LC1 LEFT DECK LC1 P2 G P1 P1 CENTER DECK 3000 PSI 3000 PSI 600 PSI .025 Working Pressure Low Pressure (Charge) Return or Suction Flow P G T G 2.75 CID 14.3 GPM 14.3 GPM 4.4 GPM 3.3 GPM E 6.1 CID L STEERING CYLINDER 0.3 0.4 1.29 1.29 CID CID CID CID R 2.00” BORE 4.20” STROKE 0.625” ROD STEERING CONTROL VALVE Lower Cutting Deck (LH Deck Shown) .0315 G4 CF LS G2 CH4 P4 80 PSI OR1 .030” 250 PSI .0315 EC CV2 4 PSI S11 3250 PSI G G CH2 RV1 30.5 GPM CH1 5000 PSI P1 S1 G3 REAR OR1 TRACTION .050 MANIFOLD T P2 CV2 PR 380 PSI M8 S5 13.7 GPM 16.8 GPM FRONT TRACTION MANIFOLD T OR9 .030 OR4 .040 C2 CH 200 PSI M3 M1 CV4 CV 650 PSI RV CH2 OR .063 CH1 OR5 .070 CENTER DECK RAM CYLINDERS 1.50” BORE 3.08” STROKE 4 PSI S3 C4 CH3 3300 PSI S2 HFD Split 55--45 CV1 P3 RV3 OR2 .063 S4 C3 RETRACTING OR3 .070 ENGINE 60 PSI CV3 PR 310 PSI LEFT DECK 2.50” BORE 6.50” STROKE 1.125” ROD 4350 PSI 1350 PSI CV1 4 PSI PRV M2 M1 S10 G G 0.51 CID S12 RV2 OR7 .070 2.14 CID / 1.16 CID 2SP 1600 PSI S6 RIGHT DECK 2.50” BORE 6.50” STROKE 1.125” ROD S7 S9 C6 S8 1.2 CID / 0.64 CID 1.2 CID / 0.64 CID COMBINATION MANIFOLD OR6 .063 C5 G1 Lower Cutting Deck Circuit Each of the cutting decks (center, right and left) can be lowered independently with the use of three (3) switches on the armrest console. Pressing the front of a lift switch provides an input for the TEC controller to lower a cutting deck. The controller provides electrical outputs to solenoids in the combination manifold to allow appropriate manifold valve shift that causes a cutting deck to lower. A relief valve (RV2) located in the combination manifold limits lift/lower circuit pressure to 1600 PSI (110 bar). An adjustable pressure relieving valve (PR) in the combination 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. When the lift/lower circuit is not being used (all lift switches in the neutral position), solenoid valve S1 in the combination manifold is not energized and gear pump section oil flow is directed toward the engine cooling fan motor. NOTE: To lower a cutting deck, the operator must be in the operator seat and the traction speed must be in the LOW speed (mow) position. Lower Center Cutting Deck To lower the center cutting deck, the front of the center console lift switch is depressed. The switch signal is an input to the TEC controller which provides an electrical output to solenoid valve S6 in the combination manifold. The energized solenoid valve shifts to allow a passage for oil flow from the barrel end of the center deck lift cylinders. The weight of the cutting deck causes the center deck lift cylinders to retract and lower the center cutting deck. Check orifice OR5 (.070) under the manifold fitting in port C2 controls the lowering speed of the cutting deck. Oil from the retracting cylinders is directed to pressure reducing valve (PR). As return oil pressure increases, the PR valve will shift to direct circuit oil to the oil filter and then to the traction charge circuit. Lower Right Cutting Deck To lower the right wing deck, the front of the right console lift switch is pushed as an input to the TEC controller. The controller provides an electrical output to solenoid valves S1, S8 and S9 in the combination manifold. The energized solenoid valves shift to allow a passage for circuit oil flow to the rod end of the right deck lift cylinder. Shifted S1 allows gear pump section oil flow to be available for the lift/lower circuits. 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. Check orifice OR7 (.070) controls the lowering speed of the cutting deck. Oil from the retracting cylinder is directed through energized S9, de--energized S7 and then to pressure reducing valve (PR). As return oil pressure increases, the PR valve will shift to direct circuit oil to the oil filter and then to the traction charge circuit. Lower Left Cutting Deck To lower the left wing deck, the front of the left console lift switch is pushed as an input to the TEC controller. The controller provides an electrical output to solenoid valves S1, S3 and S4 in the combination manifold. The energized solenoid valves shift to allow a passage for circuit oil flow to the left deck lift cylinder rod end. Shifted S1 allows gear pump section oil flow to be available for the lift/lower circuits. 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. Check orifice OR3 (.070) controls the lowering speed of the cutting deck. Oil from the retracting cylinder is directed through energized S4, de--energized S2 and then to pressure reducing valve (PR). As return oil pressure increases, the PR valve will shift to direct circuit oil to the oil filter and then to the traction charge circuit. Cutting Deck Float Cutting deck float allows the fully lowered cutting decks to follow ground surface contours. Combination manifold solenoid valves S4 (left deck), S6 (center deck) and S9 (right deck) are energized when the decks are fully lowered. These energized solenoids provide an oil passage to and from the lift cylinders to allow cylinder and cutting deck movement while mowing. Counterbalance pressure (PR) 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. Groundsmaster 4000--D/4010--D Page 4 -- 17 Hydraulic System Hydraulic System A four section gear pump is coupled to the piston (traction) pump. The third gear pump section supplies hydraulic flow to the lift/lower circuit, the engine cooling fan circuit and the traction charge circuit. Hydraulic System Page 4 -- 18 Groundsmaster 4000--D/4010--D M2 1.17 CID M1 M2 1.17 CID M1 M2 1.17 CID M1 RV PD RV PD RV PD 600 PSI .025 600 PSI .025 CD PRV CD PRV 2000 PSI CD PRV LC1 P2 P2 G P1 P2 G 50 PSI RIGHT DECK LC1 LEFT DECK LC1 P1 G P1 CENTER DECK 3000 PSI 3000 PSI 600 PSI .025 Working Pressure Low Pressure (Charge) Return or Suction Flow P G T G 1.29 CID 2.75 CID 14.3 GPM 14.3 GPM 4.4 GPM 3.3 GPM E 6.1 CID L STEERING CYLINDER 0.3 0.4 1.29 CID CID CID R 2.00” BORE 4.20” STROKE 0.625” ROD STEERING CONTROL VALVE Raise Cutting Deck (LH Deck Shown) .0315 G4 CF LS G2 CH4 P4 80 PSI OR1 .030” 250 PSI .0315 EC CV2 4 PSI S11 3250 PSI G G CH2 RV1 30.5 GPM CH1 5000 PSI P1 S1 OR3 .070 G3 P2 CV2 PR 380 PSI M8 S5 13.7 GPM 16.8 GPM FRONT TRACTION MANIFOLD T OR9 .030 OR4 .040 C2 CH 200 PSI M3 M1 CV4 CV 650 PSI RV CH2 OR .063 CH1 S3 OR5 .070 CENTER DECK RAM CYLINDERS 1.50” BORE 3.08” STROKE 4 PSI C4 CH3 3300 PSI HFD Split 55--45 CV1 P3 RV3 OR2 .063 S2 S4 C3 EXTENDING REAR OR1 TRACTION .050 MANIFOLD T ENGINE 60 PSI CV3 PR 310 PSI LEFT DECK 2.50” BORE 6.50” STROKE 1.125” ROD 4350 PSI 1350 PSI CV1 4 PSI PRV M2 M1 S10 G G 0.51 CID S12 RV2 OR7 .070 2.14 CID / 1.16 CID 2SP 1600 PSI S6 RIGHT DECK 2.50” BORE 6.50” STROKE 1.125” ROD S7 S9 C6 S8 1.2 CID / 0.64 CID 1.2 CID / 0.64 CID COMBINATION MANIFOLD OR6 .063 C5 G1 Raise Cutting Deck Circuit A relief valve (RV2) located in the combination manifold limits lift/lower circuit pressure to 1600 PSI (110 bar). An adjustable pressure relieving valve (PR) in the combination 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 raised independently with the use of three (3) lift switches on the armrest console. Pressing the rear of a switch provides an input for the TEC controller to raise a cutting deck. The controller provides electrical outputs to solenoids in the combination manifold to allow appropriate hydraulic valve shift to cause a deck to raise. When the lift/lower circuit is not being used (all lift switches in the neutral position), solenoid valve S1 in the combination manifold is not energized and gear pump section oil flow is directed toward the engine cooling fan motor. 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 lift switch is depressed. The switch signal is an input to the TEC controller which provides an electrical output to solenoid valves S1 and S5 in the combination manifold. The energized solenoid valves shift to allow a passage for circuit oil flow to the barrel end of the center deck lift cylinders. Shifted S1 allows gear pump section oil flow to be available for the lift/lower circuits. Shifted S5 allows an oil path to the barrel end of the front lift cylinders causing the lift cylinders to extend and raise the center cutting deck. Check orifice OR5 under the fitting in manifold port C2 allows oil flow to bypass the orifice when the center deck is raising. An orifice in manifold port OR4 (.040) exists to control the raise speed of the cutting deck. valves S1, S7 and S9 in the combination manifold. The energized solenoid valves shift to allow a passage for circuit oil flow to the barrel end of the right deck lift cylinder. Shifted S1 allows gear pump section oil flow to be available for the lift/lower circuits. Shifted S7 and S9 allow an oil path to the barrel end of the right lift cylinder to extend the lift cylinder and raise the right cutting deck. Orifice OR6 (.063) controls the raising of the cutting deck. Check orifice OR7 is bypassed when raising the right cutting deck. Oil from the extending cylinder is directed through S8 (de--energized), to the oil filter and then to the traction charge circuit. When the lift 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 lift switch is depressed as an input to the TEC controller. The controller provides an electrical output to solenoid valves S1, S2 and S4 in the combination manifold. The energized solenoid valves shift to allow a passage for circuit oil flow to the barrel end of the left deck lift cylinder. Shifted S1 allows gear pump section oil flow to be available for the lift/lower circuits. Shifted S2 and S4 allow an oil path to the barrel end of the right lift cylinder to extend the lift cylinder and raise the right cutting deck. Orifice OR2 (.063) controls the raising of the cutting deck. Check orifice OR3 is bypassed when raising the left cutting deck. Oil from the extending cylinder is directed through S3 (de--energized), to the oil filter and then to the traction charge circuit. When the lift switch is released, the manifold solenoids are de--energized and the lift cylinder and left cutting deck are held in position. 2 1 When the lift switch is released, the manifold solenoids are de--energized and the center deck lift cylinders and center cutting deck are held in position. Raise Right Cutting Deck To raise the right deck, the rear of the right console lift switch is depressed as an input to the TEC controller. The controller provides an electrical output to solenoid Groundsmaster 4000--D/4010--D Figure 10 1. Piston (traction) pump Page 4 -- 19 2. 3rd gear pump section Hydraulic System Hydraulic System A four section gear pump is coupled to the piston (traction) pump (Fig. 10). The third gear pump section supplies hydraulic flow to the lift/lower circuit, the engine cooling fan circuit and the traction charge circuit. Hydraulic System Page 4 -- 20 Groundsmaster 4000--D/4010--D M2 1.17 CID M1 M2 1.17 CID M1 M2 1.17 CID M1 RV PD RV PD RV PD 600 PSI .025 600 PSI .025 CD PRV CD PRV 2000 PSI CD PRV LC1 P2 G P1 P2 G 50 PSI RIGHT DECK LC1 LEFT DECK LC1 P2 G P1 P1 CENTER DECK 3000 PSI 3000 PSI 600 PSI .025 Working Pressure Low Pressure (Charge) Return or Suction Flow Mow (Front Deck Shown) STEERING CONTROL VALVE P L 0.4 CID G T STEERING CYLINDER 1.29 1.29 CID CID G 2.75 CID 14.3 GPM 14.3 GPM 4.4 GPM 3.3 GPM E 6.1 CID 0.3 CID R 2.00” BORE 4.20” STROKE 0.625” ROD .0315 G4 CF LS G2 CH4 P4 80 PSI OR1 .030” 250 PSI .0315 EC CV2 4 PSI S11 3250 PSI G G CH2 RV1 30.5 GPM CH1 5000 PSI P1 OR3 .070 G3 P2 CV2 PR 380 PSI M8 T S5 13.7 GPM OR9 .030 OR4 .040 200 PSI 16.8 GPM FRONT TRACTION MANIFOLD CH M3 M1 CV4 CV 650 PSI RV CH2 OR .063 CH1 S3 OR5 .070 C2 CENTER DECK RAM CYLINDERS 1.50” BORE 3.08” STROKE 4 PSI C4 CH3 3300 PSI S2 S4 HFD Split 55--45 CV1 P3 RV3 OR2 .063 C3 REAR OR1 TRACTION .050 MANIFOLD T ENGINE 60 PSI CV3 S1 PR 310 PSI LEFT DECK 2.50” BORE 6.50” STROKE 1.125” ROD 4350 PSI 1350 PSI CV1 4 PSI PRV M2 M1 S10 G G COOLING FAN MOTOR 0.51 CID S12 RV2 OR7 .070 2.14 CID / 1.16 CID 2SP 1600 PSI S6 RIGHT DECK 2.50” BORE 6.50” STROKE 1.125” ROD S7 S9 C6 S8 1.2 CID / 0.64 CID 1.2 CID / 0.64 CID COMBINATION MANIFOLD OR6 .063 C5 G1 Mow Circuit Each cutting deck is controlled by a hydraulic manifold equipped with a proportional relief valve (PRV), a pilot directional valve (PD), a logic valve (LC1) and a relief valve (RV). The proportional relief valve is a solenoid operated valve that also functions as the circuit relief valve when energized. 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 traction speed must be in the LOW speed (mow) position, the PTO switch must be ON and the cutting deck(s) must be fully lowered and in float. PTO Not Engaged When the PTO switch is OFF or if the deck is raised with the PTO switch ON, the PTO manifold proportional relief valve (PRV) is not energized which allows a small amount of hydraulic flow through the valve. As this hydraulic flow returns to the hydraulic reservoir, a circuit pressure increase shifts logic valve LC1. The pump flow is routed through shifted LC1 and out manifold port P2 bypassing the cutting unit motor. Pilot direction valve PD and relief valve RV remain in the unshifted position to prevent any return flow from the deck motor which keeps the motor and cutting blades from rotating. motor re--enters manifold port M2, is routed through shifted PD, 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 proportional relief valve (PRV) is energized. Deck motor case drain leakage returns to the hydraulic reservoir. PTO Circuit Relief Maximum mow circuit pressure is limited for each deck by proportional relief valve (PRV) in the PTO manifold. The center and left deck relief valves are set at 3000 PSI (207 bar) and the right deck relief valve is set at 2000 PSI (138 bar). Proportional relief valve (PRV) and logic valve (LC1) work together as a two stage circuit relief. When increased circuit resistance is met (e.g. a cutting blade strikes an object), the pressure increase is felt at the proportional relief valve. If the pressure should exceed the relief valve setting, the relief valve will open, allowing a small amount of hydraulic flow through the valve. This flow causes a pressure increase that shifts logic valve LC1 and diverts circuit flow away from the deck motor to manifold port P2 (Fig. 11). When circuit pressure lowers, proportional relief valve (PRV) closes which returns logic valve LC1 back to its neutral position allowing flow to return to the deck motor. M1 P1 PUMP Return flow from the front and right PTO manifolds is routed through the oil cooler, oil filter and then to the gear pump input. Return flow from the left PTO manifold provides supply for the right deck. G FLOW 3000 PSI .025 1.17 CID PD PRV LC1 PTO Engaged When the PTO switch is turned ON and the decks are lowered, the PTO manifold proportional relief valve (PRV) is energized by the TEC controller. This shifted solenoid valve prevents any flow through the valve which allows the logic valve LC1 to be in its neutral position directing circuit flow toward the cutting deck motor. Gear pump flow entering the manifold is routed out manifold port M1 and to the cutting deck motor to cause the motor and cutting blades to rotate. As circuit pressure increases, pilot direction valve PD shifts to provide a return path for circuit flow. The return flow from the deck Groundsmaster 4000--D/4010--D RV M2 P2 600 PSI CD RIGHT DECK RETURN RETURN Page 4 -- 21 DECK MOTOR STALLED PRV ENERGIZED PRV AND LC1 SHIFTED Figure 11 Hydraulic System Hydraulic System A four section gear pump is coupled to the piston (traction) pump. Hydraulic flow for the mow circuit is supplied by two sections of the gear pump. The gear pump section closest to the piston (traction) pump supplies hydraulic flow to the side cutting decks, while the next gear pump section supplies the front cutting deck. Mow Circuit Cutting Deck Blade Braking When the operator turns the PTO switch OFF or if a deck is raised with the PTO switch ON, PTO manifold proportional relief valve (PRV) is de--energized causing logic valve (LC1) to shift (refer to information in Mow Circuit in this section). This shifted cartridge directs oil return out of manifold port P2. As circuit pressure decreases, pilot direction valve PD is shifted to it’s neutral position, preventing return flow from the deck motor and slows the cutting blades (Fig. 12). The inertia of the rotating cutting blades, however, effectively turns the deck motor into a pump causing an increase in pressure as the flow from the motor comes up against the closed relief valve (RV). When this pressure builds to approximately 600 PSI (41 bar), relief valve (RV) opens which allows hydraulic flow to flow from the motor (Fig. 13). When return pressure drops below 600 PSI (41 bar), relief valve (RV) reseats to once again block return flow from the deck motor to further slow the cutting blades. This action of the brake relief valve opening occurs several times in a very short time frame as the blades finally come to a stop. Once the blades have stopped, relief valve (RV) remains seated to keep the deck motor from rotating. PUMP FLOW M1 P1 3000 PSI .025 1.17 CID G PD PRV LC1 RV M2 P2 600 PSI CD RIGHT DECK RETURN RETURN PTO SWITCH OFF PRV NOT ENERGIZED LC1 SHIFTED Figure 12 PUMP FLOW M1 P1 G 3000 PSI .025 1.17 CID PD PRV LC1 RV M2 P2 600 PSI CD RIGHT DECK RETURN RETURN PTO SWITCH OFF PRV NOT ENERGIZED LC1 AND RV SHIFTED Figure 13 Hydraulic System Page 4 -- 22 Groundsmaster 4000--D/4010--D Hydraulic System This page is intentionally blank. Groundsmaster 4000--D/4010--D Page 4 -- 23 Hydraulic System Hydraulic System Page 4 -- 24 Groundsmaster 4000--D/4010--D M2 1.17 CID M1 M2 1.17 CID M1 M2 1.17 CID M1 RV PD RV PD RV PD 600 PSI .025 600 PSI .025 CD PRV CD PRV 2000 PSI CD PRV LC1 P2 P2 G P1 P2 G 50 PSI RIGHT DECK LC1 LEFT DECK LC1 P1 G P1 CENTER DECK 3000 PSI 3000 PSI 600 PSI .025 Working Pressure Low Pressure (Charge) Return or Suction Flow P G 1.29 CID 2.75 CID 14.3 GPM 14.3 GPM 4.4 GPM 3.3 GPM T 0.3 0.4 1.29 CID CID CID G E L STEERING CYLINDER EXTENDING 6.1 CID R 2.00” BORE 4.20” STROKE 0.625” ROD STEERING CONTROL VALVE Steering Circuit (Right Turn Shown) .0315 G4 CF LS G2 CH4 P4 80 PSI OR1 .030” 250 PSI .0315 EC CV2 4 PSI S11 3250 PSI G G CH2 RV1 30.5 GPM CH1 5000 PSI P1 G3 P2 CV2 PR 380 PSI M8 S5 13.7 GPM 16.8 GPM FRONT TRACTION MANIFOLD T OR9 .030 OR4 .040 C2 CH 200 PSI M3 M1 CV4 CV 650 PSI RV CH2 OR .063 CH1 S3 OR5 .070 CENTER DECK RAM CYLINDERS 1.50” BORE 3.08” STROKE 4 PSI C4 CH3 3300 PSI S2 S4 HFD Split 55--45 CV1 P3 RV3 OR2 .063 C3 REAR OR1 TRACTION .050 MANIFOLD T ENGINE 60 PSI CV3 OR3 .070 S1 PR 310 PSI LEFT DECK 2.50” BORE 6.50” STROKE 1.125” ROD 4350 PSI 1350 PSI CV1 4 PSI PRV M2 M1 S10 G G 0.51 CID S12 RV2 OR7 .070 2.14 CID / 1.16 CID 2SP 1600 PSI S6 RIGHT DECK 2.50” BORE 6.50” STROKE 1.125” ROD S7 S9 C6 S8 1.2 CID / 0.64 CID 1.2 CID / 0.64 CID COMBINATION MANIFOLD OR6 .063 C5 G1 Steering Circuit NOTE: The hydraulic schematic symbol for the pressure compensator valve (EC) appears to be a two (2) position valve. In operation, this valve will direct the gear pump section flow to the steering circuit as priority depending on steering input. The remainder of the gear pump section flow will be directed to the charge and engine cooling fan circuits. If there is no steering input, the compensator valve (EC) directs all gear pump section flow to the charge and engine cooling fan circuits. The combination manifold controls the operation of the steering control valve, the engine cooling fan motor and the cutting deck lift cylinders. The pressure compensator valve (EC) in the manifold controls the oil flow to the steering control valve which is a closed center, load sensing valve. The steering control valve senses the oil flow that is needed for steering and the compensator valve (EC) will supply the correct amount. Oil flow not needed for the steering circuit is provided to the engine cooling fan motor and then to the traction charge circuit. With the steering wheel in the neutral, at rest position and the engine running, hydraulic oil from the final gear pump section enters the combination manifold port P4, flows through the pressure compensator valve (EC) and to the steering control valve where it dead heads at the steering control spool. Oil is also sent to both ends of the compensator valve (EC) spool. On one end of the spool, oil is directed to the steering relief valve (RV1) and also is directed through the OR1 orifice and out the LS manifold port to the steering control valve. This flow provides steering load sense pressure and is directed through a small passage in the steering control valve spool and sleeve before returning to the hydraulic reservoir. While this load sense pressure is returning to the reservoir, the compensator valve (EC) spool shifts to direct pump flow to the engine cooling fan motor circuit and then to the traction charge circuit. Without steering input, no oil is flowing through the steering control valve to the steering cylinder. Right Turn When a right turn is made with the engine running, the turning of the steering wheel positions the steering control valve spool so that the load sense flow is blocked off. Without load sense flow, pressures on the ends of manGroundsmaster 4000--D/4010--D ifold compensator valve (EC) start to equalize causing (EC) to move toward its neutral position which allows the needed oil flow to the steering control valve. Oil is routed out manifold port CF, into steering valve port P, through the steering control spool, is drawn through the rotary meter section and out the R port to the steering cylinder. Pressure extends the steering cylinder for a right 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 steering valve L port, the spool valve, out the T port and then returns to the hydraulic reservoir. The steering control valve returns to the neutral position when turning is completed. Left Turn When a left turn is made with the engine running, the turning of the steering wheel positions the steering control valve spool so that the load sense flow is blocked off. Without load sense flow, pressures on the ends of manifold compensator valve (EC) start to equalize causing (EC) to move toward its neutral position which allows the needed oil flow to the steering control valve. Oil is routed out manifold port CF, into steering valve port P, through the steering control spool, is drawn through the rotary meter section and out the L port to the steering cylinder. Pressure retracts the steering cylinder 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 steering valve R port, the spool valve, out the T port and then returns to the hydraulic reservoir. The steering control valve returns to the neutral position when turning is completed. Steering Relief Operation When the steering cylinder reaches the end of its stroke or if a rear wheel should encounter an obstruction (e.g. a curb) while steering, the pressure in the steering circuit will rise. Relief valve (RV1) in the combination manifold senses this pressure increase. When steering circuit pressure builds to approximately 1350 PSI (93 bar), relief valve (RV1) opens and allows hydraulic flow to return to the hydraulic reservoir. This action causes flow across the relief valve side orifice of compensator valve (EC) which shifts the spool in (EC) to send oil away from the steering circuit to the fan motor circuit. Relief valve (RV1) controls the action of compensator valve (EC) and allows the compensator valve to divert only enough oil flow to the steering circuit to maintain relief pressure. Page 4 -- 25 Hydraulic System Hydraulic System A four section gear pump is coupled to the piston (traction) pump. The fourth gear pump section (farthest from the piston pump) supplies hydraulic flow to the steering circuit, the engine cooling fan circuit and the traction charge circuit. Priority hydraulic flow from this gear pump section is provided to the steering circuit by the pressure compensator valve (EC) located in the combination manifold. Hydraulic System Page 4 -- 26 Groundsmaster 4000--D/4010--D M2 1.17 CID M1 M2 1.17 CID M1 M2 1.17 CID M1 RV PD RV PD RV PD 600 PSI .025 600 PSI .025 CD PRV CD PRV 2000 PSI CD PRV LC1 P2 G P1 P2 G 50 PSI RIGHT DECK LC1 LEFT DECK LC1 P2 G P1 P1 CENTER DECK 3000 PSI 3000 PSI 600 PSI .025 Working Pressure Low Pressure (Charge) Return or Suction Flow STEERING CONTROL VALVE P G T G 2.75 CID 14.3 GPM 14.3 GPM 4.4 GPM 3.3 GPM E 6.1 CID L STEERING CYLINDER 0.3 0.4 1.29 1.29 CID CID CID CID R 2.00” BORE 4.20” STROKE 0.625” ROD Engine Cooling Fan Circuit (Forward Direction Shown) .0315 G4 CF LS G2 CH4 P4 80 PSI OR1 .030” 250 PSI .0315 EC CV2 4 PSI S11 3250 PSI G G CH2 RV1 30.5 GPM CH1 5000 PSI P1 G3 P2 CV2 PR 380 PSI M8 S5 13.7 GPM 16.8 GPM FRONT TRACTION MANIFOLD T OR9 .030 OR4 .040 C2 CH 200 PSI M3 M1 CV4 CV 650 PSI RV CH2 OR .063 CH1 S3 OR5 .070 CENTER DECK RAM CYLINDERS 1.50” BORE 3.08” STROKE 4 PSI C4 CH3 3300 PSI S2 S4 HFD Split 55--45 CV1 P3 RV3 OR2 .063 C3 REAR OR1 TRACTION .050 MANIFOLD T ENGINE 60 PSI CV3 OR3 .070 S1 PR 310 PSI LEFT DECK 2.50” BORE 6.50” STROKE 1.125” ROD 4350 PSI 1350 PSI CV1 4 PSI PRV M2 M1 S10 G G 0.51 CID S12 RV2 OR7 .070 2.14 CID / 1.16 CID 2SP 1600 PSI S6 RIGHT DECK 2.50” BORE 6.50” STROKE 1.125” ROD S7 S9 C6 S8 1.2 CID / 0.64 CID 1.2 CID / 0.64 CID COMBINATION MANIFOLD OR6 .063 C5 G1 Engine Cooling Fan Circuit A four section gear pump is coupled to the piston (traction) pump (Fig. 14). The fourth gear pump section (farthest from the piston pump) supplies hydraulic flow to the steering circuit, the engine cooling fan circuit and the traction charge circuit. The third gear pump section supplies hydraulic flow to the engine cooling fan circuit, the lift/lower circuit and the traction charge circuit. When the engine is shut off, the over--running inertia load of the engine cooling fan blades keeps driving the fan motor and turns it into a pump. The check valve (CV1) in the combination manifold will open to keep the motor circuit full of oil so the fan motor will not cavitate. So that there is sufficient oil flow for the engine cooling fan circuit, oil flow from either or both of the third or fourth gear pump section is used to drive the hydraulic cooling fan motor depending on what other machine functions are being used (steering, lift/lower). If additional oil flow is needed for cooling fan operation in extreme conditions (e.g. high ambient temperatures, cutting very heavy grass), the TEC controller can allow flow from the two pump sections to be combined. During normal, forward direction fan operation, circuit oil flow is sent through the de--energized solenoid valve (S10) in the combination manifold to rotate the cooling fan motor. Return flow from the motor re--enters the manifold (port M2), through the de--energized solenoid valve (S10), to the oil filter and then out of the manifold (port CH2). After exiting the manifold, circuit oil is routed to the traction charge circuit. Priority oil flow from the fourth gear pump section is provided to the steering circuit. All excess flow from this gear pump section is normally routed to the traction charge circuit by energized solenoid valve (S11). This valve is energized by the TEC controller as long as the lift/lower function is not being used and the hydraulic oil and engine coolant temperatures are within normal ranges. If inputs to the TEC controller suggest additional oil flow is necessary for the cooling fan (e.g. lift/lower circuit is engaged or engine coolant temperature is elevated), solenoid valve (S11) will be de--energized allowing excess pump section oil flow to be directed toward the engine cooling fan motor. Oil flow from the gear pump section(s) to the cooling fan motor is controlled by the proportional relief valve (PRV) in the combination manifold. This valve adjusts fan circuit pressure and flow based on a PWM (Pulse Width Modulation) signal from the TEC controller. The controller uses engine coolant and hydraulic oil temperatures as inputs to determine the proper PWM signal for the (PRV) valve. The fan circuit flow determines the speed of the cooling fan motor and thus, the speed of the cooling fan. If the fan motor is stalled for any reason during machine operation, the manifold proportional relief valve (PRV) has a secondary function as a circuit relief to limit fan motor pressure to 3250 PSI (224 bar). Groundsmaster 4000--D/4010--D Reverse Direction Fan Operation The TEC controller can reverse the cooling 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 all pump oil flow to the traction charge circuit. The controller then energizes solenoid valve (S10) in the combination manifold to reverse cooling fan motor oil flow so that the motor runs in the reverse direction. A lower PWM signal is sent to the (PRV) valve allowing 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 the fan should be run in reverse before fan rotation is returned to the forward direction. NOTE: The operator can manually cause the cooling fan to reverse by simultaneously pressing the right and left buttons on the InfoCenter display. 3 1 2 Figure 14 1. Piston (traction) pump 2. 4th gear pump section Page 4 -- 27 3. 3rd gear pump section Hydraulic System Hydraulic System Oil flow from the third gear pump section is routed to the combination manifold (port P3) where it is available either for the lift/lower circuit or the engine cooling fan circuit. When the lift/lower circuit is not being used (all lift switches in the neutral position), solenoid valve (S1) in the combination manifold is not energized and gear pump section oil flow is directed toward the engine cooling fan motor. Forward Direction Fan Operation 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 Figure 15 15 GPM Hydraulic Tester Kit (Pressure and Flow) Use to test hydraulic circuits and components for flow and pressure capacities as recommended in the Testing section of this chapter. This tester includes the following: 1. INLET HOSE: Hose connected from the system circuit to the inlet side of the hydraulic tester. 2. LOAD VALVE: A simulated working load is created in the circuit by turning the valve to restrict flow. 3. 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 (5 to 55 LPM). Figure 16 5. OUTLET HOSE: A hose from the outlet side of the hydraulic tester connects to the hydraulic system circuit. 6. FITTINGS: An assortment of hydraulic fittings are included with this kit. Toro Part Number: TOR214678 Hydraulic System Page 4 -- 28 Groundsmaster 4000--D/4010--D 40 GPM Hydraulic Tester (Pressure and Flow) Use to test hydraulic circuits and components for flow and pressure capacities as recommended in the Testing section of this chapter. This tester includes the following: 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 Figure 17 NOTE: This tester does not include hoses (see Hydraulic Hose Kit TOR6007 below). Hydraulic Hose Kit Hydraulic System This kit includes fittings and hoses needed to connect 40 GPM hydraulic tester (AT40002) or high flow hydraulic filter kit (TOR6011) to machine hydraulic traction system components. Toro Part Number: TOR6007 Figure 18 Groundsmaster 4000--D/4010--D Page 4 -- 29 Hydraulic System 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--directional filtration which prevents filtered debris from being allowed back into the 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 or after replacing a failed traction circuit component (e.g. piston pump 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 loop and thus, do not cause additional component damage. Toro Part Number: TOR6011 Figure 19 NOTE: This kit does not include hoses (see Hydraulic Hose Kit TOR6007 above). NOTE: Replacement filter element is Toro part number TOR6012. Filter element cannister tightening torque is 25 ft--lb (34 N--m). O--Ring Kit The O--ring kit includes O--rings in a variety of sizes for face seal and port seal hydraulic connections. It is recommended that O--rings be replaced whenever a hydraulic connection is loosened. Toro Part Number: 117--2727 Figure 20 Hydraulic System Page 4 -- 30 Groundsmaster 4000--D/4010--D Hydraulic Test Fitting Kit This kit includes a variety of O--ring Face Seal fittings to enable you to connect test gauges into the system. TORO TEST FITTING KIT (TOR4079) The kit includes: tee’s, unions, reducers, plugs, caps and male test fittings. Toro Part Number: TOR4079 Figure 21 Measuring Container Hydraulic System Use this container for doing hydraulic motor efficiency testing (motors with case drain lines only). Measure efficiency of a hydraulic motor by restricting the outlet flow from the motor and measuring leakage from the case drain line while the motor is pressurized by the hydraulic system. The table in Figure 23 provides gallons per minute (GPM) conversion for measured milliliter or ounce motor case drain leakage. Toro Part Number: TOR4077 Figure 22 Figure 23 Groundsmaster 4000--D/4010--D Page 4 -- 31 Hydraulic System Remote Starter Switch After flushing the hydraulic system or replacing a hydraulic component (e.g. gear pump, piston pump, wheel motor), it is necessary to prime the hydraulic pumps. A remote starter switch (Fig. 24) can be used for this purpose. Obtain a remote starter switch locally. IMPORTANT: When using a remote starter switch, it is highly recommended to include a 20 amp inline fuse between the battery and switch connector for circuit protection. Figure 24 A remote stater switch can also be constructed using Toro switch #106--2027, a length of 14 gauge wire, a 20 amp in--line fuse, two (2) alligator clips and necessary connectors. Connecting the wire to switch terminals 1 and 2 will allow the momentary switch contacts to be used for the remote starter switch (Fig. 25). MACHINE BATTERY NOTE: For information on using the remote starter switch to prime the hydraulic pumps, see Flush Hydraulic System in the Service and Repairs section of this chapter. TORO SWITCH (#106--2027) 20 AMP FUSE STARTER SOLENOID MACHINE STARTER Figure 25 3 2 1 Figure 26 1. Starter motor 2. Starter solenoid Hydraulic System Page 4 -- 32 3. B+ terminal Groundsmaster 4000--D/4010--D 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. 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. Engine RPM is too low. NOTE: An indication that the hydraulic system is operating at excessive temperatures would be frequent reversing of the cooling fan and a normal engine coolant temperature. Brakes are applied or sticking. Hydraulic reservoir oil level is low. Hydraulic System 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--D Page 4 -- 33 Hydraulic System Traction Circuit Problems Problem Possible Cause Machine operates in one direction only. Piston (traction) pump by--pass valve is open or damaged. Traction relief valve is leaking or faulty. Piston (traction) pump servo control valve orifices or screens are plugged or damaged. Problem with TEC output to piston (traction) pump servo control exists (see Chapter 5 -- Electrical System). Traction pedal response is sluggish. Traction pedal components are stuck or binding. Traction charge pressure is low. Piston (traction) pump servo control valve orifices are plugged or damaged. Machine travels too far before stopping when the traction pedal is released. Traction pedal components are stuck or binding. Traction charge pressure is low. Adjustment of relief valve (RV) in rear traction manifold is incorrect. Piston (traction) pump servo control valve orifices are plugged or damaged. Traction power is lost or machine will not operate in either direction. Hydraulic reservoir oil level is low (NOTE: Other hydraulic systems are affected as well). Piston (traction) pump by--pass valve is open or damaged. Traction charge pressure is low. Traction circuit pressure is low. Traction pedal position sensor is not plugged in or is faulty (see Chapter 5 -- Electrical System). Problem with TEC output to piston (traction) pump servo control exists (see Chapter 5 -- Electrical System). LOW traction speed (mow) will not engage. Electrical problem exists that prevents solenoid valve S12 from being de--energized (see Chapter 5 -- Electrical System). NOTE: LOW (mow) will not engage when the cutting decks are lowered. Solenoid valve (S12) in combination manifold is faulty. LOW traction speed (mow) will not disengage. Electrical problem exists that prevents solenoid valve S12 from being energized (see Chapter 5 -- Electrical System). Solenoid valve (S12) in combination manifold is faulty. Hydraulic System Page 4 -- 34 Groundsmaster 4000--D/4010--D Mow Circuit Problems Problem Possible Cause None of the cutting decks will operate. Electrical problem exists that prevents PRV solenoid valve in PTO manifolds from being energized (see Chapter 5 -- Electrical System). NOTE: To engage the mow circuit, the seat must be occupied, the cutting deck(s) must be fully lowered, the traction speed must be in the LOW (mow) position and the PTO switch must be ON. One cutting deck will not operate. Front two (2) gear pump sections for mow circuits are worn or damaged. Electrical problem (e.g. solenoid coil in PTO manifold, cutting deck position switch) exists (see Chapter 5 -- Electrical System). Cutting deck problem exists (e.g. drive belt, deck spindle). System pressure to the affected cutting deck is low. Woodruff key on affected deck motor is damaged. Cartridge valve in PTO manifold for affected deck is damaged or sticking. Deck motor for affected deck is damaged (NOTE: if appropriate, transfer a suspected damaged motor to another cutting deck. If problem follows the motor, motor is faulty and needs repair or replacement). Gear pump section for affected deck is worn or damaged. All cutting decks operate slowly. Engine RPM is low. All deck motors are worn or damaged. Front two (2) gear pump sections for mow circuits are worn or damaged. Cutting deck stops under load. Proportional relief valve in PTO manifold for affected deck is by-passing. Deck motor has internal leakage (by--passing oil). Gear pump section for affected deck is worn or damaged. Groundsmaster 4000--D/4010--D Page 4 -- 35 Hydraulic System Hydraulic System Proportional relief valve (PRV) in PTO manifold for affected deck is faulty. Lift Circuit Problems Problem Possible Cause Cutting decks will not raise. Engine RPM is too low. NOTE: Seat must be occupied in order to raise cutting decks. Hydraulic oil level in reservoir is low (NOTE: Other hydraulic systems are affected as well). Solenoid valve (S1) in combination manifold is faulty. Electrical problem exists (see Chapter 5 -- Electrical System). Lift arm pivots are binding. Lift/lower relief valve in combination manifold is stuck. Lift cylinder(s) is (are) damaged. Gear pump section for lift circuit is worn or damaged (NOTE: A worn or damaged gear pump section will also affect the steering, engine cooling fan motor and traction charge circuits). Cutting decks raise, but will not stay up. NOTE: Lift cylinders cannot provide an absolutely perfect seal. A cutting deck will eventually lower if left in the raised position during storage. Lift circuit hydraulic lines or fittings are leaking. Combination manifold cartridge valve(s) for lift/lower circuits has damaged seals or is faulty. Lift cylinder for affected deck is damaged. Cutting decks will not lower. Lift arm pivots are binding. NOTE: To lower a cutting deck, the seat must be occupied and the traction speed must be in the LOW (mow) position. Electrical problem exists (see Chapter 5 -- Electrical System). Solenoid valve (S1) in combination manifold is faulty. Counterbalance pressure is excessive. Lift cylinder for affected deck is damaged. Hydraulic System Page 4 -- 36 Groundsmaster 4000--D/4010--D Steering Circuit Problems Problem Possible Cause Steering inoperative or sluggish Steering components (e.g. tie rods, steering cylinder ends) are worn or binding. Steering cylinder is binding. Oil level in hydraulic reservoir is low (NOTE: Other hydraulic systems are affected as well). Steering relief valve (RV1) in combination manifold is stuck or damaged. The pressure compensator valve (EC) in combination manifold is stuck or damaged. Steering cylinder leaks internally. Steering control valve is worn or damaged. Hydraulic System Gear pump section is worn or damaged (NOTE: A worn or damaged gear pump section will also affect the lift/lower, engine cooling fan motor and traction charge circuits). Groundsmaster 4000--D/4010--D Page 4 -- 37 Hydraulic System Engine Cooling Fan Circuit Problems Problem Possible Cause Cooling fan runs only in forward direction (fan does not run in reverse direction). Solenoid cartridge valve (S10) in combination control manifold is faulty. Cooling fan does not rotate. Cooling fan motor is worn or damaged. Electrical problem exists that prevents combination control manifold solenoid valve (S10) operation (see Chapter 5 -- Electrical System). Proportional relief valve (PRV) in combination manifold is stuck or damaged. Gear pump section for engine cooling fan circuit is worn or damaged (NOTE: A worn or damaged gear pump section will also affect the steering, lift/lower and traction charge circuits). Cooling fan always rotates at slow speed. Combination manifold cartridge valve seals are leaking. Check valve in combination manifold is not seating. Proportional relief valve (PRV) in combination manifold is stuck or damaged. Hydraulic fan motor is worn or damaged. Cooling fan always rotates at fast speed. Hydraulic System Proportional relief valve (PRV) in combination manifold is faulty. Electrical problem exists that prevents correct operation of combination manifold proportional relief valve (PRV) (see Chapter 5 -Electrical System). Page 4 -- 38 Groundsmaster 4000--D/4010--D Hydraulic System This page is intentionally blank. Groundsmaster 4000--D/4010--D Page 4 -- 39 Hydraulic System Testing The most effective method for isolating problems in the hydraulic system is by using hydraulic test equipment such as pressure gauges and flow meters in the circuits during various operational checks (see the Special Tools section in this Chapter). IMPORTANT: All obvious areas such as hydraulic oil supply, oil filters, binding components, loose fasteners or improper adjustments must be checked before assuming that a hydraulic component is the source of the problem. CAUTION Failure to use gauges with recommended pressure (PSI/bar) rating as listed in test procedures could result in damage to the gauge and possible personal injury from leaking hot oil. WARNING Keep body and hands away from pin hole leaks or nozzles that eject hydraulic fluid under high pressure. Do not use hands to search for leaks; use paper or cardboard. Hydraulic fluid escaping under pressure can have sufficient force to penetrate the skin and cause serious injury. If fluid is injected into the skin, it must be surgically removed within a few hours by a doctor familiar with this type of injury. Gangrene may result from such an injury. 1. Clean machine thoroughly before disconnecting or disassembling any hydraulic components. Always keep in mind the need for cleanliness when working on hydraulic equipment. Contamination will cause excessive wear of components. 2. Before conducting a hydraulic test, make sure hydraulic oil is at normal operating temperature by operating the machine under load for approximately ten (10) minutes. 3. Put metal caps or plugs on any hydraulic lines left open or exposed during testing or removal of components. 4. The engine must be in good operating condition. Use a phototac to determine engine speed when performing a hydraulic test. Engine speed will affect the accuracy of the tester readings. See Chapter 3 -- Yanmar Diesel Engine for engine speed specifications. 5. 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. 6. 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. 7. Install fittings finger tight and far enough to make sure that they are not cross--threaded before tightening them with a wrench. 8. Position tester hoses to prevent rotating machine parts from contacting and damaging the hoses or tester. WARNING Before disconnecting or performing any work on the hydraulic system, all pressure in the system must be relieved. See Relieving Hydraulic System Pressure in the General Information section in this chapter. CAUTION All testing should be performed by two (2) people. One person should be in the seat to operate the machine, and the second person should read test instruments and record test results. Hydraulic System Precautions for Hydraulic Testing 9. Check oil level in the hydraulic reservoir. After connecting test equipment, make sure reservoir is full. 10.Check control linkages for improper adjustment, binding or broken parts. 11. After installing test gauges, run engine at low idle speed and check for any hydraulic oil leaks. Correct any leaks before proceeding with test procedure. 12.Before returning machine to use, make sure that hydraulic reservoir has correct fluid level. Page 4 -- 40 Groundsmaster 4000--D/4010--D Which Hydraulic Tests Are Necessary? Before beginning any hydraulic test, identify if the problem is related to the traction circuit, cutting (mow) circuit, lift/lower 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, Reverse Traction Circuit Reducing Valve (PR) Pressure, Rear Traction Circuit Relief Valve (RV) Pressure, Piston (Traction) Pump Flow and/ or Gear Pump Flow Tests. 3. If a lift/lower circuit problem exists, consider performing one or more of the following tests: Lift/Lower Circuit Relief Pressure and/or Gear Pump Flow Tests. 4. If a steering circuit problem exists, consider performing one or more of the following tests: Steering Circuit Relief Pressure, Steering Cylinder Internal Leakage and/or Gear Pump Flow Tests. 5. If a engine cooling fan circuit problem exists, consider performing one or more of the following tests: Engine Cooling Fan Circuit and/or Gear Pump Flow Tests. Hydraulic System IMPORTANT: Refer to Traction Circuit Component Failure in the General Information section of this chapter for information regarding the importance of removing contamination from the traction circuit. 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 Case Drain Leakage and/or Gear Pump Flow Tests. Groundsmaster 4000--D/4010--D Page 4 -- 41 Hydraulic System Hydraulic System TO LEFT DECK PTO MANIFOLD TO CENTER DECK PTO MANIFOLD PRESSURE GAUGE Page 4 -- 42 FROM OIL FILTER 0.3 CID FROM CENTER DECK PTO MANIFOLD 0.4 CID G 1.29 CID G 1.29 CID 14.3 GPM 14.3 GPM 4.4 GPM 2.75 CID .0315 TO COMBINATION MANIFOLD 3.3 GPM 250 PSI .0315 FROM COMBINATION MANIFOLD G G 5000 PSI 4350 PSI 30.5 GPM CV PR RV 13.7 GPM 200 PSI 16.8 GPM FRONT TRACTION MANIFOLD CH M8 M3 M1 650 PSI CH2 OR .063 380 PSI HFD Split 55--45 P2 CV2 CV1 CH1 TO COMBINATION MANIFOLD REAR OR1 TRACTION .050 MANIFOLD T ENGINE P1 FROM COMBINATION MANIFOLD 2.14 CID / 1.16 CID 1.2 CID / 0.64 CID 1.2 CID / 0.64 CID FROM COMBINATION MANIFOLD Traction Circuit Charge Pressure (Using Pressure Gauge) Groundsmaster 4000--D/4010--D Procedure for Traction Circuit Charge Pressure Test CAUTION Prevent personal injury and/or damage to equipment. Read all WARNINGS, CAUTIONS and Precautions for Hydraulic Testing at the beginning of this section. 1. Park machine on a level surface with the cutting decks lowered and off. Make sure hydraulic oil is at normal operating temperature, engine is off and the parking brake is applied. NOTE: If the gear pump section that supplies the charge circuit is worn or damaged, charge, steering, lift/ lower and engine cooling fan circuits may all be affected. 7. Next, with the pressure gauge still connected to the charge pressure test port, take a gauge reading while operating the machine in forward and reverse. Start the engine and put throttle at high idle speed. Apply the brakes and push the traction pedal forward while monitoring the pressure gauge. Repeat for reverse direction. Stop engine and record test results. 8. 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. 2. Raise and support operator seat. 9. When testing is completed, disconnect pressure gauge from test fitting. Secure dust cap to test fitting. 3. Connect a 1000 PSI (70 bar) pressure gauge to test fitting attached to tee fitting in final section of gear pump (Fig. 27). 10.Lower and secure operator seat. NOTE: Make sure that steering wheel is not turned during charge pressure testing. Also, if engine coolant temperature is elevated, gear pump flow from the final pump section might be directed to the cooling fan motor which may affect charge pressure testing results. 2 3 1 4. Start engine and increase engine speed to high idle speed with no load on the hydraulic system. GAUGE READING TO BE 200 to 300 PSI (13.8 to 20.6 bar). 5. Stop engine and record test results. 6. If there is no pressure or pressure is low, check for restriction in gear pump intake line. Also, inspect charge relief valve located in piston (traction) pump (see Piston (Traction) Pump Service in the Service and Repairs section of this chapter). A worn or damaged gear pump section could also be considered (see Gear Pump Flow Test in this section). Groundsmaster 4000--D/4010--D Figure 27 1. Piston (traction) pump 2. Gear pump Page 4 -- 43 3. Charge pressure port Hydraulic System Hydraulic System The traction charge circuit is designed to replace loss of hydraulic fluid from the closed loop traction circuit. This test is used to make sure that traction charge pressure is correct. Hydraulic System FROM OIL FILTER 0.3 CID G 0.4 CID 1.29 CID G 1.29 CID 14.3 GPM 14.3 GPM 4.4 GPM 2.75 CID .0315 TO COMBINATION MANIFOLD 3.3 GPM 250 PSI .0315 FROM COMBINATION MANIFOLD G G 5000 PSI 4350 PSI 30.5 GPM Page 4 -- 44 REAR TRACTION MANIFOLD ENGINE P1 FROM COMBINATION MANIFOLD PRESSURE GAUGE TO LEFT DECK PTO MANIFOLD TO CENTER DECK PTO MANIFOLD FROM CENTER DECK PTO MANIFOLD .050 T OR1 P2 CV2 CV1 CV PR RV 13.7 GPM 200 PSI 16.8 GPM FRONT TRACTION MANIFOLD CH M8 M3 M1 650 PSI OR .063 CH2 380 PSI HFD Split 55--45 CH1 TO COMBINATION MANIFOLD 1.16 CID 2.14 CID / 0.64 CID 1.2 CID / 0.64 CID 1.2 CID / FROM COMBINATION MANIFOLD Traction Circuit Relief Pressure (Using Pressure Gauge) FORWARD TRACTION CIRCUIT RELIEF PRESSURE TEST SHOWN Groundsmaster 4000--D/4010--D Procedure for Traction Circuit Relief Pressure Test NOTE: The traction charge circuit is designed to replace loss of hydraulic fluid from the closed loop traction circuit. CAUTION Prevent personal injury and/or damage to equipment. Read all WARNINGS, CAUTIONS and Precautions for Hydraulic Testing at the beginning of this section. 6. Release traction pedal and stop engine. Record test results. 7. If traction pressure is too low, inspect traction pump relief valves (Fig. 28 or 29). Clean or replace relief valves as necessary. These cartridge type valves are factory set, and are not adjustable. If relief valves are in good condition, traction pump or wheel motors should be suspected of wear and inefficiency. 8. When testing is completed, disconnect pressure gauge from test port. Secure dust cap to test fitting. FRONT 1. Park machine on a level surface with the cutting decks lowered and off. Make sure hydraulic oil is at normal operating temperature, engine is off and the parking brake is applied. 2 CAUTION When performing the traction circuit relief pressure test, move machine to an open area, away from people and obstructions. 2. Drive machine to an open area, lower cutting decks, turn the engine off and apply the parking brake. 3. Connect a 10,000 PSI (700 bar) pressure gauge to traction circuit test port for function to be checked (Fig. 28 or 29). Hydraulic System 1 Figure 28 1. Forward traction port 2. Forward relief valve 2 4. Start engine and increase engine speed to high idle speed. Release parking brake. Make sure that HI/LOW speed switch is in the HI (transport) position. RIGHT FRONT NOTE: If possible, turn off Smart PowerTM by using the InfoCenter display protected menu. Machines with TEC software above revision level G will allow Smart PowerTM to be disabled for testing. Check software revision level using the InfoCenter About screen. 1 5. Sit on seat, apply brakes fully and slowly depress the traction pedal in the appropriate direction (forward or reverse). While pushing traction pedal, look at pressure reading on gauge: GAUGE READING TO BE: Forward: 4100 to 4600 PSI (283 to 317 bar) Reverse: 4750 to 5250 PSI (328 to 362 bar) Groundsmaster 4000--D/4010--D Figure 29 1. Reverse traction port Page 4 -- 45 2. Reverse relief valve Hydraulic System Hydraulic System TO RESERVOIR TO STEERING CONTROL VALVE Page 4 -- 46 EC CV2 4 PSI FROM GEAR PUMP FROM GEAR PUMP G4 CF LS G2 CH4 S10 M1 G P4 80 PSI OR1 .030” 0.51 CID S11 3250 PSI CH2 RV1 1350 PSI CV1 4 PSI PRV M2 G 60 PSI CV3 TO FRONT TRACTION VALVE CH1 OR3 .070 C3 S4 S2 C4 S3 S1 PR 310 PSI P3 RV3 OR2 .063 G3 3300 PSI TO RESERVOIR CH3 CV4 4 PSI OR5 .070 T OR9 .030 OR4 .040 S5 C2 3.08” STROKE 6.50” STROKE 1.125” ROD 1.50” BORE 2.50” BORE CENTER DECK RAM CYLINDERS LEFT DECK S12 RV2 2SP OR7 .070 S9 S7 C6 COMBINATION MANIFOLD OR6 .063 C5 TO WHEEL/AXLE MOTORS 1600 PSI S6 1.125” ROD 6.50” STROKE 2.50” BORE RIGHT DECK S8 G1 Counterbalance Pressure (Using Pressure Gauge) PRESSURE GAUGE TO PISTON PUMP TO STEERING CONTROL VALVE Groundsmaster 4000--D/4010--D Procedure for Counterbalance Pressure Test C. To increase pressure setting, turn the adjustment screw on the valve in a clockwise direction. A 1/8 turn on the screw will make a measurable change in counterbalance pressure. CAUTION Prevent personal injury and/or damage to equipment. Read all WARNINGS, CAUTIONS and Precautions for Hydraulic Testing at the beginning of this section. 1. Park machine on a level surface with the cutting decks lowered and off. Make sure hydraulic oil is at normal operating temperature, engine is off and the parking brake is applied. D. To decrease pressure setting, turn the adjustment screw on the valve in a counterclockwise direction. A 1/8 turn on the screw will make a measurable change in counterbalance pressure. E. Tighten lock nut to secure adjustment. Check counterbalance pressure and readjust as needed. 7. When testing is completed, disconnect pressure gauge from manifold test port. Secure dust cap to test fitting. Lower operator seat. 2. Raise and support operator seat to gain access to combination manifold. 3. Connect a 1000 PSI (70 bar) pressure gauge to test port G1 on combination manifold (Fig. 30). 2 IMPORTANT: While testing counterbalance pressure, DO NOT raise any of the cutting decks. If decks are raised, system pressure increase will damage pressure gauge. 4. Start engine and increase engine speed to high idle speed with no load on the hydraulic system. Do not engage the cutting decks. Hydraulic System NOTE: The cutting decks need to be in the float position when checking counterbalance pressure. Also, make sure that all of the cutting deck castor wheels are on the ground when testing or adjusting counterbalance pressure. 1 3 Figure 30 1. Combination manifold 2. Test port G1 GAUGE READING TO BE approximately 325 PSI (22.4 bar). 3. Pressure reducing valve 3 NOTE: The recommended counterbalance pressure for your Groundsmaster is 325 PSI (22.4 bar). 2 5. Stop engine and record test results. 6. The pressure reducing valve on the combination manifold is used to set the counterbalance pressure (Fig. 31). If necessary, adjust pressure reducing valve: NOTE: Because of valve design, the pressure reducing valve can be adjusted with the engine running. Do not remove the pressure reducing valve from the hydraulic manifold for adjustment. A. Locate pressure reducing valve on combination manifold (Fig. 31). Loosen lock nut on pressure reducing valve. 1 Figure 31 1. Combination manifold 2. Pressure reducing valve 3. Adjustment screw B. Start engine and increase engine speed to high idle speed with no load on the hydraulic system. Do not engage the cutting decks. Groundsmaster 4000--D/4010--D Page 4 -- 47 Hydraulic System Hydraulic System Page 4 -- 48 FROM OIL FILTER TO LEFT DECK PTO MANIFOLD TO CENTER DECK PTO MANIFOLD FROM CENTER DECK PTO MANIFOLD 0.3 CID G 0.4 CID 1.29 CID G 1.29 CID 14.3 GPM 14.3 GPM 4.4 GPM 2.75 CID .0315 TO COMBINATION MANIFOLD 3.3 GPM 250 PSI .0315 FROM COMBINATION MANIFOLD G G 5000 PSI 4350 PSI 30.5 GPM REAR TRACTION MANIFOLD ENGINE P1 FROM COMBINATION MANIFOLD T OR1 .050 P2 CV2 CV1 CV PR RV PRESSURE GAUGE 200 PSI 16.8 GPM FRONT TRACTION MANIFOLD CH M8 M3 M1 650 PSI OR .063 CH2 380 PSI 55--45 HFD Split CH1 TO COMBINATION MANIFOLD 13.7 GPM 1.16 CID 2.14 CID / 0.64 CID 1.2 CID / 0.64 CID 1.2 CID / FROM COMBINATION MANIFOLD Reverse Traction Circuit Reducing Valve (PR) Pressure (Using Pressure Gauge) Groundsmaster 4000--D/4010--D NOTE: When in reverse, pressure reducing valve (PR) limits the pressure to the rear axle motor to 380 PSI (26 bar) so the rear wheels will not scuff the turf. CAUTION Prevent personal injury and/or damage to equipment. Read all WARNINGS, CAUTIONS and Precautions for Hydraulic Testing at the beginning of this section. NOTE: The rear traction circuit relief valve (RV) pressure test uses the same pressure gauge position as used to measure reverse traction circuit reducing valve (PR) pressure. If necessary, conduct the rear traction circuit relief valve (RV) pressure test before removing pressure gauge from rear traction manifold. 8. When testing is completed, disconnect pressure gauge from the installed diagnostic fitting. Remove diagnostic fitting from manifold and install removed plug into manifold. Torque plug to 25 ft--lb (34 N--m). 1 1. Park machine on a level surface with the cutting decks lowered and off. Make sure hydraulic oil is at normal operating temperature, engine is off and the parking brake is applied. NOTE: The #6 zero leak plug on the inside of rear traction manifold is a zero leak plug that has a tapered sealing surface on the plug head. Lightly rap the plug head using a punch and hammer before using an allen wrench to remove the plug: the impact will allow plug removal with less chance of damage to the socket head of the plug. 4 2 3 Figure 32 1. Rear traction manifold 2. #6 zero leak plug 2. Locate rear traction manifold that is attached to the front frame next to the left side front wheel (Fig. 32). Remove #6 zero leak plug on the inside of rear traction manifold and install diagnostic fitting (Toro part number 59--7410) into manifold port. 3. Relief (RV) valve 4. Reducing (PR) valve 1 3. Connect a 1000 PSI (70 bar) pressure gauge with hydraulic hose attached to installed diagnostic fitting. 4 4. Start engine and increase engine speed to high idle speed. Make sure that HI/LOW speed switch is in the LOW speed (mow) position and release parking brake. 5. Sit on seat, apply brakes fully and slowly depress the traction pedal in the reverse direction. While pushing traction pedal, carefully monitor the pressure gauge to identify the opening pressure of the pressure reducing (PR) valve: GAUGE READING TO BE approximately 380 PSI (26 bar) when the pressure reducing (PR) valve opens. 2 3 Figure 33 1. Rear traction manifold 2. #6 zero leak plug 3. Relief (RV) valve 4. Reducing (PR) valve 6. Stop engine and record test results. 7. The pressure reducing (PR) valve is located on the rear side of the rear traction manifold (Figs. 32 and 33). If test pressure is incorrect, adjust pressure reducing (PR) valve (see Adjust Control Manifold Relief Valves in the Adjustments section of this chapter). Recheck pressure reducing valve pressure after any adjustment. Groundsmaster 4000--D/4010--D Page 4 -- 49 Hydraulic System Hydraulic System Procedure for Reverse Traction Circuit Reducing Valve (PR) Pressure Test Hydraulic System Page 4 -- 50 FROM OIL FILTER TO LEFT DECK PTO MANIFOLD TO CENTER DECK PTO MANIFOLD FROM CENTER DECK PTO MANIFOLD 0.3 CID G 0.4 CID 1.29 CID G 1.29 CID 14.3 GPM 14.3 GPM 4.4 GPM 2.75 CID .0315 TO COMBINATION MANIFOLD 3.3 GPM 250 PSI .0315 FROM COMBINATION MANIFOLD G G 5000 PSI 4350 PSI 30.5 GPM REAR TRACTION MANIFOLD ENGINE P1 FROM COMBINATION MANIFOLD T OR1 .050 P2 CV2 CV1 CV PR RV PRESSURE GAUGE 200 PSI 16.8 GPM FRONT TRACTION MANIFOLD CH M8 M3 M1 650 PSI OR .063 CH2 380 PSI 55--45 HFD Split CH1 TO COMBINATION MANIFOLD 13.7 GPM 1.16 CID 2.14 CID / 0.64 CID 1.2 CID / 0.64 CID 1.2 CID / FROM COMBINATION MANIFOLD Rear Traction Circuit Relief Valve (RV) Pressure (Using Pressure Gauge) Groundsmaster 4000--D/4010--D NOTE: Adjustable relief valve (RV) in the rear traction control manifold reduces rear axle motor pressure created in down hill, dynamic braking conditions to prevent rear wheel lock up. CAUTION Prevent personal injury and/or damage to equipment. Read all WARNINGS, CAUTIONS and Precautions for Hydraulic Testing at the beginning of this section. 1. Park machine on a level surface with the cutting decks lowered and off. Make sure hydraulic oil is at normal operating temperature, engine is off and the parking brake is applied. 6. Stop engine and record test results. NOTE: If the rear traction circuit reducing valve (PR) pressure is excessive, operation of the rear traction relief valve (RV) may be affected. Before adjusting rear traction relief valve (RV), make sure that pressure reducing valve (PR) pressure is correct. 7. The rear traction circuit relief valve (RV) is located on the rear side of the rear traction manifold (Figs. 34 and 35). If test pressure is incorrect, adjust relief valve (RV) (see Adjust Control Manifold Relief Valves in the Adjustments section of this chapter). 8. When testing is completed, disconnect pressure gauge from the installed diagnostic fitting. Remove diagnostic fitting from manifold and install removed plug into manifold. Torque plug to 25 ft--lb (34 N--m). 1 NOTE: This test uses the same pressure gauge position as used to measure reverse traction circuit reducing valve (PR) pressure. 4 NOTE: The #6 zero leak plug on the inside of rear traction manifold is a zero leak plug that has a tapered sealing surface on the plug head. Lightly rap the plug head using a punch and hammer before using an allen wrench to remove the plug: the impact will allow plug removal with less chance of damage to the socket head of the plug. 2. Locate rear traction manifold that is attached to the front frame next to the left side front wheel (Fig. 34). Remove #6 zero leak plug on inside of rear traction manifold and install diagnostic fitting (Toro part number 59--7410) into manifold port. Hydraulic System Procedure for Rear Traction Circuit Relief Valve (RV) Pressure Test 2 3 Figure 34 1. Rear traction manifold 2. #6 zero leak plug 3. Relief (RV) valve 4. Reducing (PR) valve 1 3. Connect a 1000 PSI (70 bar) pressure gauge with hydraulic hose attached to installed diagnostic fitting. 4. Start engine and increase engine speed to high idle speed. Make sure that HI/LOW switch is in the LOW (mow) position and release the parking brake. 4 5. Operate the machine in LOW speed (mow) with the cutting decks lowered. Drive down a slope in a forward direction, decrease pressure on the traction pedal and monitor the pressure gauge. Pressure should increase until the rear traction circuit relief valve lifts. GAUGE READING TO BE approximately 650 PSI (45 bar) when the rear traction relief valve (RV) opens. Groundsmaster 4000--D/4010--D 2 3 Figure 35 1. Rear traction manifold 2. #6 zero leak plug Page 4 -- 51 3. Relief (RV) valve 4. Reducing (PR) valve Hydraulic System Hydraulic System Page 4 -- 52 FROM OIL FILTER TO LEFT DECK PTO MANIFOLD TO CENTER DECK PTO MANIFOLD FROM CENTER DECK PTO MANIFOLD 0.3 CID G 0.4 CID 1.29 CID G 1.29 CID 14.3 GPM 14.3 GPM 4.4 GPM 2.75 CID .0315 TO COMBINATION MANIFOLD 3.3 GPM 250 PSI .0315 FROM COMBINATION MANIFOLD G 5000 PSI 4350 PSI 30.5 GPM G P1 REAR TRACTION MANIFOLD ENGINE FROM COMBINATION MANIFOLD T OR1 .050 P2 OR .063 M8 RV CH CH2 650 PSI HFD Split 55--45 PR 380 PSI CV CV2 CV1 CH1 TO COMBINATION MANIFOLD 200 PSI M3 M1 16.8 GPM FRONT TRACTION MANIFOLD 13.7 GPM 2.14 CID / 1.16 CID 1.2 CID / 0.64 CID 1.2 CID / 0.64 CID FROM COMBINATION MANIFOLD Piston (Traction) Pump Flow Test (Using Tester with Pressure Gauge and Flow Meter) TESTER Groundsmaster 4000--D/4010--D Procedure for Piston (Traction) Pump Flow Test This test measures piston (traction) pump output (flow). During this test, pump load is created at the flow meter using the adjustable load valve on the tester. NOTE: Before performing piston pump flow test, make sure that traction speed is set to 100% using the InfoCenter settings menu. IMPORTANT: Traction circuit flow for the Groundsmaster 4000/4010 is approximately 30 GPM (113.5 LPM). Use 40 GPM Hydraulic Tester #AT40002 (pressure and flow) for this test (see Special Tools in this chapter). CAUTION NOTE: If possible, turn off Smart PowerTM by using the InfoCenter display protected menu. Machines with TEC software above revision level G will allow Smart PowerTM to be disabled for testing. Check software revision level using the InfoCenter About screen. 6. Slowly push traction pedal to fully forward position. Keep pedal fully depressed in the fully forward position. 7. Have second person watch pressure gauge on tester carefully while slowly closing the flow control valve until 1000 PSI (69 bar) is obtained. Verify with the InfoCenter display that the engine speed is still at the correct high idle speed. NOTE: If engine speed drops during testing, pump flow will decrease and flow test results will be inaccurate. 8. Observe flow gauge. Flow indication should be approximately 30 GPM (113 LPM). 1. Park machine on a level surface with the cutting decks lowered and off. Make sure hydraulic oil is at normal operating temperature, engine is off and the parking brake is applied. 9. Release traction pedal to neutral, open flow control valve on tester and shut off engine. Record test results. 10.If flow is less than 24 GPM (91 LPM), consider the following: A. The traction pedal is not calibrated correctly (see Traction Pedal Calibration in the Adjustments section of Chapter 5 -- Electrical System). B. The piston pump swash plate is not being rotated fully (e.g. traction speed is not set to 100%). CAUTION C. The forward traction relief valve is faulty. All wheels will be off the ground and rotating during this test. Make sure machine is supported so it will not move and accidentally fall to prevent injuring anyone near the machine. 2. Raise and support machine so all wheels are off the ground (see Jacking Instructions in Chapter 1 -- Safety). 3. Thoroughly clean junction of hydraulic hose and right side fitting on bottom of piston pump (forward port) (Fig. 36). Disconnect hose from right side pump fitting. D. The piston pump needs to be repaired or replaced as necessary. 11. Make necessary repairs before performing any additional traction circuit tests. 12.When testing is complete, disconnect tester from pump fitting and machine hydraulic hose. Reconnect hose to pump fitting. Lower machine to ground. FRONT 4. Install tester with pressure gauge and flow meter in series between piston pump fitting and disconnected hose to allow flow from traction pump to tester. Use hydraulic hose kit (see Special Tools in this chapter) to connect tester to machine. Make sure that fitting and hose connections are properly tightened. Also, make sure the flow control valve on tester is fully open. 1 2 5. Start engine and adjust engine speed to high idle speed. Figure 36 1. Piston (traction) pump Groundsmaster 4000--D/4010--D Page 4 -- 53 2. Forward direction hose Hydraulic System Hydraulic System Prevent personal injury and/or damage to equipment. Read all WARNINGS, CAUTIONS and Precautions for Hydraulic Testing at the beginning of this section. Hydraulic System Page 4 -- 54 M2 1.17 CID M1 M2 1.17 CID M1 M2 1.17 CID M1 RV PD RV PD RV PD 600 PSI .025 600 PSI .025 600 PSI .025 CD PRV 2000 PSI CD PRV 3000 PSI CD PRV 3000 PSI RIGHT DECK LC1 LEFT DECK LC1 P2 P2 G P1 P2 G P1 50 PSI CENTER DECK LC1 G P1 0.3 CID 0.4 CID G TO COMBINATION MANIFOLD 1.29 CID G 1.29 CID 2.75 CID 14.3 GPM 14.3 GPM .0315 250 PSI .0315 TO COMBINATION MANIFOLD 3.3 GPM FROM STEERING CONTROL VALVE 5000 PSI 4350 PSI FROM REAR AXLE MOTOR FROM CENTER DECK MANIFOLD G G 30.5 GPM FROM REAR TRACTION MANIFOLD ENGINE TO FRONT TRACTION MANIFOLD TO RESERVOIR FROM COMBINATION MANIFOLD Cutting Deck Circuit Pressure (Using Pressure Gauge) FRONT DECK CIRCUIT PRESSURE TEST SHOWN FROM MANIFOLD AND FAN MOTOR PRESSURE GAUGE Groundsmaster 4000--D/4010--D Procedure for Cutting Deck Circuit Pressure Test 2 CAUTION Prevent personal injury and/or damage to equipment. Read all WARNINGS, CAUTIONS and Precautions for Hydraulic Testing at the beginning of this section. 1 1. Park machine on a level surface with the cutting decks lowered and off. Make sure hydraulic oil is at normal operating temperature, engine is off and the parking brake is applied. 2. Install 5000 PSI (350 bar) pressure gauge with hydraulic hose attached to manifold test port (G) for the deck to be tested (Fig. 37). Figure 37 1. PTO manifold (front) 2. Manifold test port CAUTION Hydraulic System Cutting deck blades will rotate when cutting decks are lowered with PTO switch in ON position. Keep away from decks during test to prevent personal injury from rotating blades. Do not stand in front of the machine. 3. Start engine and increase engine speed to high idle speed. Release the parking brake. 4. Watch pressure gauge carefully while mowing with the machine. 5. Cutting deck circuit pressure should be as follows and will vary depending on mowing conditions: LH Deck: 1000 to 3000 PSI (69 to 207 bar) Center Deck: 1000 to 3000 PSI (69 to 207 bar) RH Deck: 1000 to 2000 PSI (69 to 137 bar) 6. Disengage cutting decks. Shut off engine and record test results. 7. When testing is completed, disconnect pressure gauge with hose from manifold test fitting. Secure dust cap to test fitting. Groundsmaster 4000--D/4010--D Page 4 -- 55 Hydraulic System Hydraulic System 1.17 CID 1.17 CID 1.17 CID M2 M1 M2 M1 M2 M1 Page 4 -- 56 600 PSI .025 600 PSI .025 600 PSI CD PRV 2000 PSI CD PRV 3000 PSI CD PRV 3000 PSI RIGHT DECK LC1 LEFT DECK LC1 P2 P2 G P1 P2 G P1 50 PSI CENTER DECK LC1 G 0.3 CID 0.4 CID G TO COMBINATION MANIFOLD 1.29 CID G 1.29 CID 2.75 CID 14.3 GPM 14.3 GPM .0315 250 PSI .0315 TO COMBINATION MANIFOLD 3.3 GPM FROM STEERING CONTROL VALVE 5000 PSI 4350 PSI FROM REAR AXLE MOTOR FROM CENTER DECK MANIFOLD G G 30.5 GPM TO RESERVOIR FROM COMBINATION MANIFOLD FROM REAR TRACTION MANIFOLD ENGINE TO FRONT TRACTION MANIFOLD FRONT PTO RELIEF PRESSURE TEST SHOWN RV PD RV PD RV PD .025 P1 PTO Relief Pressure (Using Tester with Pressure Gauge and Flow Meter) FROM MANIFOLD AND FAN MOTOR TESTER Groundsmaster 4000--D/4010--D The PTO circuit relief pressure test should be performed to make sure that the PTO circuit relief pressures are correct. Procedure for PTO Relief Pressure Test CAUTION Prevent personal injury and/or damage to equipment. Read all WARNINGS, CAUTIONS and Precautions for Hydraulic Testing at the beginning of this section. 1. Park machine on a level surface with the cutting decks lowered and off. Make sure hydraulic oil is at normal operating temperature, engine is off and the parking brake is applied. 7. Fully open tester flow control valve and disengage cutting decks. Shut off engine and record test results. 8. If relief pressure is incorrect, remove PRV valve on mow manifold and clean or replace valve (see PTO Manifold Service in the Service and Repairs section of this chapter). Also, if pressure is still low after PRV valve service, check for restriction in pump intake line. The front gear pump section (center cutting deck circuit) and/ or the second gear pump section (side cutting deck circuits) could also be suspected of wear, damage or inefficiency (see Gear Pump Flow Test in this section). 9. When relief pressure testing is complete, disconnect tester from PTO manifold and hydraulic hose. Reconnect hydraulic hose that was disconnected for test procedure. 3 RIGHT FRONT 2. Locate PTO (deck) manifold to be tested (Fig. 38). Disconnect hydraulic hose at PTO manifold port (M1). 1 Hydraulic System NOTE: An alternative to using manifold port (M1) would be to disconnect the inlet hydraulic hose to the deck motor. 3. Install tester (flow and pressure) in series with the disconnected hose and PTO manifold port (M1) (or motor inlet if hose was disconnected at deck motor). Make sure the flow control valve on tester is fully open. 2 CAUTION Figure 38 Cutting deck blades will rotate when cutting decks are lowered with PTO switch in ON position. Keep away from cutting decks during test to prevent personal injury from rotating blades. Do not stand in front of the machine. 1. Center PTO manifold 2. LH PTO manifold 3. RH PTO manifold LEFT PTO MANIFOLD SHOWN 2 4. Start engine and increase engine speed to high idle speed. Release the parking brake. 5. Watch pressure gauge carefully while slowly closing the tester flow control valve to fully closed. 6. As the PTO relief valve lifts, system pressure should be approximately: 2900 to 3100 PSI (200 to 213 bar) for the center and left decks 1900 to 2100 PSI (131 to 144 bar) for the right deck Groundsmaster 4000--D/4010--D 1 Figure 39 1. PTO manifold Page 4 -- 57 2. PRV valve Hydraulic System Cutting Deck Motor Case Drain Leakage (Using Tester with Pressure Gauge and Flow Meter) CENTER CUTTING DECK MOTOR CASE DRAIN LEAKAGE TEST SHOWN M1 P1 1.17 CID .025 G 3000 PSI PD PRV TESTER LC1 RV P2 600 PSI M2 CD CENTER DECK FROM STEERING CONTROL VALVE CAP P1 M1 G 3000 PSI .025 1.17 CID PD TO RESERVOIR PRV LC1 MEASURING CONTAINER RV P2 600 PSI M2 CD LEFT DECK M1 FROM SECOND GEAR PUMP SECTION .025 1.17 CID 2000 PSI G PD PRV LC1 RV M2 600 PSI CD FROM FRONT GEAR PUMP SECTION RIGHT DECK TO RESERVOIR Hydraulic System Page 4 -- 58 Groundsmaster 4000--D/4010--D Procedure for Cutting Deck Motor Case Drain Leakage Test NOTE: Over a period of time, a deck motor can wear internally. A worn motor may by--pass oil to its case drain causing the motor to be less efficient. Eventually, enough oil loss will cause the deck motor to stall under heavy cutting conditions. Continued operation with a worn, inefficient motor can generate excessive heat, cause damage to seals and other components in the hydraulic system and affect quality of cut. NOTE: One method to find a failing or malfunctioning deck motor is to have another person observe the machine while mowing in dense turf. A bad motor will run slower, produce fewer clippings and may cause a different appearance on the turf. 4. Sit on seat and start the engine. With engine running, increase engine speed to high idle speed and release the parking brake. Engage the cutting decks. 5. 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. 41). 6. Have a second person collect the flow from the case drain line for 15 seconds, then move the PTO switch to OFF and stop the engine (Fig. 41). 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. 7. If flow is more than 22.4 ounces (662 ml) (0.7 GPM/2.6 LPM) in 15 seconds, the motor is worn or damaged and should be repaired or replaced. Prevent personal injury and/or damage to equipment. Read all WARNINGS, CAUTIONS and Precautions for Hydraulic Testing at the beginning of this section. 8. After testing is completed, disconnect tester from motor and hose. Reconnect hose to the deck motor. Remove cap from tee fitting and reconnect case drain hose to tee fitting. 1. Park machine on a level surface with the cutting decks lowered and off. Make sure hydraulic oil is at normal operating temperature, engine is off and the parking brake is applied. 3 NOTE: The side deck motors are connected in series. To isolate a faulty side deck motor, both motors in the circuit may have to be tested by starting with the left side motor first. 2 2. Disconnect hose from return of the motor to be tested (Fig. 40). Install tester (flow and pressure) in series with the motor and disconnected return hose. Make sure the flow control valve on tester is fully open. 3. Disconnect the motor case drain hose (small diameter hose) where it connects to hydraulic manifold tee fitting (not at the motor). Put a steel cap on the fitting at the tee fitting; leave the case drain hose open. Hydraulic System CAUTION 1 Figure 40 1. Deck motor (RH shown) 2. Return hose 3. Case drain hose CAUTION Cutting deck blades will rotate when cutting decks are lowered with PTO switch in ON position. Keep away from cutting decks during test to prevent personal injury from rotating blades. Do not stand in front of the machine. Figure 41 Groundsmaster 4000--D/4010--D Page 4 -- 59 Hydraulic System Hydraulic System Page 4 -- 60 FROM LEFT AND RIGHT DECK PTO MANIFOLDS 0.3 CID P 0.4 CID 6.1 CID G R T G 1.29 CID 1.29 CID 14.3 GPM 14.3 GPM 4.4 GPM 3.3 GPM E L STEERING CYLINDER 2.75 CID G4 CF LS G2 CH4 G EC CV2 4 PSI S10 M1 .0315 P4 250 PSI G G CH2 30.5 GPM CH1 5000 PSI 60 PSI CV3 S1 OR3 .070 G3 P2 CV2 M3 PR 380 PSI M8 T S5 13.7 GPM OR9 .030 OR4 .040 C2 200 PSI 16.8 GPM FRONT TRACTION MANIFOLD CH M1 CV4 CV 650 PSI RV CH2 OR .063 S3 OR5 .070 CENTER DECK RAM CYLINDERS 1.50” BORE 3.08” STROKE 4 PSI C4 CH3 CH1 3300 PSI HFD Split 55--45 CV1 P3 RV3 OR2 .063 S2 S4 C3 FULLY EXTENDED REAR OR1 TRACTION .050 MANIFOLD T ENGINE P1 PR 310 PSI LEFT DECK 2.50” BORE 6.50” STROKE 1.125” ROD 4350 PSI RV1 80 PSI S11 3250 PSI 1350 PSI CV1 4 PSI PRV M2 G OR1 .030” .0315 PRESSURE GAUGE FROM OIL FILTER TO LEFT DECK PTO MANIFOLD TO CENTER DECK PTO MANIFOLD FROM CENTER DECK PTO MANIFOLD TO CENTER DECK PTO MANIFOLD STEERING CONTROL VALVE 2.00” BORE 4.20” STROKE 0.625” ROD 0.51 CID S12 RV2 2.14 CID / 1.16 CID 2SP 1600 PSI S6 RIGHT DECK 2.50” BORE 6.50” STROKE 1.125” ROD OR7 .070 S7 S9 C6 S8 1.2 CID / 0.64 CID 1.2 CID / 0.64 CID COMBINATION MANIFOLD OR6 .063 C5 G1 Lift/Lower Circuit Relief Pressure (Using Pressure Gauge) LEFT DECK LIFT SWITCH PRESSED IS SHOWN Groundsmaster 4000--D/4010--D The lift/lower circuit relief pressure test should be performed to make sure that the cutting unit lift and lower circuit relief pressure is correct. 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). B. If relief pressure is too low, check for restriction in gear pump intake line. Check the lift cylinders for internal leakage. If pump intake line is not restricted and lift cylinders are not leaking, adjust relief valve RV2 to increase lift/lower circuit relief pressure (see Adjust Control Manifold Relief Valves in the Adjustments section of this chapter). C. If pressure is still too low after relief valve adjustment, lift cylinder(s) or the third section of the gear pump should be suspected of wear or damage. 8. When relief pressure testing is completed, disconnect pressure gauge from test fitting. Secure dust cap to test fitting. CAUTION Prevent personal injury and/or damage to equipment. Read all WARNINGS, CAUTIONS and Precautions for Hydraulic Testing at the beginning of this section. 9. Lower and secure operator seat. 2 1 1. Park machine on a level surface with the cutting decks lowered and off. Make sure hydraulic oil is at normal operating temperature, engine is off and the parking brake is applied. Hydraulic System 2. Raise and support operator seat. 3. Connect a 5,000 PSI (345 bar) pressure gauge to test fitting attached to tee fitting in third section of gear pump (Fig. 42). 3 4. Sit on the seat and start the engine. With engine running, increase engine speed to high idle speed. 5. While sitting on the seat, depress the rear of one of the lift switches to fully raise the cutting deck. Momentarily hold the switch with the deck fully raised while watching the pressure gauge. 4 Figure 42 1. Gear pump 2. 3rd section test fitting 3. Combination manifold 4. Relief valve RV2 2 GAUGE READING TO BE approximately 1550 to 1650 PSI (107 to 113 bar). 6. Release the lift switch, stop the engine and record test results. 7. If specification is not met, clean or adjust relief valve RV2 located in the combination control manifold (see Combination Manifold Service in the Service and Repairs section of this chapter). A. If relief pressure is too high, adjust relief valve RV2 to reduce lift/lower circuit relief pressure (see Adjust Control Manifold Relief Valves in the Adjustments section of this chapter). 1 Figure 43 1. Combination manifold Groundsmaster 4000--D/4010--D Page 4 -- 61 2. Relief valve RV2 Hydraulic System Hydraulic System Page 4 -- 62 M2 1.17 CID M1 M2 1.17 CID M1 M2 1.17 CID M1 RV PD RV PD RV PD 600 PSI .025 600 PSI .025 CD PRV CD PRV 2000 PSI CD PRV LC1 P2 G P1 P2 G 50 PSI RIGHT DECK LC1 LEFT DECK LC1 P2 G P1 CENTER DECK 3000 PSI 3000 PSI 600 PSI .025 P1 STEERING CONTROL VALVE P 0.3 CID G E L 0.4 CID 6.1 CID R 2.00” BORE 4.20” STROKE 0.625” ROD T STEERING CYLINDER 1.29 1.29 CID CID G 2.75 CID 14.3 GPM 14.3 GPM 4.4 GPM 3.3 GPM FULLY EXTENDED P4 80 PSI S11 3250 PSI G G CH2 RV1 30.5 GPM CH1 5000 PSI P1 G3 P2 CV2 PR 380 PSI T 16.8 GPM S12 OR7 .070 2.14 CID / 1.16 CID 2SP 1600 PSI S6 RIGHT DECK 2.50” BORE 6.50” STROKE 1.125” ROD RV2 13.7 GPM FRONT TRACTION MANIFOLD M8 S5 OR9 .030 OR4 .040 C2 CH 200 PSI M3 M1 CV4 CV 650 PSI RV CH2 OR .063 CH1 S3 OR5 .070 CENTER DECK RAM CYLINDERS 1.50” BORE 3.08” STROKE 4 PSI C4 CH3 3300 PSI S2 S4 HFD Split 55--45 CV1 P3 RV3 OR2 .063 C3 REAR OR1 TRACTION .050 MANIFOLD T ENGINE 60 PSI CV3 OR3 .070 S1 PR 310 PSI LEFT DECK 2.50” BORE 6.50” STROKE 1.125” ROD 4350 PSI 1350 PSI CV1 4 PSI PRV OR1 .030” .0315 EC CV2 4 PSI 250 PSI .0315 G4 CF LS G2 CH4 M2 M1 S10 G G 0.51 CID S7 S9 C6 S8 G1 1.2 CID / 0.64 CID 1.2 CID / 0.64 CID COMBINATION MANIFOLD OR6 .063 C5 Steering Circuit Relief Pressure (Using Pressure Gauge) PRESSURE GAUGE Groundsmaster 4000--D/4010--D The steering circuit relief pressure test should be performed to make sure that the steering circuit relief pressure is correct. Procedure for Steering Circuit Relief Pressure Test CAUTION Prevent personal injury and/or damage to equipment. Read all WARNINGS, CAUTIONS and Precautions for Hydraulic Testing at the beginning of this section. 7. If pressure is incorrect, inspect steering relief valve in steering control valve (see Steering Control Valve in the Service and Repairs section of this chapter). If relief valve is operating properly and if lift/lower problems also exist, flow divider in fan manifold and/or gear pump (third section) should be suspected of wear and inefficiency. If steering wheel continues to turn at end 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 fitting. Secure dust cap to test fitting. 9. Lower and secure operator seat. 1. Park machine on a level surface with the cutting deck lowered and off. Make sure hydraulic oil is at normal operating temperature, engine is off and the parking brake is applied. 2 3 1 2. Raise and support operator seat. 3. Connect a 5000 PSI (350 bar) pressure gauge to test fitting attached to tee fitting in final section of gear pump (Fig. 44). Hydraulic System 4. Start engine and increase engine speed to high idle speed. IMPORTANT: Hold steering wheel at full lock only long enough to get a system relief pressure reading. 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. Figure 44 1. Piston (traction) pump 2. Gear pump 3. Test fitting GAUGE READING TO BE 1300 to 1400 PSI (90 to 96 bar). 6. Stop the engine and record test results. Groundsmaster 4000--D/4010--D Page 4 -- 63 Hydraulic System Steering Cylinder Internal Leakage STEERING CYLINDER CYLINDER FULLY EXTENDED 2.00” BORE 4.20” STROKE 0.625” ROD LOOK FOR LEAKAGE STEEL CAP R L STEERING CONTROL VALVE STEERING WHEEL TURNED FOR RIGHT TURN 6.1 CID P E T TO RESERVOIR FROM COMBINATION MANIFOLD Hydraulic System FROM COMBINATION MANIFOLD Page 4 -- 64 Groundsmaster 4000--D/4010--D Procedure for Steering Cylinder Internal Leakage Test NOTE: Steering circuit operation will be affected by rear tire pressure, binding of steering cylinder, extra weight on the vehicle and/or binding of rear axle steering components. Make sure that these items are checked before proceeding with steering cylinder internal leakage test. CAUTION Prevent personal injury and/or damage to equipment. Read all WARNINGS, CAUTIONS and Precautions for Hydraulic Testing at the beginning of this section. 1. Park machine on a level surface with the cutting decks lowered and off. Make sure hydraulic oil is at normal operating temperature, engine is off and the parking brake is applied. 2. Turn the steering wheel for a right turn so that the steering cylinder rod is fully extended. 4. Place a drain pan under the steering cylinder. Remove hydraulic hose from the fitting on the rod end of the steering cylinder. Install a steel plug in the disconnected hose. Leave cylinder fitting open. 5. Remove all hydraulic oil from drain pan. Make sure that empty drain pan remains under the open fitting of the steering cylinder. 6. With the engine off, turn the steering wheel for a right turn. Observe the open fitting on the extended steering cylinder as the steering wheel is turned. If oil comes out of the fitting while turning the steering wheel, the steering cylinder has internal leakage and must be repaired (see Steering Cylinder and Steering Cylinder Service in the Service and Repairs section of this chapter). Check drain pan for any evidence of oil that would indicate cylinder leakage. 7. If a steering problem exists and the steering cylinder tested acceptably, the steering control valve requires service (see Steering Control Valve and Steering Control Valve Service in the Service and Repairs section of this chapter). 8. After testing is completed, remove plug from the hydraulic hose. Connect hose to the steering cylinder fitting. 9. Check oil level in hydraulic reservoir and adjust if needed. 3. Thoroughly clean the area around the hydraulic hose at the rod end of the steering cylinder. Groundsmaster 4000--D/4010--D Page 4 -- 65 Hydraulic System Hydraulic System The steering cylinder internal leakage test should be performed if a steering problem is identified. This test will determine if the steering cylinder is faulty. Hydraulic System Page 4 -- 66 FROM LEFT AND RIGHT DECK PTO MANIFOLDS FROM OIL FILTER P R 0.3 CID 6.1 CID E L 0.4 CID G 1.29 CID G 1.29 CID 2.75 CID 14.3 GPM 14.3 GPM 4.4 GPM 3.3 GPM T STEERING CYLINDER .0315 G4 CF LS G2 CH4 PRESSURE GAUGE TO LEFT DECK PTO MANIFOLD TO CENTER DECK PTO MANIFOLD FROM CENTER DECK PTO MANIFOLD TO CENTER DECK PTO MANIFOLD STEERING CONTROL VALVE 2.00” BORE 4.20” STROKE 0.625” ROD 250 PSI 80 PSI OR1 .030” P4 .0315 EC CV2 4 PSI S11 3250 PSI G G CH2 RV1 30.5 GPM CH1 5000 PSI 60 PSI CV3 OR3 .070 P2 CV2 G3 PR 380 PSI RV CH M8 M3 CV 650 PSI CH2 M1 CV4 T S5 13.7 GPM OR9 .030 OR4 .040 200 PSI 16.8 GPM FRONT TRACTION MANIFOLD S3 OR5 .070 C2 CENTER DECK RAM CYLINDERS 1.50” BORE 3.08” STROKE 4 PSI C4 CH3 OR .063 CH1 3300 PSI S2 S4 HFD Split 55--45 CV1 P3 RV3 OR2 .063 C3 REAR OR1 TRACTION .050 MANIFOLD T ENGINE P1 S1 PR 310 PSI LEFT DECK 2.50” BORE 6.50” STROKE 1.125” ROD 4350 PSI 1350 PSI CV1 4 PSI PRV M2 M1 S10 G G 0.51 CID S12 RV2 2.14 CID / 1.16 CID 2SP 1600 PSI S6 RIGHT DECK 2.50” BORE 6.50” STROKE 1.125” ROD OR7 .070 S7 S9 C6 S8 1.2 CID / 0.64 CID 1.2 CID / 0.64 CID COMBINATION MANIFOLD OR6 .063 C5 G1 Engine Cooling Fan Circuit (Using Pressure Gauge and Phototac) Groundsmaster 4000--D/4010--D The cooling fan circuit test should be performed to make sure that the engine cooling fan circuit has the correct system pressure and fan speed. Procedure for Engine Cooling Fan Circuit Test CAUTION Prevent personal injury and/or damage to equipment. Read all WARNINGS, CAUTIONS and Precautions for Hydraulic Testing at the beginning of this section. 1. Park machine on a level surface with the cutting decks lowered and off. Make sure hydraulic oil is at normal operating temperature, engine is off and the parking brake is applied. 8. If circuit pressure rises to approximately 3250 PSI (224 bar) but fan speed is low, consider that the fan motor is worn or damaged. If pressure and fan speed are both low, consider that the gear pump section is worn or damaged (see Gear Pump Flow Test in this section). NOTE: If pressure and fan speed are both low and gear pump flow proves to be correct, suspect that engine cooling fan circuit cartridge valve seals in combination manifold (e.g. S10, S11, PRV) are leaking or faulty (see Combination Manifold Service in the Service and Repairs section of this chapter). 9. When testing is complete, remove pressure gauge from hydraulic tube test port and reconnect wire harness connectors to PRV and S11 solenoids. Lower and secure hood and operator seat. 1 2. Raise and support hood to gain access to the hydraulic tubes that supply hydraulic flow to engine cooling fan motor (Fig. 45). Connect a 5,000 PSI (345 bar) pressure gauge with hydraulic hose attached to test port on hydraulic tube connected in the upper location on radiator shroud. Hydraulic System 2 3. Raise seat to gain access to the combination manifold (Fig. 46). Locate PRV and S11 solenoid valves on manifold. 4. Have a phototac available to identify cooling fan speed once engine is running. 5. Start engine and increase engine speed to high idle speed. DO NOT engage the cutting decks. Figure 45 1. Upper hydraulic tube 6. While monitoring the pressure gauge and using the phototac to identify the cooling fan speed, disconnect the wire harness connectors from the PRV solenoid (white/green and black wires) and S11 solenoid (violet and black wires) on combination manifold (Fig. 46). Both fan speed and pressure should increase and stabilize after the solenoids are disconnected. 2. Test port 2 3 PRESSURE GAUGE READING TO BE approximately 3250 PSI (224 bar). PHOTOTAC READING (FAN SPEED) TO BE approximately 2800 to 3000 RPM. 1 NOTE: The cooling fan speed will depend on hydraulic oil temperature. Higher oil temperatures will result in slower fan speed. 7. Stop engine and record test results. Groundsmaster 4000--D/4010--D Figure 46 1. Combination manifold 2. PRV solenoid Page 4 -- 67 3. S11 solenoid Hydraulic System Gear Pump Flow (Using Tester with Pressure Gauge and Flow Meter) Hydraulic System G CID CID FROM OIL FILTER FROM MANIFOLD AND FAN MOTOR FROM MOW CIRCUIT 1.29 0.4 CID 1.29 CID 2.75 The gear pump flow test should be performed to make sure that the mow, steering, lift/lower, cooling fan and traction charge circuits have adequate hydraulic flow. The front gear pump section provides hydraulic flow for the side cutting decks (Fig. 47). The second gear pump section provides hydraulic flow for the center cutting deck. The third gear pump section provides hydraulic flow for the cooling fan, lift/lower and traction charge circuits. The fourth gear pump section provides hydraulic flow for the steering, traction charge and cooling fan circuits. 0.3 G G TO LEFT DECK PTO MANIFOLD TO CENTER DECK PTO MANIFOLD TESTER CID 14.3 GPM 14.3 GPM TO COMBINATION MANIFOLD 3.3 GPM TO COMBINATION MANIFOLD .0315 250 PSI FROM REAR AXLE MOTOR 5000 PSI 4350 PSI .0315 G FROM CENTER DECK MANIFOLD ENGINE GPM FROM COMBINATION MANIFOLD 30.5 TO FRONT TRACTION MANIFOLD FROM REAR TRACTION MANIFOLD SECOND GEAR PUMP SECTION FLOW TEST SHOWN NOTE: Over a period of time, the gears and wear plates in the gear pump can wear. A worn pump will by pass oil and make the pump less efficient. Eventually, enough oil loss will occur to cause circuit problems (e.g. cutting deck motors stalling under heavy cutting conditions, lift or steering problems). Continued operation with a worn, inefficient gear pump can generate excessive heat and cause damage to the seals and other components in the hydraulic system. Page 4 -- 68 Groundsmaster 4000--D/4010--D 10.If a pressure of 1000 PSI (69 bar) cannot be obtained or flow was less than the minimum flow listed in Figure 48, check for restriction in the pump intake line. If line is not restricted, consider that the tested gear pump section is worn or damaged. Procedure for Gear Pump Flow 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. 11. After testing is completed, disconnect flow tester from hydraulic hose and fitting in gear pump section. Reconnect hose to the pump fitting. 12.Lower and secure operator seat. 1. Park machine on a level surface with the cutting decks lowered and off. Make sure hydraulic oil is at normal operating temperature, engine is off and the parking brake is applied. 1 2 2. Raise and support operator seat to gain access to gear pump. 3 4 3. Determine which gear pump section is to be tested. Disconnect hydraulic hose from fitting in gear pump section that is to be tested (Fig. 47). Hydraulic System 4. Install tester (flow and pressure) in series with the disconnected hose and hydraulic fitting in gear pump section. 5. Make sure the flow control valve on tester is fully open. 6. Start engine and increase engine speed to high idle speed. Do not engage the cutting decks. IMPORTANT: Do not fully restrict oil flow through tester. In this test, the flow tester is positioned before the relief valve. Pump damage can occur if the oil flow is fully restricted. Figure 47 1. 2. 3. 4. 7. Watch pressure gauge carefully while slowly closing the flow control valve until 1000 PSI (69 bar) is obtained. Verify with the InfoCenter display that the engine is still running at the correct high idle speed. NOTE: If engine speed drops during testing, pump flow will decrease and flow test results will be inaccurate. 8. Normal flow indication for the four (4) gear pump sections is listed in Figure 48. PUMP SECTION NORMAL FLOW MINIMUM FLOW FRONT SECTION 14 GPM (53 LPM) 11 GPM (41.6 LPM) SECOND SECTION 14 GPM (53 LPM) 11 GPM (41.6 LPM) THIRD SECTION 4.3 GPM (16.3 LPM) 3.4 GPM (12.8 LPM) FOURTH SECTION 3.2 GPM (12.1 LPM) 2.5 GPM (9.5 LPM) Figure 48 9. Shut off engine and record test results. Groundsmaster 4000--D/4010--D Front pump section (LH and RH PTO) 2nd pump section (front PTO) 3rd pump section (cooling fan, lift/lower and charge) 4th pump section (steering, charge and cooling fan) Page 4 -- 69 Hydraulic System Adjustments Adjust Control Manifold Relief Valves Several of the hydraulic control manifolds on your Groundsmaster include adjustable relief valves. The following procedure can be used to adjust these relief valves. Refer to the Testing section of this chapter for information on testing relief pressure. NOTE: Do not remove relief valve from the hydraulic manifold for adjustment. 1 1. Locate relief valve on control manifold. 2. Remove cap on relief valve with an allen wrench. 3. To increase pressure setting, turn the adjustment socket on the valve in a clockwise direction. A 1/8 turn on the socket will make a measurable change in relief pressure. 2 4. To decrease pressure setting, turn the adjustment socket on the valve in a counterclockwise direction. A 1/8 turn on the socket will make a measurable change in relief pressure. 5. Install and tighten cap on relief valve. Figure 49 6. Recheck relief pressure and readjust as needed. Hydraulic System 1. Relief valve cap Page 4 -- 70 2. Adjustment socket Groundsmaster 4000--D/4010--D Service and Repairs General Precautions for Removing and Installing Hydraulic System Components Before Repair or Replacement of Components After Repair or Replacement of Components 1. Before removing any parts from the hydraulic system, park machine on a level surface, apply parking brake, lower cutting decks or attachments and stop engine. Remove key from the ignition switch. 1. Check oil level in the hydraulic reservoir and add correct oil if necessary. Drain and refill hydraulic system reservoir and change oil filters if component failure was severe or system is contaminated (see Flush Hydraulic System in this section). WARNING Before disconnecting or performing any work on the hydraulic system, all pressure in the system must be relieved. See Relieving Hydraulic System Pressure in the General Information section in this chapter. 3. Put caps or plugs on any hydraulic lines, hydraulic fittings and components left open or exposed to prevent contamination. 4. Put labels on disconnected hydraulic lines and hoses for proper installation after repairs are completed. 5. Note the position of hydraulic fittings (especially elbow fittings) on hydraulic components before removal. Mark parts if necessary to make sure they will be aligned properly when installing hydraulic hoses and tubes. IMPORTANT: Follow all local codes and regulations when recycling or disposing hydraulic fluid and filters. 2. Lubricate O--rings and seals with clean hydraulic oil before installing hydraulic components. 3. Make sure caps or plugs are removed from the hydraulic lines, hydraulic fittings and components before reconnecting. 4. Use proper tightening methods when installing hydraulic lines and fittings (see Hydraulic Hose and Tube Installation and Hydraulic Fitting Installation in the General Information section of this chapter). 5. After repairs, check control linkages or cables for proper adjustment, binding or broken parts. 6. If piston (traction) pump, front wheel motors or rear axle motor was removed from machine for service, fill housing through case drain with new hydraulic oil before starting engine. This will ensure that internal components have adequate lubrication during initial operation. 7. After disconnecting or replacing any hydraulic components, operate machine functions slowly until air is out of system (see Charge Hydraulic System in this section). 8. Check for hydraulic oil leaks. Shut off engine and correct leaks if necessary. Check oil level in hydraulic reservoir and add correct oil if necessary. Groundsmaster 4000--D/4010--D Page 4 -- 71 Hydraulic System Hydraulic System 2. Clean machine before disconnecting, removing or disassembling any hydraulic components. Make sure that all hydraulic components, hose connections and fittings are cleaned thoroughly. Always keep in mind the need for cleanliness when working on hydraulic equipment. Check Hydraulic Lines and Hoses IMPORTANT: Check hydraulic lines and hoses daily for leaks, kinked lines, loose mounting supports, wear, loose fittings or any hose deterioration. Make all necessary repairs before operating. WARNING Keep body and hands away from pin hole leaks or nozzles that eject hydraulic fluid under high pressure. Use paper or cardboard, not hands, to search for leaks. Hydraulic fluid escaping under pressure can have sufficient force to penetrate the skin and cause serious injury. If fluid is injected into the skin, it must be surgically removed within a few hours by a doctor familiar with this type of injury. Gangrene may result from such an injury. Priming Hydraulic Pumps Whenever the hydraulic system is flushed, the hydraulic system is charged or hydraulic components are installed, it is important to properly prime the hydraulic pumps. Hydraulic pump priming ensures that the gear pump and piston (traction) pump have adequate oil during initial start--up and running. The pumps can be primed by using a remote starter switch (see Special Tools in this chapter) to crank engine which allows the pumps to prime. 4. Engage remote starter switch and crank starter for thirty (30) seconds to prime hydraulic pumps. Wait thirty (30) seconds to allow the starter motor and starter solenoid to cool. Repeat cranking procedure a second time. 5. Disconnect remote starter switch leads from starter motor solenoid terminal and positive post of the battery. Use the following procedure to prime the hydraulic pumps: 3 2 1. Make sure that ignition switch is in the OFF position and key is removed from switch. 2. Check hydraulic reservoir oil level and adjust if necessary. NOTE: A blue wire connects to the starter motor solenoid B+ terminal (Fig. 50). It is not necessary to remove this blue wire from the solenoid terminal for hydraulic pump priming. 3. Connect remote starter switch electrical leads to the starter motor solenoid B+ terminal and the positive post of the battery. Hydraulic System 1 Figure 50 1. Starter motor 2. Starter solenoid Page 4 -- 72 3. B+ terminal Groundsmaster 4000--D/4010--D Flush Hydraulic System IMPORTANT: Flush the hydraulic system any time there is a severe component failure or the system is contaminated. Contaminated oil may appear milky or black or may contain metal particles. IMPORTANT: If a component failure occurred in the closed loop traction circuit (e.g. piston pump or wheel motor), filtering the traction circuit is recommended. See Filtering Closed--Loop Traction Circuit in this section. 1. Park machine on a level surface. Lower cutting decks to the ground, stop engine and apply parking brake. Remove key from the ignition switch. IMPORTANT: Follow all local codes and regulations when recycling or disposing hydraulic fluid and filters. 5. Inspect and clean hydraulic reservoir (see Hydraulic Reservoir in this section). 6. Connect all hydraulic hoses, lines and components that were disconnected while draining system. IMPORTANT: When filling hydraulic reservoir, use only hydraulic fluids specified in Operator’s Manual. Other fluids could cause system damage. 7. Fill hydraulic reservoir with new hydraulic fluid. WARNING Before disconnecting or performing any work on the hydraulic system, all pressure in the system must be relieved. See Relieving Hydraulic System Pressure in the General Information section in this chapter. 9. Start engine and let it run at low idle speed for a minimum of two (2) minutes. Increase engine speed to high idle for minimum of one (1) minute under no load. IMPORTANT: Make sure to clean around any hydraulic connections that will be disconnected for draining. 11. Shut off engine and check for hydraulic oil leaks. Check oil level in hydraulic reservoir and add correct amount of oil if necessary. 2. Drain hydraulic reservoir. Remove suction screen from reservoir and clean thoroughly. Consider removing and cleaning reservoir if necessary. 12.Operate machine for two (2) hours under normal operating conditions. 3. Drain hydraulic system. Drain all hoses, tubes and components while the system is warm. 13.Check condition of hydraulic oil. If the new fluid shows any signs of contamination, repeat steps 1 through 12 again until oil is clean. 4. Change and replace both hydraulic oil filters. Groundsmaster 4000--D/4010--D 10.Raise and lower cutting decks several times. Turn steering wheel fully left and right several times. 14.Assume normal operation and follow recommended maintenance intervals. Page 4 -- 73 Hydraulic System Hydraulic System 8. Prime hydraulic pumps (see Priming Hydraulic Pumps in this section). Filtering Closed--Loop Traction Circuit Filtering of a closed--loop hydraulic system after a major component failure (e.g. traction (piston) pump or front wheel motor) is a requirement to prevent debris from transmitting throughout the system. If a closed--loop hydraulic system filtering tool is not used to ensure system cleanliness, repeat failures, as well as subsequent damage to other hydraulic components in the affected system, will occur. To effectively remove contamination from closed--loop traction circuit, use of the Toro high flow hydraulic filter and hydraulic hose kits are recommended (see Special Tools in this chapter). 1. Park machine on a level surface with engine stopped and key removed from ignition switch. 2. Raise and support machine so all wheels are off the ground (see Jacking Instructions in Chapter 1 -- Safety). NOTE: If front wheel or rear axle motor was replaced, install high flow filter to the inlet of new motor instead of to the traction pump fitting. This will prevent system contamination from entering and damaging the new motor. 3. Thoroughly clean junction of hydraulic hose and left side fitting on bottom of piston (traction) pump (Fig. 51). Disconnect hose from left side pump fitting. 7. With engine running at low idle speed, slowly move the traction pedal to the forward direction to allow flow through the traction circuit and high flow filter. Keep traction circuit engaged for five (5) minutes while gradually increasing both forward pressure on traction pedal and engine speed. Monitor filter indicator to make sure that green color is showing during operation. 8. With engine running at high idle speed and traction pedal moved to the forward direction, periodically apply brakes to increase pressure in traction circuit. While monitoring filter indicator, continue this process for an additional five (5) minutes. IMPORTANT: If using a filter that is not the bi--directional Toro high flow filter, do not press the traction pedal in the reverse direction. If flow is reversed when using a filter that is not bi--directional, debris from the filter will re--enter the traction circuit. 9. With engine running at high idle speed, alternately move traction pedal from forward to reverse. While monitoring filter indicator, continue this process for an additional five (5) minutes. 10.Shut engine off and remove key from ignition switch. 4. Connect Toro high flow hydraulic filter in series between piston pump fitting and disconnected hose. Use hydraulic hose kit (see Special Tools in this chapter) to connect filter to machine. Make sure that fitting and hose connections are properly tightened. 11. Remove high flow hydraulic filter and hydraulic hose kit from machine. Connect hydraulic hose to right side piston (traction) pump fitting. Make sure to properly tighten hose (see Hydraulic Hose and Tube Installation in the General Information section of this chapter). IMPORTANT: When filling hydraulic reservoir, use only hydraulic fluids specified in Operator’s Manual. Other fluids could cause system damage. 12.Lower machine to ground. 5. After installing high flow filter to machine, check and fill hydraulic reservoir with new hydraulic oil as required. 13.Check oil level in hydraulic reservoir and add correct oil if necessary. 1 6. Start engine and run at idle speed. Check for any hydraulic leakage from filter and hose connections. Correct any leaks before proceeding. RIGHT FRONT CAUTION All wheels will be off the ground and rotating during this procedure. Make sure machine is well supported so it will not move and accidentally fall to prevent injuring anyone around machine. IMPORTANT: While engaging the traction circuit, monitor the high flow hydraulic filter indicator. If the indicator should show red, either reduce traction pedal setting or reduce engine speed to decrease hydraulic flow through the filter. Hydraulic System 2 Figure 51 1. Piston (traction) pump Page 4 -- 74 2. Left side fitting/hose Groundsmaster 4000--D/4010--D Charge Hydraulic System IMPORTANT: Change hydraulic oil filters whenever hydraulic components are repaired or replaced. 8. After the hydraulic system starts to show signs of fill, actuate a lift switch until the lift cylinder rod moves in and out several times. If the lift cylinder does not move after ten (10) to fifteen (15) seconds, or if the pump emits abnormal sounds, shut the engine off immediately and determine cause or problem. Inspect for the following: A. Loose filter or suction lines. 1. Park machine on a level surface. Lower cutting decks, stop engine and apply parking brake. Remove key from the ignition switch. B. Blocked suction line. 2. Make sure all hydraulic connections, lines and components are secured tightly. D. Faulty gear pump. 3. If hydraulic component failure was severe or the hydraulic system is contaminated, flush and refill hydraulic system and hydraulic reservoir (see Flush Hydraulic System in this section). IMPORTANT: When filling hydraulic reservoir, use only hydraulic fluids specified in Operator’s Manual. Other fluids could cause system damage. 4. Make sure hydraulic reservoir is full. Add correct hydraulic oil to reservoir if necessary. 5. Prime hydraulic pumps (see Priming Hydraulic Pumps in this section). WARNING Before jacking up the machine, review and follow Jacking Instructions in Chapter 1 -- Safety. 6. Raise machine so that all wheels are off the ground and place appropriate jack stands under the frame to support the machine. IMPORTANT: During initial operation, check hydraulic reservoir oil level frequently and add oil as necessary. 7. Make sure traction pedal and lift switches are in neutral. Start engine and run at low idle speed. The gear pump should pick up oil and fill the hydraulic system. If there is no indication of fill in thirty (30) seconds, stop the engine and determine the cause. Groundsmaster 4000--D/4010--D C. Faulty charge relief valve. 9. Once the lift cylinder does move in ten (10) to fifteen (15) seconds, proceed to step 10. 10.Operate the traction pedal in the forward and reverse directions. The wheels should rotate in the proper direction. A. If the wheels rotate in the wrong direction, stop engine and check for proper hydraulic hose and electrical connections at traction pump and motors. Correct as needed. B. If the wheels rotate in the proper direction, stop engine. 11. Check operation of the traction interlock switch (see Check Interlock System in Chapter 5 -- Electrical System). 12.With engine not running and ignition switch in the OFF position, remove jack stands that are supporting the machine and lower the machine to the ground. 13.If the piston (traction) pump or a traction motor was replaced or rebuilt, run the machine so all wheels turn slowly for ten (10) minutes. 14.Operate machine by gradually increasing its work load to full over a ten (10) minute period. 15.Stop the machine. Check hydraulic reservoir and fill if necessary. Check hydraulic components for leaks and tighten any loose connections. Page 4 -- 75 Hydraulic System Hydraulic System NOTE: When initially starting the hydraulic system with new or rebuilt components such as motors, pumps or lift cylinders, it is important that the hydraulic system be charged properly. Air must be purged from the system to reduce the chance of component damage. Hydraulic Reservoir 26 27 RIGHT FRONT 9 8 80 to 88 ft--lb (109 to 119 N--m) 30 28 10 7 12 6 11 31 14 3 1 15 23 29 4 3 25 24 13 18 19 16 17 20 2 5 21 22 Figure 52 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. Hydraulic reservoir Cap screw Recess bumper (2 used) Thin spacer Flange nut Breather Bushing (3 used) Stand pipe (3 used) Hose clamp Reservoir cap O--ring Hydraulic System 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. Dipstick Screen filter Tank strainer Cap screw Flat washer Thick spacer Retainer nut Tank mount Flange nut Flat washer Page 4 -- 76 22. 23. 24. 25. 26. 27. 28. 29. 30. 31. Cap screw Plug Hose clamp Suction hose Hose clamp (4 used) Hydraulic hose Hydraulic hose O--ring Hydraulic hose O--ring Groundsmaster 4000--D/4010--D Removal (Fig. 52) 1. Park machine on a level surface, lower cutting decks, stop engine, apply parking brake and remove key from the ignition switch. 2. Read the General Precautions for Removing and Installing Hydraulic System Components at the beginning of the Service and Repairs section of this chapter. 3. Drain reservoir into a suitable container. IMPORTANT: Follow all local codes and regulations when recycling or disposing hydraulic fluid. 2. Slide tank mount assembly (items 15, 16, 3, 17, 18 and 19) between frame and hydraulic reservoir and position bumper into slot on left side of reservoir. Align tank mount with hole in frame. Secure mount with cap screw and flat washer (Fig. 53). 3. Install tank strainer into reservoir port and torque from 80 to 88 ft--lb (109 to 119 N--m). 4. Remove plugs from hydraulic hoses and reservoir fittings that were placed during the removal process. Using labels placed during reservoir removal, connect hydraulic hoses to fittings on reservoir. Secure hoses with hose clamps. IMPORTANT: Make sure to not damage the electrical wire harness, hydraulic hoses or other components while lowering the operator platform. IMPORTANT: Make sure to not damage the electrical wire harness, hydraulic hoses or other components while raising the operator platform. 5. Carefully lower operator platform to the main frame (see Operator Platform in the Service and Repairs section of Chapter 6 -- Chassis). Make sure that fasteners are properly torqued during assembly. 4. Raise and support operator platform from the main frame to allow clearance to remove the hydraulic reservoir from the machine (see Operator Platform in the Service and Repairs section of Chapter 6 -- Chassis). IMPORTANT: Use only hydraulic fluids specified in Operator’s Manual. Other fluids could cause system damage. 5. Disconnect hydraulic hoses from reservoir. Label disconnected hydraulic hoses for proper installation. Put plugs on open hydraulic hoses and reservoir fittings to prevent contamination. 6. Loosen hose clamp (item 24) that secures suction hose to tank strainer. Remove suction hose (item 25) from strainer. 6. Fill reservoir with new hydraulic oil to proper level. 7. Properly fill hydraulic system (see Charge Hydraulic System in this section). 8. Stop engine and check for hydraulic oil leaks. Check hydraulic reservoir oil level. 1 7. Remove tank strainer (item 14) from reservoir. 8. Remove cap screw (item 22) and flat washer (item 21) that secure tank mount (item 19) to left side of frame. 3 9. Carefully remove hydraulic reservoir and tank mount assembly (items 3, 15, 16, 17, 18 and 19) from machine. Inspection FRONT 1. Clean hydraulic reservoir and tank strainer with solvent. 2 4 2. Inspect reservoir for leaks, cracks or other damage. Figure 53 Installation (Fig. 52) NOTE: Make sure that recess bumper (item 3) and thin spacer (item 4) are secured to right side of frame before hydraulic reservoir is installed to machine. 1. Hydraulic reservoir 2. Cap screw 3. Flat washer 4. Tank mount 1. Position hydraulic reservoir to machine. Make sure that recess bumper (item 3) on right side of frame is inserted into tank slot. Groundsmaster 4000--D/4010--D Page 4 -- 77 Hydraulic System Hydraulic System NOTE: The operator platform needs to be raised from the main frame so that the hydraulic reservoir can be removed from the machine (see Operator Platform in the Service and Repairs section of Chapter 6 -- Chassis). Radiator and Oil Cooler Assembly 31 30 27 28 26 3 25 32 33 2 24 23 4 6 1 29 3 21 5 34 9 8 22 3 20 10 16 11 19 Thread Sealant 12 18 17 RIGHT FRONT 35 7 13 36 4 14 15 9 12 3 Figure 54 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. LH radiator support Cap screw (2 used) Flange nut (12 used) Hose clamp (3 used) Hose Flange nut (6 used) Foam plug (2 used) Flange head screw (6 used) Flange head screw (9 used) Foam strip Hose bracket R--clamp (2 used) 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. Cap screw (2 used) Hose Coolant reservoir Tank mount Flat washer (7 used) Cap screw (6 used) Lower radiator hose Hose clamp (4 used) Upper radiator hose Lower radiator shroud Upper radiator shroud Hose clamp 25. 26. 27. 28. 29. 30. 31. 32. 33. 34. 35. 36. Air cleaner inlet hose Radiator/hydraulic oil cooler Bulb seal RH radiator support Straight hydraulic fitting Intake bracket 90o hydraulic fitting Pipe plug Hex plug with O--ring Foam pad (2 used) Draincock Cap screw (2 used) NOTE: The hydraulic oil cooler on your Groundsmaster is combined with the radiator. See Radiator and Oil Cooler Assembly in the Service and Repairs section of Chapter 3 -- Diesel Engine for information on removal and installation of the radiator/oil cooler assembly. Hydraulic System Page 4 -- 78 Groundsmaster 4000--D/4010--D Hydraulic System This page is intentionally blank. Groundsmaster 4000--D/4010--D Page 4 -- 79 Hydraulic System Gear Pump RIGHT 24 FRONT 26 19 1 16 13 18 20 9 6 11 14 22 10 9 17 8 23 15 25 27 21 15 20 12 2 4 5 1 3 1 2 7 Figure 55 1. 2. 3. 4. 5. 6. 7. 8. 9. Hose clamp (3 used) Hose clamp (2 used) Hydraulic hose Suction hose Tee fitting Straight hydraulic fitting Plug Cap screw (2 used) Flat washer (4 used) Hydraulic System 10. 11. 12. 13. 14. 15. 16. 17. 18. Gear pump O--ring Hydraulic fitting 45o hydraulic fitting Hydraulic tee fitting (2 used) Dust cap (4 used) Piston pump 90o hydraulic fitting Cap screw (2 used) Page 4 -- 80 19. 20. 21. 22. 23. 24. 25. 26. 27. 90o hydraulic fitting Test nipple (2 used) Straight hydraulic fitting (2 used) Straight hydraulic fitting 90o hydraulic fitting Engine (model 30603/30605 shown) Test fitting (2 used) 90o barbed hydraulic fitting Hydraulic hose Groundsmaster 4000--D/4010--D Removal (Fig. 55) Remove plugs before installing gear pump to piston pump 1. Park machine on a level surface, lower cutting decks, stop engine, apply parking brake and remove key from the ignition switch. 1 2. Raise and support machine to gain access to gear pump from the underside of the machine. 3. Drain the hydraulic reservoir. IMPORTANT: Follow all local codes and regulations when recycling or disposing hydraulic fluid. 2 4. To prevent contamination of hydraulic system during removal, thoroughly clean exterior of pump and fittings. 5. Read the General Precautions for Removing and Installing Hydraulic System Components at the beginning of the Service and Repairs section of this chapter. IMPORTANT: Dry weight of gear pump is 23 pounds (10.2 kg). 7. Support gear pump assembly to prevent it from falling. 8. Remove two (2) cap screws and washers securing gear pump to piston pump. Lower and remove gear pump from machine. NOTE: A case drain exists in the piston (traction) pump and a suction port is near the input shaft of the gear pump (Fig. 56). When the gear pump is removed from the piston pump, plug piston pump case drain hole to prevent draining the piston pump. 9. Remove O--ring (item 11) from between the gear pump and piston pump. Discard O--ring. 10.If hydraulic fittings are to be removed from gear pump, mark fitting orientation to allow correct assembly. Remove fittings from pump and discard O--rings. Installation (Fig. 55) 1. If fittings were removed from gear pump, lubricate and place new O--rings onto fittings. Install fittings into pump openings using marks made during the removal process to properly orientate fittings. Tighten fittings (see Hydraulic Fitting Installation in the General Information section of this chapter). 2. Make sure mounting and O--ring sealing surfaces on the gear pump and piston pump are clean. 3. Apply clean hydraulic oil to gear pump flange O--ring (item 11). Place O--ring on the gear pump. Groundsmaster 4000--D/4010--D 2. Gear pump suction port IMPORTANT: Position gear pump to the piston (traction) pump so that the gear pump inlet (suction) ports are facing down. IMPORTANT: A case drain exists in the piston (traction) pump and a suction port is near the input shaft of the gear pump (Fig. 56). Before the gear pump is installed to the piston pump, make sure that plugs placed in either of these ports are removed. Failure to remove plugs will cause excessive pressure in the piston pump and damage seals. Also, before securing gear pump to piston pump, fill piston pump housing with clean hydraulic oil through case drain hole. 4. Remove plugs that were placed in piston pump case drain and gear pump suction port. Fill piston pump housing with clean hydraulic oil through case drain hole. 5. Position gear pump to the piston (traction) pump so that the pump inlet ports are facing down. 6. Align gear teeth and slide gear pump input shaft into piston pump shaft. Secure gear pump to piston pump with two (2) cap screws and flat washers. 7. Remove caps and plugs from hydraulic lines and fittings. Using labels placed during gear pump removal, properly install lines to gear pump (see Hydraulic Hose and Tube Installation in the General Information section of this chapter). 8. Fill piston pump housing through case drain (90o barbed fitting) with new hydraulic oil (Fig. 57). This will ensure that internal pump components have adequate lubrication during initial operation. 9. Lower machine to ground. Page 4 -- 81 Hydraulic System Hydraulic System 6. Disconnect hydraulic lines from gear pump and put caps or plugs on open hydraulic lines and fittings. Label disconnected hydraulic lines for proper installation. Figure 56 1. Piston pump case drain 10.Replace hydraulic filters and fill hydraulic reservoir with new hydraulic oil. 2 1 11. Prime hydraulic pumps (see Priming Hydraulic Pumps in this section). 3 12.Properly fill hydraulic system (see Charge Hydraulic System in this section). 13.Stop engine and check for hydraulic oil leaks. Check hydraulic reservoir oil level. Figure 57 1. Piston (traction) pump 2. Gear pump Hydraulic System Page 4 -- 82 3. Piston pump case drain Groundsmaster 4000--D/4010--D Hydraulic System This page is intentionally blank. Groundsmaster 4000--D/4010--D Page 4 -- 83 Hydraulic System Gear Pump Service 11 15 13 16 9 7 3 2 5 18 10 12 14 17 21 8 4 6 24 1 25 23 22 20 33 ft--lb (45 N--m) 19 Figure 58 1. 2. 3. 4. 5. 6. 7. 8. 9. Front cover Dowel pin (4 used) Pressure seal Back--up gasket Front thrust plate Seal (8 used) Front body Idler gear Drive shaft 10. 11. 12. 13. 14. 15. 16. 17. Thrust plate (7 used) Dowel pin (6 used) Splined connecting shaft (3 used) Flange (3 used) Back--up gasket Pressure seal Drive gear Idler gear Disassembly (Fig. 58) NOTE: The gear pump must be replaced as a complete assembly. Individual gears, housings and thrust plates are not available separately. Disassemble gear pump for cleaning, inspection and seal replacement only. 18. 19. 20. 21. 22. 23. 24. 25. Body Body Idler gear Drive gear Rear body Rear cover Washer (4 used) Cap screw (4 used) DIAGONAL LINE IMPORTANT: Keep bodies, gears, flanges and thrust plates for each pump section together; do not mix parts between pump sections. 1. Plug pump ports and thoroughly clean exterior of pump with cleaning solvent. Make sure work area is clean. 2. Use a marker to make a diagonal line across the gear pump for assembly purposes (Fig. 59). Hydraulic System Page 4 -- 84 Figure 59 Groundsmaster 4000--D/4010--D IMPORTANT: Use caution when clamping gear pump in a vise to avoid distorting any pump components. 1 2 3. Secure the front cover of the pump in a vise with the drive shaft pointing down. 4. Loosen the four (4) cap screws that secure pump assembly. 3 4 5. Remove pump from vise and remove fasteners. 6. Support the pump assembly and gently tap the pump case with a soft face hammer to loosen the pump sections. Be careful to not drop parts or disengage gear mesh. 7. Remove the thrust plates and seals from each pump section. Before removing each gear set, apply marking dye to mating teeth to retain ”timing”. Pump efficiency may be affected if the teeth are not installed in the same position during assembly. Keep the parts for each pump section together; do not mix parts between sections. Figure 60 1. 2. 3. 4. LH and RH PTO pump section Front PTO pump section Cooling fan, lift/lower and charge pump section Steering, charge and cooling fan pump section Hydraulic System IMPORTANT: Mark the relative positions of the gear teeth and the thrust plates so they can be reassembled in the same position. Do not touch the gear surfaces as residue on hands may be corrosive to gear finish. 8. Clean all parts. Check all components for burrs, scoring, nicks and other damage. 9. Replace the entire pump assembly if parts are excessively worn or scored. Assembly (Fig. 58) 1. Apply clean hydraulic oil to all parts before assembling. NOTE: Pressure seals and back--up gaskets fit in grooves machined into thrust plates. Body seals fit in grooves machined in body faces. 2. Assemble pump sections starting at front cover end. Apply grease or petroleum jelly to new section seals to hold them in position during gear pump assembly. 3. After pump has been assembled, tighten cap screws by hand. Rotate the drive shaft to check for binding. Protect the shaft if using a pliers. 4. Tighten the four (4) cap screws evenly in a crossing pattern to a torque of 33 ft--lb (45 N--m). Groundsmaster 4000--D/4010--D Page 4 -- 85 Hydraulic System Piston (Traction) Pump RIGHT FRONT 24 26 19 1 16 13 18 20 9 6 11 14 22 10 9 17 8 23 15 25 27 21 15 20 12 2 4 5 1 3 1 2 7 Figure 61 1. 2. 3. 4. 5. 6. 7. 8. 9. Hose clamp (3 used) Hose clamp (2 used) Hydraulic hose Suction hose Tee fitting Straight hydraulic fitting Plug Cap screw (2 used) Flat washer (4 used) Hydraulic System 10. 11. 12. 13. 14. 15. 16. 17. 18. Gear pump O--ring Hydraulic fitting 45o hydraulic fitting Hydraulic tee fitting (2 used) Dust cap (4 used) Piston pump 90o hydraulic fitting Cap screw (2 used) Page 4 -- 86 19. 20. 21. 22. 23. 24. 25. 26. 27. 90o hydraulic fitting Test nipple (2 used) Straight hydraulic fitting (2 used) Straight hydraulic fitting 90o hydraulic fitting Engine (model 30603/30605 shown) Test fitting (2 used) 90o barbed hydraulic fitting Hydraulic hose Groundsmaster 4000--D/4010--D Removal (Fig. 61) 1. Park machine on a level surface, lower cutting decks, stop engine, apply parking brake and remove key from the ignition switch. 2 2. To prevent contamination of hydraulic system during removal, thoroughly clean exterior of pump assembly. 3. Raise and support machine to gain access to pump assembly from the underside of machine. 4. Label wire harness connectors that attach to the two (2) solenoid coils on left side of piston pump (Fig. 62). Disconnect harness connectors from solenoid coils on piston pump. 5. Read the General Precautions for Removing and Installing Hydraulic System Components at the beginning of the Service and Repairs section of this chapter. 7. Put a drain pan below the pump assembly. Remove hydraulic lines connected to piston and gear pump fittings. Put plugs or caps on disconnected hydraulic lines and fittings to prevent contamination of the system. FRONT Figure 62 1. Piston pump 2. Solenoid coil (forward) 3. Solenoid coil (reverse) To prevent draining the pumps, install plugs in piston pump case drain and gear pump suction port after gear pump is removed. Remove plugs before installing gear pump to piston pump NOTE: If fuel tank is removed from the machine, the gear pump and piston pump can be removed as a complete assembly. 8. Remove gear pump from machine (see Gear Pump in this section). IMPORTANT: Dry weight of piston (traction) pump is 90 pounds (41 kg). 1 NOTE: A case drain exists in the piston (traction) pump and a suction port is near the input shaft of the gear pump (Fig. 63). When the gear pump is removed from the piston pump, plug piston pump case drain hole to prevent draining the piston pump. 2 9. Support the piston pump to prevent it from falling. Remove two (2) cap screws and washers retaining pump assembly to engine flywheel plate. Carefully pull pump assembly from flywheel plate and lower it out of the machine. 10.If hydraulic fittings are to be removed from piston pump, mark fitting orientation to allow correct assembly. Remove fittings from pump and discard O--rings. Groundsmaster 4000--D/4010--D Figure 63 1. Piston pump case drain Page 4 -- 87 2. Gear pump suction port Hydraulic System Hydraulic System 6. For installation purposes, label all hydraulic lines that connect to gear pump and piston pump. 3 1 Installation (Fig. 61) 1. If fittings were removed from piston pump, lubricate and place new O--rings onto fittings. Install fittings into pump openings using marks made during the removal process to properly orientate fittings. Tighten fittings (see Hydraulic Fitting Installation in the General Information section of this chapter). IMPORTANT: To prevent spring coupler damage, make sure that piston pump is properly supported and does not put side load into coupler during pump installation. 2. Carefully raise piston pump into the machine, align pump input shaft to spring coupler on engine and position it to the engine flywheel plate. Support pump to prevent it from producing any side load into coupler and also to align pilot diameter of pump to flywheel plate bore. 3. While maintaining pump alignment with spring coupler and flywheel plate, install two (2) cap screws and washers to secure piston pump to engine. IMPORTANT: A case drain exists in the piston (traction) pump and a suction port is near the input shaft of the gear pump (Fig. 63). Before the gear pump is installed to the piston pump, make sure that plugs placed in either of these ports are removed. Failure to remove plugs will cause excessive pressure in the piston pump and damage seals. Also, before securing gear pump to piston pump, fill piston pump housing with clean hydraulic oil through case drain hole. 7. Fill piston (traction) pump housing with new hydraulic oil through the case drain (90o barbed fitting) at the top of the pump (Fig. 64). This will ensure that internal pump components have adequate lubrication during initial operation. 8. Remove plugs and caps from disconnected hydraulic lines and fittings of the pump assembly. Install hydraulic lines to correct location on gear and piston pumps (see Hydraulic Fitting Installation and Hydraulic Hose and Tube Installation in the General Information section of this chapter). 9. Lower machine to ground. 10.Install new hydraulic filter and fill hydraulic reservoir with correct oil. IMPORTANT: Refer to Traction Circuit Component Failure in the General Information section of this chapter for information regarding the importance of removing contamination from the traction circuit. 11. Prime hydraulic pumps (see Priming Hydraulic Pumps in this section). 12.Properly fill hydraulic system (see Charge Hydraulic System in this section). 13.Stop engine and check for hydraulic oil leaks. Check hydraulic reservoir oil level. 2 1 4. Remove plugs that were placed in piston pump case drain and gear pump suction port. Fill piston pump housing with new hydraulic oil through case drain hole. 3 5. Install gear pump to piston pump (see Gear Pump in this section). 6. Using labels placed during pump removal, connect wire harness connectors to the two (2) solenoid coils on left side of piston pump. Figure 64 1. Piston (traction) pump 2. Gear pump Hydraulic System Page 4 -- 88 3. Piston pump case drain Groundsmaster 4000--D/4010--D Hydraulic System This page is intentionally blank. Groundsmaster 4000--D/4010--D Page 4 -- 89 Hydraulic System Piston (Traction) Pump Service 43 41 51 42 52 45 53 42 46 44 45 46 47 48 42 55 42 41 39 49 37 50 34 33 35 3 2 8 30 44 36 7 15 13 40 38 1 14 25 3 34 7 29 2 31 6 33 32 29 25 10 54 10 10 24 28 4 23 11 16 5 18 17 27 26 20 12 21 22 19 9 10 Figure 65 Hydraulic System Page 4 -- 90 Groundsmaster 4000--D/4010--D Figure 65 (Continued) 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. Screen (2 used) Plug with O--ring (2 used) Plug with O--ring (2 used) Cylinder block assembly Valve plate Servo piston Screw (4 used) Orifice (2 used) Screw (4 used) Plug with O--ring (4 used) Screw (2 used) Plug Shaft Bearing assembly Retaining ring Gasket Adapter Adapter seal Coupling 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 31. 32. 33. 34. 35. 36. 37. Bearing Screw (4 used) Thrust plate Forward relief valve assembly Reverse relief valve assembly Swash plate bearing assembly Screw (2 used) Bracket (2 used) Charge relief valve assembly Servo piston seal assembly Piston follower Swashplate Dowel pin (2 used) Servo cylinder assembly (2 used) Locking plate (2 used) Dowel pin (2 used) Feedback pin Seal 38. 39. 40. 41. 42. 43. 44. 45. 46. 47. 48. 49. 50. 51. 52. 53. 54. 55. O--ring Seal carrier Retaining ring Coil nut (2 used) O--ring Forward solenoid coil Screw (3 used per solenoid) Solenoid (2 used) O--ring Control housing Screen (2 used) Retaining ring (2 used) Gasket Lock nut Plug Screw (6 used) Plug (2 used) Reverse solenoid coil Piston (Traction) Pump Service (Fig. 65) For service of the piston (traction) pump, see the Sauer-Danfoss H1 Closed Circuit Axial Piston Pumps Service Manual at the end of this chapter. NOTE: The forward (item 43) and reverse (item 55) solenoid coils are identical. Groundsmaster 4000--D/4010--D Page 4 -- 91 Hydraulic System Rear Axle Motor 2 1 9 12 11 13 4 3 7 18 8 19 6 10 14 5 15 16 17 9 to 11 ft--lb (12.3 to 14.9 N--m) 20 21 RIGHT FRONT Figure 66 1. 2. 3. 4. 5. 6. 7. Rear axle motor 90o hydraulic fitting (2 used) 90o hydraulic fitting Straight hydraulic fitting 90o hydraulic fitting Temperature sender Cap screw (2 used) Hydraulic System 8. 9. 10. 11. 12. 13. 14. Flat washer (2 used) O--ring External snap ring (2 used) Pinion gear (27T) Cap screw (6 used) Lock washer (6 used) Cover plate Page 4 -- 92 15. 16. 17. 18. 19. 20. 21. Dowel pin (2 used) Gasket External snap ring (2 used) Gear (45T) Needle bearing Plug with O--ring Drive axle assembly Groundsmaster 4000--D/4010--D Removal (Fig. 66) Installation (Fig. 66) 1. Park machine on a level surface, lower cutting decks, stop engine, apply parking brake and remove key from the ignition switch. IMPORTANT: Refer to Traction Circuit Component Failure in the General Information section of this chapter for information regarding the importance of removing contamination from the traction circuit. 3. Read the General Precautions for Removing and Installing Hydraulic System Components at the beginning of the Service and Repairs section of this chapter. 4. To prevent contamination of hydraulic system during axle motor removal, thoroughly clean exterior of motor and fittings. 5. Disconnect wire harness connector from temperature sender (item 6) on rear axle motor. 1. If fittings were removed from axle motor, lubricate and place new O--rings onto fittings. Install fittings into port openings using marks made during the removal process to properly orientate fittings. Tighten fittings (see Hydraulic Fitting Installation in the General Information section of this chapter). 2. If temperature sender (item 6) was removed from rear axle motor, thread sender into motor port. Torque sender from 9 to 11 ft--lb (12.3 to 14.9 N--m). NOTE: To ease installation, label the hydraulic lines to show their correct position on the axle motor. 3. If removed, install pinion gear (item 11) to axle motor. Make sure that retaining rings are fully seated into the grooves of the motor shaft. 6. Disconnect hydraulic lines from motor. Put caps or plugs on motor fittings and hydraulic line openings to prevent contamination. 4. Install O--ring (item 9) onto motor. Position motor to rear axle assembly and align gear teeth. Slide motor into place. IMPORTANT: Before loosening fasteners that secure rear axle motor, support motor to prevent it from falling during removal. 5. Secure motor to axle with cap screws and flat washers. 7. Remove motor from rear axle using Figure 66 as a guide. 8. If hydraulic fittings are to be removed from motor, mark fitting orientation to allow correct assembly. Remove fittings from motor and discard O--rings. 9. If necessary, remove temperature sender (item 6) from rear axle motor. 10.If necessary, remove pinion gear (item 11) from rear axle motor shaft. 6. Remove plugs from motor fittings and hydraulic line openings. Using labels placed during motor removal, correctly attach hydraulic lines to axle motor fittings (see Hydraulic Hose and Tube Installation in the General Information section of this chapter). 7. Secure wire harness connector to temperature sender (item 6) on rear axle motor. 8. Fill rear axle gearbox with SAE 85W--140 weight gear lube. Gearbox capacity is approximately 16 fl. oz. (0.47 liters). 9. Fill reservoir with hydraulic fluid as required. 10.Properly fill hydraulic system (see Charge Hydraulic System in this section). 11. After assembly is completed, verify that hydraulic lines and fittings do not contact anything. Groundsmaster 4000--D/4010--D Page 4 -- 93 Hydraulic System Hydraulic System 2. Drain lubricant from rear axle gearbox. Front Wheel Motors 4 1 15 13 3 8 11 7 6 14 5 12 1 13 8 10 2 6 RIGHT 7 FRONT 9 Figure 67 1. 2. 3. 4. 5. Front wheel motor Internal retaining ring Splined brake shaft RH brake assembly Planetary assembly (2 used) Hydraulic System 6. 7. 8. 9. 10. Cap screw (2 used per motor) Flat washer (2 used per motor) O--ring LH brake assembly Hydraulic tee fitting Page 4 -- 94 11. 12. 13. 14. 15. 90o hydraulic fitting (2 used) Hydraulic connector Hydraulic tee fitting (2 used) 90o hydraulic fitting Straight hydraulic fitting Groundsmaster 4000--D/4010--D Removal (Fig. 67) Installation (Fig. 67) 1. Park machine on a level surface, lower cutting decks, stop engine, apply parking brake and remove key from the ignition switch. IMPORTANT: Refer to Traction Circuit Component Failure in the General Information section of this chapter for information regarding the importance of removing contamination from the traction circuit. 3. To prevent contamination of hydraulic system during wheel motor removal, thoroughly clean exterior of motor and fittings. NOTE: To ease installation, label the hydraulic lines to show their correct position on the wheel motor. 4. Disconnect hydraulic hoses and tubes from wheel motor. Put caps or plugs on motor ports and hose openings to prevent contamination. IMPORTANT: Before loosening fasteners that secure wheel motor, support motor to prevent it from falling during removal. 5. Remove wheel motor using Figure 67 as a guide. 6. If hydraulic fittings are to be removed from wheel motor, mark fitting orientation to allow correct assembly. Remove fittings from motor and discard O--rings. 1. If fittings were removed from motor, lubricate and place new O--rings onto fittings. Install fittings into port openings using marks made during the removal process to properly orientate fittings. Tighten fittings (see Hydraulic Fitting Installation in the General Information section of this chapter). 2. Install new O--ring (item 8) onto motor. 3. Align splines on motor shaft and splined brake shaft. Slide motor into brake assembly. 4. Secure motor to brake assembly with cap screws and flat washers. 5. Remove plugs from wheel motor fittings and hydraulic line openings. Using labels placed during motor removal, correctly attach hydraulic hoses and tubes to wheel motor fittings (see Hydraulic Hose and Tube Installation in the General Information section of this chapter). 6. Fill reservoir with hydraulic fluid as required. 7. Properly fill hydraulic system (see Charge Hydraulic System in this section). Groundsmaster 4000--D/4010--D Page 4 -- 95 Hydraulic System Hydraulic System 2. Read the General Precautions for Removing and Installing Hydraulic System Components at the beginning of the Service and Repairs section of this chapter. Rear Axle and Front Wheel Motor Service 1 2 3 4 5 6 8 7 9 10 12 13 11 14 16 24 15 25 17 16 20 21 22 23 21 18 19 Figure 68 1. 2. 3. 4. 5. 6. 7. 8. 9. Plug with O--ring Minimum angle stop Bias spring Servo piston O--ring O--ring Socket head screw (5 used) Endcap Dowel Hydraulic System 10. 11. 12. 13. 14. 15. 16. 17. Dowel pin Bearing Gasket Valve plate Cylinder block kit Swashplate Swash plate bearing assembly Output shaft Page 4 -- 96 18. 19. 20. 21. 22. 23. 24. 25. Housing Bearing Retaining ring Retaining ring (2 used) Seal Support washer Plug with O--ring (2 used) Plug with O--ring Groundsmaster 4000--D/4010--D NOTE: The front wheel motors on your Groundsmaster are identical (Fig. 68). The rear axle motor includes a flushing valve for cooling of the closed loop traction circuit and therefore has some differences from the front motors (Fig. 69). Service of the wheel and axle motors uses the same procedure. REAR AXLE MOTOR FLUSHING VALVE 3 10 NOTE: For service of the front wheel and rear axle motors, see the Sauer--Danfoss K and L Frame Variable Motors Service Manual at the end of this chapter. 1 5 4 4 2 3 9 1 8 2 7 6 Groundsmaster 4000--D/4010--D Page 4 -- 97 Plug O--ring Centering spring Spring retaining washer Shift spool 6. 7. 8. 9. 10. Plug O--ring Centering spring Orifice poppet Endcap Hydraulic System Hydraulic System Figure 69 1. 2. 3. 4. 5. Rear Traction Manifold 2 3 1 14 11 9 8 7 10 12 13 5 15 16 18 17 4 RIGHT FRONT 6 Figure 70 1. 2. 3. 4. 5. 6. Front frame PTO manifold (center deck) Front traction manifold Rear traction manifold Cap screw (2 used) Flange nut (2 used) 7. 8. 9. 10. 11. 12. 90o hydraulic fitting O--ring o 45 hydraulic fitting O--ring O--ring Straight fitting 13. 14. 15. 16. 17. 18. O--ring O--ring 45o hydraulic fitting O--ring O--ring O--ring NOTE: The ports on the rear traction manifold are marked for easy identification of components. Example: P2 is a piston pump connection port and RV is the location for the relief valve (see Hydraulic Schematic in Chapter 10 -- Foldout Drawings to identify the function of the hydraulic lines and cartridge valves at each port). Hydraulic System Page 4 -- 98 Groundsmaster 4000--D/4010--D Removal (Fig. 70) Installation (Fig. 70) 1. Read the General Precautions for Removing and Installing Hydraulic System Components at the beginning of the Service and Repairs section of this chapter. 1. If fittings were removed from manifold, lubricate and place new O--rings onto fittings. Install fittings into manifold openings using marks made during the removal process to properly orientate fittings. Tighten fittings (see Hydraulic Fitting Installation in the General Information section of this chapter). 2. To prevent contamination of hydraulic system during manifold removal, thoroughly clean exterior of manifold and fittings. 3. Disconnect hydraulic lines from manifold and put caps or plugs on open hydraulic lines and fittings. Label disconnected hydraulic lines for proper installation. 4. Remove hydraulic manifold from the frame using Figure 70 as a guide. 3. Remove caps and plugs from fittings and hydraulic lines. Using labels placed during manifold removal, properly connect hydraulic lines to manifold (see Hydraulic Hose and Tube Installation in the General Information section of this chapter). 4. Make sure hydraulic tank is full. Add correct oil if necessary before returning machine to service. Hydraulic System 5. If hydraulic fittings are to be removed from manifold, mark fitting orientation to allow correct assembly. Remove fittings from manifold and discard O--rings. 2. Install hydraulic manifold to the frame using Figure 70 as a guide. Groundsmaster 4000--D/4010--D Page 4 -- 99 Hydraulic System Rear Traction Manifold Service 3 25 ft--lb (34 N--m) 2 50 ft--lb (67 N--m) 20 ft--lb (27 N--m) 4 1 7 35 ft--lb (47 N--m) 25 ft--lb (34 N--m) 5 6 Figure 71 1. Rear traction manifold body 2. Relief valve (port RV) 3. Pressure reducing valve (port PR) 4. #4 zero leak plug with O--ring 5. #6 zero leak plug with O--ring NOTE: The ports on the rear traction manifold are marked for easy identification of components. Example: P2 is a piston pump connection port and RV is the location for the relief valve (see Hydraulic Schematic in Chapter 10 -- Foldout Drawings to identify the function of the hydraulic lines and cartridge valves at each port). NOTE: The rear traction manifold uses several zero leak plugs. These plugs have a tapered sealing surface on the plug head that is designed to resist vibration induced plug loosening. The zero leak plugs also have an O--ring as a secondary seal. If zero leak plug removal is necessary, lightly rap the plug head using a punch and hammer before using an allen wrench to remove the plug: the impact will allow plug removal with less chance of damage to the socket head of the plug. Hydraulic System 6. Check valve (port CV) 7. Orifice (0.050) (port OR1) For rear traction manifold cartridge valve service procedures, see Control Manifold Cartridge Valve Service in this section. Refer to Figure 71 for rear traction manifold cartridge valve and plug installation torque. IMPORTANT: A flow control orifice (item 7) is located beneath the hydraulic fitting in rear traction manifold port T/OR1. If the orifice is removed from this manifold port, make sure to label its position for assembly purposes. When installing the orifice in the manifold, make sure that the orifice is properly tightened in the port. Page 4 -- 100 Groundsmaster 4000--D/4010--D Hydraulic System This page is intentionally blank. Groundsmaster 4000--D/4010--D Page 4 -- 101 Hydraulic System Front Traction Manifold 2 7 8 9 10 5 11 12 4 11 1 13 16 15 14 19 17 18 3 6 RIGHT FRONT Figure 72 1. 2. 3. 4. 5. 6. 7. Front frame PTO manifold (center deck) Rear traction manifold Front traction manifold Cap screw (2 used) Flange nut (2 used) O--ring 8. 9. 10. 11. 12. 13. Check fitting O--ring Hydraulic straight fitting O--ring 90o hydraulic elbow O--ring 14. 15. 16. 17. 18. 19. O--ring Check adapter O--ring O--ring 45o hydraulic elbow O--ring NOTE: The ports on the front traction manifold are marked for easy identification of components. Example: P1 is the gear pump connection port and HFD is the location for the flow divider valve (see Hydraulic Schematic in Chapter 10 -- Foldout Drawings to identify the function of the hydraulic lines and cartridge valves at each manifold port). Hydraulic System Page 4 -- 102 Groundsmaster 4000--D/4010--D Removal (Fig. 72) Installation (Fig. 72) 1. Read the General Precautions for Removing and Installing Hydraulic System Components at the beginning of the Service and Repairs section of this chapter. 1. If fittings were removed from manifold, lubricate and place new O--rings onto fittings. Install fittings into manifold openings using marks made during the removal process to properly orientate fittings. Tighten fittings (see Hydraulic Fitting Installation in the General Information section of this chapter). 2. To prevent contamination of hydraulic system during manifold removal, thoroughly clean exterior of manifold and fittings. 3. Disconnect hydraulic lines from manifold and put caps or plugs on open hydraulic lines and fittings. Label disconnected hydraulic lines for proper reassembly. 4. Remove front traction manifold from the frame using Figure 72 as a guide. 3. Remove caps and plugs from fittings and hydraulic lines. Using labels placed during manifold removal, properly connect hydraulic lines to manifold (see Hydraulic Hose and Tube Installation in the General Information section of this chapter). 4. Make sure hydraulic tank is full. Add correct oil if necessary before returning machine to service. Hydraulic System 5. If hydraulic fittings are to be removed from manifold, mark fitting orientation to allow correct assembly. Remove fittings from manifold and discard O--rings. 2. Install front traction manifold to the frame using Figure 72 as a guide. Groundsmaster 4000--D/4010--D Page 4 -- 103 Hydraulic System Front Traction Manifold Service 2 6 25 ft--lb (34 N--m) 4 20 ft--lb (27 N--m) 120 ft--lb (162 N--m) 1 UP 6 25 ft--lb (34 N--m) UP 25 ft--lb (34 N--m) 20 ft--lb (27 N--m) 2 6 25 ft--lb (34 N--m) 5 3 7 20 ft--lb (27 N--m) Figure 73 1. Flow divider valve (port HFD) 2. SAE #4 plug with O--ring 3. Orifice (0.063) (port OR) 4. Front traction manifold 5. Check valve (ports CV1 and CV2) 6. SAE #6 plug with O--ring 7. #4 zero leak plug with O--ring NOTE: The ports on the front traction manifold are marked for easy identification of components. Example: P1 is the gear pump connection port and HFD is the location for the flow divider valve (see Hydraulic Schematic in Chapter 10 -- Foldout Drawings to identify the function of the hydraulic lines and cartridge valves at each manifold port). Hydraulic System Page 4 -- 104 Groundsmaster 4000--D/4010--D Front Traction Manifold Service (Fig. 73) For front traction manifold cartridge valve service procedures, see Control Manifold Cartridge Valve Service in this section. Refer to Figure 73 for front traction manifold cartridge valve and plug installation torque. Hydraulic System IMPORTANT: A flow control orifice is located beneath the plug in the front traction manifold port OR. If the orifice is removed from the manifold port, make sure to label its position for assembly purposes. When installing the orifice in the manifold, make sure that the orifice is properly tightened in the port. Groundsmaster 4000--D/4010--D Page 4 -- 105 Hydraulic System Combination Manifold 5 1 RIGHT 4 FRONT 3 2 Figure 74 1. Combination manifold 2. Flange nut (3 used) 3. Flat washer (3 used) 4. Mount (3 used) 5. Spacer (3 used) NOTE: The ports on the combination manifold are marked for easy identification of components. Example: P3 and P4 are the gear pump connection ports, S1 is the location for solenoid valve S1 and OR6 is the location for orifice OR6 (see Hydraulic Schematic in Chapter 10 -Foldout Drawings to identify the function of the hydraulic lines and cartridge valves at each port). Hydraulic System Page 4 -- 106 Groundsmaster 4000--D/4010--D Removal (Fig. 74) 1. Read the General Precautions for Removing and Installing Hydraulic System Components at the beginning of the Service and Repairs section of this chapter. 14 2 2. To prevent contamination of hydraulic system during manifold removal, thoroughly clean exterior of combination manifold and fittings. 1 3. Label all wire harness connectors that attach to solenoid coils on combination manifold. Disconnect wire harness connectors from solenoid coils on the combination manifold. 2 2 10 7 5 8 9 Figure 75 1. 2. 3. 4. 5. 6. 7. Manifold Straight fitting Straight fitting Straight fitting Oil filter Straight fitting Straight fitting 8. 9. 10. 11. 12. 13. 14. Straight fitting Barbed 90o fitting Hose clamp Hose 90o fitting Test nipple Straight fitting 1. If fittings were removed from manifold, lubricate and place new O--rings onto fittings. Install fittings into manifold openings using marks made during the removal process to properly orientate fittings. Tighten fittings (see Hydraulic Fitting Installation in the General Information section of this chapter). 2. Install combination manifold to the frame using Figure 74 as a guide. 3. Remove caps and plugs from fittings and hydraulic lines. Using labels placed during manifold removal, properly connect hydraulic lines to manifold (see Hydraulic Hose and Tube Installation in the General Information section of this chapter). 4. Using labels made during manifold removal, connect wire harness connectors to the solenoid coils on the combination manifold. 5. Make sure hydraulic tank is full. Add correct oil if necessary before returning machine to service. Groundsmaster 4000--D/4010--D Page 4 -- 107 Hydraulic System Hydraulic System Installation (Fig. 74) 3 4 6 NOTE: The combination manifold has three (3) studs on the bottom surface of the manifold used for securing the manifold to the machine. 6. If hydraulic fittings are to be removed from manifold, mark fitting orientation to allow correct assembly (Fig. 75). Remove fittings from manifold and discard O--rings. 11 12 4. Disconnect hydraulic lines from combination manifold and put caps or plugs on open hydraulic lines and fittings. Label disconnected hydraulic lines for proper reassembly. 5. Remove combination manifold from the frame using Figure 74 as a guide. 13 2 Combination Manifold Service UP FRONT 20 ft--lb (27 N--m) 25 ft--lb (34 N--m) 20 ft--lb (27 N--m) 25 ft--lb (34 N--m) 25 ft--lb (34 N--m) 20 ft--lb (27 N--m) 12 13 20 ft--lb (27 N--m) 11 25 ft--lb (34 N--m) 10 9 14 8 15 8 20 ft--lb (27 N--m) 20 ft--lb (27 N--m) 16 20 ft--lb (27 N--m) 5 25 ft--lb (34 N--m) 7 17 18 2 6 19 5 20 ft--lb (27 N--m) 18 4 2 20 21 25 ft--lb (34 N--m) 17 2 17 22 2 3 4 5 25 ft--lb (34 N--m) 1 20 ft--lb (27 N--m) 2 20 ft--lb (27 N--m) Figure 76 1. 2. 3. 4. 5. 6. 7. 8. Combination manifold #6 zero leak plug with O--ring Check valve (CV3) #4 zero leak plug with O--ring Solenoid valve (S4, S6 and S9) Solenoid valve (S5) Relief valve (RV2) Solenoid valve (S2, S3, S7 and S8) Hydraulic System 9. 10. 11. 12. 13. 14. 15. Solenoid valve (S1) Pressure reducing valve (PR) Proportional relief valve (PRV) Solenoid valve (S10) Solenoid valve (S11) Relief valve (RV1) Relief valve (RV3) Page 4 -- 108 16. 17. 18. 19. 20. 21. 22. Solenoid valve (S12) Orifice (0.070) (C2, C3 and C5) Orifice (0.030) (OR1 and OR9) #4 zero leak plug with O--ring Check valve (CV4) Straight fitting Fitting adapter Groundsmaster 4000--D/4010--D NOTE: The ports on the combination manifold are marked for easy identification of components. Example: P4 is the gear pump connection port, S1 is the lift/lower solenoid valve and SV10 is the engine cooling fan solenoid valve (see Hydraulic Schematic in Chapter 10 -Foldout Drawings to identify the function of the hydraulic lines and cartridge valves at each port). 3 For combination manifold cartridge valve service procedures, see Control Manifold Cartridge Valve Service in this section. Refer to Figures 76, 77 and 78 for combination manifold cartridge valve and plug installation torque. IMPORTANT: A flow control orifice is located beneath several plugs in the combination control manifold. If an orifice is removed from a manifold port, make sure to label its position for assembly purposes. When installing the orifice in the manifold, make sure that the orifice is properly tightened in the port. IMPORTANT: A flow control orifice is placed beneath hydraulic fittings in combination manifold ports C2, C3 and C5. If any of these fittings is removed from the manifold, make sure to remove orifice and label its position for assembly purposes. Also note location of groove in orifice for assembly purposes. When installing the orifice in the manifold, make sure that the orifice is flat in the base of the port. Groundsmaster 4000--D/4010--D 2 1 1 If combination manifold is attached to machine, make sure that cutting units are fully lowered before loosening hydraulic lines or cartridge valves from combination manifold. If cutting units are raised as components are loosened in manifold, cutting units may drop unexpectedly. Combination Manifold Service 2 8 7 NOTE: The combination manifold uses several zero leak plugs. These plugs have a tapered sealing surface on the plug head that is designed to resist vibration induced plug loosening. The zero leak plugs also have an O--ring as a secondary seal. If zero leak plug removal is necessary, lightly rap the plug head using a punch and hammer before using an allen wrench to remove the plug: the impact will allow plug removal with less chance of damage to the socket head of the plug. 1 25 ft--lb (34 N--m) 4 1 5 1 6 20 ft--lb (27 N--m) 20 ft--lb (27 N--m) Figure 77 1. 2. 3. 4. #4 zero leak plug #6 zero leak plug Orifice (0.040) #4 zero leak plug 5. Orifice (0.063) 6. Check valve 7. Compensator valve Hydraulic System WARNING 25 ft--lb (34 N--m) 20 to 26 ft--lb (27 to 35 N--m) 9 to 11 ft--lb (12 to 14 N--m) 1 2 1 1 Figure 78 1. #6 hex head plug Page 4 -- 109 2. #4 hex head plug Hydraulic System Control Manifold Cartridge Valve Service 1. Make sure the control manifold is clean before removing the cartridge valve from the control manifold. 2. If cartridge valve is solenoid operated, remove nut securing solenoid coil to the cartridge valve. Carefully slide coil off the valve. IMPORTANT: Use care when handling the cartridge valve. Slight bending or distortion of the stem tube can cause binding and malfunction. When removing cartridge valve from manifold, make sure that deep well socket fully engages the valve base. 3. Remove cartridge valve from manifold using a deep socket wrench. Note correct location for O--rings, sealing rings and backup rings. Remove seal kit from cartridge valve and discard removed seals. 4. Visually inspect the port in the manifold for damage to the sealing surfaces, damaged threads and contamination. 6. Clean cartridge valve using clean mineral spirits. Submerge valve in clean mineral spirits to flush out contamination. Particles as fine as talcum powder can affect the operation of high pressure hydraulic valves. If cartridge design allows, use a wood or plastic probe to push the internal spool in and out 20 to 30 times to flush out contamination. Be extremely careful not to damage cartridge. Use compressed air for cleaning. 7. Install the cartridge valve into the manifold: A. Lubricate new seal kit components with clean hydraulic oil and install on valve. The O--rings, sealing rings and backup rings must be arranged properly on the cartridge valve for proper operation and sealing. B. Dip assembled cartridge into clean hydraulic oil. 5. Visually inspect cartridge valve for damaged sealing surfaces and contamination. IMPORTANT: Use care when handling the valve cartridge. Slight bending or distortion of the stem tube can cause binding and malfunction. When installing cartridge valve into manifold, make sure that deep well socket fully engages the valve base. A. Contamination may cause valves to stick or hang up. Contamination can become lodged in small valve orifices or seal areas causing malfunction. C. Thread cartridge valve carefully into manifold port by hand until the top O--ring is met. The valve should go into manifold port easily without binding. B. If valve sealing surfaces appear pitted or damaged, the hydraulic system may be overheating or there may be water in the system. D. Torque cartridge valve using a deep socket wrench to value identified in control manifold illustration. 8. If cartridge valve is solenoid operated, carefully install solenoid coil to the cartridge valve. Secure coil to valve with nut and torque nut to 60 in--lb (6.8 N--m). CAUTION Use eye protection such as goggles when using compressed air. Hydraulic System 9. If problems still exist after assembly, remove valve and clean again or replace valve. Page 4 -- 110 Groundsmaster 4000--D/4010--D Hydraulic System This page is intentionally blank. Groundsmaster 4000--D/4010--D Page 4 -- 111 Hydraulic System Steering Control Valve 1 2 3 6 20 to 26 ft--lb (28 to 35 N--m) 4 7 27 to 33 ft--lb (37 to 44 N--m) 5 8 10 9 17 11 19 18 10 7 RIGHT 20 12 13 14 15 FRONT 16 Figure 79 1. 2. 3. 4. 5. 6. 7. Steering wheel cover Hex nut Flat washer Steering wheel Foam collar Steering seal External snap ring (2 used) Hydraulic System 8. 9. 10. 11. 12. 13. 14. Steering shaft Flange bushing Thrust washer (as needed) Cap screw (4 used) Washer (4 used) Washer (4 used) Mount (4 used) Page 4 -- 112 15. 16. 17. 18. 19. 20. Valve mount plate Steering control valve Steering column Cap screw (2 used) Pivot hub (2 used) Flange nut (2 used) Groundsmaster 4000--D/4010--D Removal (Fig. 79) 1. Park machine on a level surface, lower cutting decks, stop engine, apply parking brake and remove key from the ignition switch. 1 5 2. Remove steering tower cover to allow access to steering control valve. 3 2 3. Read the General Precautions for Removing and Installing Hydraulic System Components at the beginning of the Service and Repairs section of this chapter. 4 3 4. To prevent contamination of hydraulic system during steering control valve removal, thoroughly clean exterior of control valve and fittings. NOTE: To ease installation, label the hydraulic lines to show their correct position on the steering control valve. 6. Remove steering control valve from machine using Figure 79 as a guide. Figure 80 1. Steering control valve 2. 45o hydraulic fitting 3. Straight fitting (2 used) 7. If hydraulic fittings are to be removed from steering control valve, mark fitting orientation to allow correct assembly. Remove fittings from valve and discard O--rings (Figs. 80 and 81). 2 1 4. 45o hydraulic fitting 5. Straight fitting 3 2 7 4 5 Installation (Fig. 79) 6 1. If fittings were removed from steering control valve, lubricate and place new O--rings onto fittings. Install fittings into port openings using marks made during the removal process to properly orientate fittings (Figs. 80 and 81). Tighten fittings (see Hydraulic Fitting Installation in the General Information section of this chapter). 2 2. Install steering control valve using Figure 79 as a guide. 3. Using labels placed during steering control valve removal, properly install hydraulic lines to control valve (see Hydraulic Hose and Tube Installation in the General Information section of this chapter). 3 2 8 7 Figure 81 1. 2. 3. 4. Steering control valve O--ring Straight fitting Straight fitting 5. 6. 7. 8. 45o fitting 45o fitting O--ring O--ring 4. Make sure hydraulic tank is full. 5. Properly fill hydraulic system (see Charge Hydraulic System in this section). 6. Install steering tower cover to machine. Groundsmaster 4000--D/4010--D Page 4 -- 113 Hydraulic System Hydraulic System 5. Remove hydraulic lines from steering control valve. Steering Control Valve Service 8 7 17 11 18 5 3 16 19 1 6 9 4 2 20 10 15 21 14 23 13 12 150 in--lb (17 N--m) 22 140 to 160 in--lb (16 to 18 N--m) Figure 82 1. 2. 3. 4. 5. 6. 7. 8. Steering valve housing Dust seal O--ring Spool Spring retaining ring Pin Sleeve Centering springs/spacers 9. 10. 11. 12. 13. 14. 15. 16. Cap screw (7 used) End cap O--ring Seal ring O--ring Geroter O--ring Quad seal 17. 18. 19. 20. 21. 22. 23. Geroter drive Wear plate Bearing race Thrust bearing Plug O--ring Check ball NOTE: For steering control valve repair procedures, see the Eaton Parts and Repair Information: 5 Series Steering Control Units at the end of this chapter. Hydraulic System Page 4 -- 114 Groundsmaster 4000--D/4010--D Hydraulic System This page is intentionally blank. Groundsmaster 4000--D/4010--D Page 4 -- 115 Hydraulic System Steering Cylinder 7 6 4 5 3 4 8 1 2 10 13 RIGHT 9 FRONT 12 11 79 to 84 ft--lb (108 to 113 N--m) Figure 83 1. 2. 3. 4. 5. Steering cylinder Ball joint Ball joint Retaining ring (2 used) Grease fitting Hydraulic System 6. 7. 8. 9. Grease fitting 90o hydraulic fitting (2 used) Drive axle assembly Ball joint spacer Page 4 -- 116 10. 11. 12. 13. Axle washer Slotted hex nut (2 used) Cotter pin (2 used) Bulkhead mount plate Groundsmaster 4000--D/4010--D Removal (Fig. 83) 1. Park machine on a level surface, lower cutting decks, stop engine, apply parking brake and remove key from the ignition switch. 2. Read the General Precautions for Removing and Installing Hydraulic System Components at the beginning of the Service and Repairs section of this chapter. 3. To prevent contamination of hydraulic system during cylinder removal, thoroughly clean exterior of cylinder and fittings. 4. Install hydraulic hoses to steering cylinder (see Hydraulic Hose and Tube Installation in the General Information section of this chapter). 5. Fill reservoir with new hydraulic fluid as required. 6. Properly fill hydraulic system (see Charge Hydraulic System in this section). 7. After assembly is completed, operate steering cylinder to verify that hydraulic hoses and fittings are not contacted by anything. NOTE: To ease installation, label the hydraulic hoses to show their correct position on the steering cylinder. 4 4. Remove hydraulic hoses from steering cylinder (Fig. 84). 5. Remove cotter pins, slotted hex nuts, axle washer and ball joint spacer from the threaded ends of ball joints. Remove steering cylinder with ball joints from machine. 3 6. If hydraulic fittings are to be removed from steering cylinder, mark fitting orientation to allow correct assembly. Remove fittings from cylinder and discard O--rings. 2 7. If needed, remove ball joints from steering cylinder. Installation (Fig. 83) 5 1. If removed, install ball joints into steering cylinder. 2. If fittings were removed from steering cylinder, lubricate and place new O--rings onto fittings. Install fittings into port openings using marks made during the removal process to properly orientate fittings. Tighten fittings (see Hydraulic Fitting Installation in the General Information section of this chapter). Figure 84 1. Steering cylinder 2. Hydraulic hose 3. Hydraulic hose 4. 90o hydraulic fitting 5. Bulkhead mount plate 3. Slide ram end ball joint through hole on steering arm. Secure with axle washer and hex slotted nut. Slide fixed end of cylinder through hole on axle. Secure with slotted hex nut. Torque slotted hex nuts from 79 to 84 ft--lbs (108 to 113 N--m) and then continue tightening the nut until hex nut groove aligns with cotter pin hole in ball joint. Install cotter pin to nut and ball joint. Groundsmaster 4000--D/4010--D Page 4 -- 117 Hydraulic System Hydraulic System 1 Steering Cylinder Service 6 9 8 7 3 1 2 5 4 12 10 11 40 ft--lb (54 N--m) 1 8 9 2 10 12 11 3 4 7 6 5 Figure 85 1. 2. 3. 4. Barrel Rod Piston Head Hydraulic System 5. 6. 7. 8. Internal collar Backup ring O--ring Dust seal Page 4 -- 118 9. 10. 11. 12. Rod seal O--ring Piston seal Lock nut Groundsmaster 4000--D/4010--D Disassembly (Fig. 85) Assembly (Fig. 85) 1. Pump oil out of steering cylinder into a drain pan by slowly moving rod in and out of cylinder bore. After oil has been removed from cylinder, plug ports and clean outside of cylinder. 1. Use a complete repair kit when rebuilding the steering cylinder. Put a coating of clean hydraulic oil on all new seals and O--rings. 2. Mount steering cylinder securely in a vise by clamping on the clevis end of the barrel. Use of a vise with soft jaws is recommended. 2. Install new lubricated O--rings and seals to the piston and head. IMPORTANT: Do not clamp vise jaws against the rod surface. 3. Mount rod securely in a vise by clamping on the clevis of the rod. 3. Use a spanner wrench to loosen and remove internal collar (item 5) from barrel. 4. Lubricate rod with clean hydraulic oil. Carefully slide internal collar, head and then piston onto the rod. 4. Grasp end of rod and use a twisting and pulling motion to carefully extract rod, piston and head assembly from cylinder barrel. 5. Install and tighten lock nut onto rod. Torque lock nut 40 ft--lb (54 N--m). IMPORTANT: Do not clamp vise jaws against rod surface; the rod will be damaged. 6. Remove rod assembly from vise. 7. Put a coating of clean hydraulic oil on all cylinder parts to ease assembly. 5. Securely mount rod, piston and head assembly into vise with soft jaws. 8. Carefully slide rod assembly into cylinder barrel. 6. Remove lock nut and then piston from the rod. Slide head and then internal collar off the rod. IMPORTANT: Prevent damage when clamping the cylinder in a vise, clamp on the clevis only. Use of a vise with soft jaws is recommended. 7. Remove and discard all seals and O--rings from the piston and the head. CAUTION 9. Mount steering cylinder securely in a vise by clamping on the clevis end of the barrel. Use of a vise with soft jaws is recommended. 10.Secure head in barrel by using a spanner wrench to install and tighten internal collar (item 5) into barrel. Use eye protection such as goggles when using compressed air to dry cylinder components. 8. Wash cylinder parts in clean solvent. Dry parts with compressed air. Do not wipe parts dry with paper towels or cloth. Lint in a hydraulic system will cause damage. 9. Carefully inspect internal surface of barrel for damage (deep scratches, out--of--round, etc.). Inspect rod and piston for evidence of excessive scoring, pitting or wear. Replace steering cylinder if internal components are worn or damaged. Groundsmaster 4000--D/4010--D Page 4 -- 119 Hydraulic System Hydraulic System IMPORTANT: Prevent damage when clamping the cylinder in a vise, clamp on the clevis only. Use of a vise with soft jaws is recommended. Engine Cooling Fan Motor 6 26 RIGHT FRONT 16 1 15 27 12 to 14 ft--lb (17 to 18 N--m) 9 20 8 14 17 4 12 11 18 5 2 19 10 7 5 3 19 23 21 13 24 25 28 22 5 24 29 30 Figure 86 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. Hydraulic fan motor O--ring Fan bracket Hydraulic fitting (2 used) O--ring Radiator/oil cooler assembly Fan hub Washer Hex nut Lower radiator shroud Hydraulic System 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. Cap screw (4 used) Washer (4 used) Fan Lock nut (2 used) Cap screw (2 used) Flat washer (2 used) O--ring Hydraulic fitting O--ring Hydraulic tube Page 4 -- 120 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. Hydraulic tube Hydraulic tube Support shim Bulkhead nut (2 used) Bulkhead nut Cap used (6 used) Flange nut (6 used) Hydraulic tube Hydraulic tube Hydraulic tube Groundsmaster 4000--D/4010--D Removal (Fig. 86) 10 1. Park machine on a level surface, lower cutting decks, stop engine, apply parking brake and remove key from the ignition switch. RIGHT 1 FRONT 2 2. Unlatch and raise hood. CAUTION The radiator and oil cooler may be hot. To avoid possible burns, allow the engine and cooling systems to cool before removing fan motor. 3 12 3. Read the General Precautions for Removing and Installing Hydraulic System Components at the beginning of the Service and Repairs section of this chapter. 9 7 4. Thoroughly clean three (3) hydraulic tubes at lower radiator shroud. Disconnect hydraulic tubes and put caps or plugs on tubes to prevent contamination. Label disconnected hydraulic tubes for proper installation. 6. Remove flange head screws and flange nuts that secure radiator supports to frame (items 11 and 12 in Fig. 87). This will allow radiator assembly to be moved slightly to ease removal of cooling fan motor and bracket assembly. 7. Remove four (4) cap screws (item 11) and washers used to secure fan to fan hub. Remove fan. IMPORTANT: Make sure to not damage the radiator or other machine components while loosening and removing the fan motor and bracket assembly. 8. Remove cooling fan motor and bracket assembly. A. To prevent contamination of hydraulic system, thoroughly clean exterior of fan motor and fittings. B. Disconnect three (3) hydraulic tubes from fan motor. Put caps or plugs on fittings and tubes to prevent contamination. Label hydraulic lines for proper assembly. C. Remove six (6) cap screws and flange nuts that secure fan motor bracket to radiator. D. Carefully remove fan motor and bracket assembly from machine and place on suitable work surface. Groundsmaster 4000--D/4010--D 8 6 5 4 Figure 87 1. 2. 3. 4. 5. 6. Radiator Upper radiator shroud Lower radiator shroud Screw (4 used) Flange nut (4 used) Cap screw (2 used) 7. 8. 9. 10. 11. 12. Cap screw (6 used) Flat washer (7 used) R--clamp Air cleaner inlet hose Screw (4 used) Flange nut (4 used) 9. Remove hex nut (item 9) and washer (item 8) that secure fan hub to fan motor. Use suitable puller to carefully remove fan hub from fan motor shaft. Locate and retrieve woodruff key from motor shaft. 10.Remove two (2) cap screws (item 15), flat washers (item 16) and lock nuts (item 14) that secure fan motor to fan motor bracket. Remove fan motor from bracket. 11. If necessary, remove fittings from motor and discard O--rings. Installation (Fig. 86) 1. If fittings were removed from fan motor, lubricate and place new O--rings onto fittings. Install and tighten fittings in port openings (see Hydraulic Fitting Installation in the General Information section of this chapter). 2. Position fan motor to fan motor bracket and secure with cap screws (item 15), flat washers (item 16) and lock nuts (item 14). 3. Thoroughly clean tapered surfaces of fan motor shaft and fan hub. Place woodruff key in slot in motor shaft. Page 4 -- 121 Hydraulic System Hydraulic System 5. Remove air cleaner inlet hose and radiator shrouds (upper and lower) to allow easier access to hydraulic fan motor (Fig. 87). 11 4. Position fan hub onto motor shaft and secure with washer (item 8) and hex nut (item 9). IMPORTANT: Make sure to not damage the radiator or other machine components while installing the fan motor and bracket assembly. 5. Carefully position fan motor and bracket assembly to radiator and secure with six (6) cap screws and flange nuts. 6. Secure radiator assembly to frame with removed fasteners (Fig. 87). 7. Connect three (3) hydraulic tubes to cooling fan motor (see Hydraulic Hose and Tube Installation in the General Information section of this chapter). Hydraulic System 8. Position fan to fan hub and secure with four (4) cap screws and washers. Torque screws from 12 to 14 ft--lb (17 to 18 N--m). 9. Install radiator shrouds (lower and upper) and air cleaner hose (Fig. 87). Make sure that clearance between shrouds and cooling fan is at least 0.180” (4.6 mm) at all points. 10.Connect three (3) hydraulic tubes at lower radiator shroud (see Hydraulic Hose and Tube Installation in the General Information section of this chapter). 11. Lower and secure hood. 12.Make sure hydraulic tank is full. 13.Properly fill hydraulic system (see Charge Hydraulic System in this section). Page 4 -- 122 Groundsmaster 4000--D/4010--D Hydraulic System This page is intentionally blank. Groundsmaster 4000--D/4010--D Page 4 -- 123 Hydraulic System Engine Cooling Fan Motor Service 10 15 6 3 14 7 1 16 9 8 4 5 14 11 12 8 33 ft--lb (45 N--m) 9 2 13 Figure 88 1. 2. 3. 4. 5. 6. Flange washer O--ring Front flange Dust seal Retaining ring Front wear plate 7. 8. 9. 10. 11. Shaft seal Backup gasket Pressure seal Rear wear plate Body 12. 13. 14. 15. 16. NOTE: Internal components for a cooling fan motor are not available separately. Disassemble motor for cleaning, inspection and seal replacement only. Idler gear Cap screw (4 used) Dowel (2 used) Drive gear Washer (4 used) MARKER LINE Disassembly (Fig. 88) 1. Plug motor ports and clean the outside of the motor thoroughly. After cleaning, remove plugs and drain any oil out of the motor. 2. Use a marker to make a diagonal line across the front flange and body for assembly purposes (Fig. 89). IMPORTANT: Prevent damage when clamping the fan motor in a vise; clamp on the front flange only. Also, use a vise with soft jaws. Figure 89 4. Loosen cap screws from the rear of the body. IMPORTANT: Note position of the open and closed side of the wear plates before removing. Also, identify wear plates (front and rear) with a marker for proper assembly. 5. Remove motor from the vise. Turn motor so that the shaft end is facing down. Remove cap screws. 7. Carefully remove rear wear plate, idler gear, drive gear and front wear plate from the front flange. 6. Carefully remove body. Lift body straight up to remove. Make sure the rear wear plate remains on the drive and idler gear shafts. Remove and discard O-rings from the body. Locate and retrieve dowel pins. 8. Remove and discard back--up gaskets and pressure seals from wear plates. 3. Clamp front flange of motor in a vise with soft jaws with the shaft end down. Hydraulic System 9. Turn front flange over, with seal side up. Page 4 -- 124 Groundsmaster 4000--D/4010--D IMPORTANT: Make sure not to damage the front flange counter bore when removing the seals from the front flange. 1 2 3 4 10.Carefully remove dust seal, retaining ring, flange washer and shaft seal from the front flange (Fig. 90). Note orientation of seal lips during removal. Discard removed seals. Inspection 1. Remove any nicks and burrs from all parts with emery cloth. Figure 90 1. Dust seal 2. Retaining ring 3. Flange washer 4. Shaft seal Use eye protection such as goggles when using compressed air. 3 2. Clean all parts with solvent. Dry all parts with compressed air. 4 1 3. Inspect drive gears and idler gears for the following (Fig. 91): 2 A. Gear shafts should be free of rough surfaces and excessive wear at bushing points and sealing areas. Scoring, rough surfaces or wear on gear shafts indicates need for replacement. B. Gear teeth should be free of excessive scoring and wear. Any broken or nicked gear teeth must be replaced. C. Inspect gear face edge for sharpness. Sharp edges of gears will mill into wear plates and, thus, must be replaced. 4. Inspect wear plates for the following: A. Bearing areas should not have excessive wear or scoring. B. Face of wear plates that are in contact with gears should be free of wear, roughness or scoring. 4 2 3 Figure 91 1. Gear shaft spline 2. Gear shaft 3. Gear teeth 4. Gear face edge Assembly (Fig. 88) NOTE: When assembling motor, check the marker line on each part to make sure parts are properly aligned during assembly. 1. Lubricate O--rings, pressure seals, back--up gaskets and wear plate grooves with a thin coat of petroleum jelly. Lubricate all other internal parts freely with clean hydraulic oil. 2. Install new seals into front flange (Fig. 90). Note orientation of seal lips during installation: C. Thickness of wear plates should be equal. 5. Inspect front flange and body for damage or wear. A. Press shaft seal into front flange until it reaches the bottom of the bore. B. Install flange washer into front flange and then install retaining ring into the groove of the front flange. C. Install new dust seal into front flange. Groundsmaster 4000--D/4010--D Page 4 -- 125 Hydraulic System Hydraulic System CAUTION 3. Place front flange, seal side down, on a flat surface. 4. Install the pressure seals, flat side outward, into the grooves in the wear plates. Follow by carefully placing the backup gaskets, flat side outward, between the pressure seals and the grooves in the wear plate. 5. Apply a light coating of petroleum jelly to the exposed side of the front flange. 6. Lubricate the drive gear shaft with clean hydraulic oil. Insert the drive end of the drive shaft through the wear plate with the pressure seal side down and the open side of the pressure seal pointing to the inlet side of the motor. Carefully install shaft into front flange. 7. Lubricate the idler gear shaft with clean hydraulic oil. Install idler gear shaft into the remaining position in the front wear plate. Apply a light coating of clean hydraulic oil to gear faces. 8. Install rear wear plate with pressure seal side up and open side of the pressure seal pointing to the inlet side of the motor. 9. Apply a light coating of petroleum jelly to new O-rings and O--ring grooves in the body. Install new O-rings to the body. Hydraulic System 10.Install locating dowels in body. Align marker line on the body and front flange. IMPORTANT: Do not dislodge seals during installation. 11. Gently slide the body onto the assembly. Firm hand pressure should be sufficient to engage the dowels. 12.Install the four (4) cap screws with washers and hand tighten. IMPORTANT: Prevent damage when clamping the fan motor into a vise; clamp on the front flange only. Also, use a vise with soft jaws. 13.Place front flange of the motor into a vise with soft jaws and alternately torque the cap screws 33 ft--lb (45 N--m). 14.Remove motor from vise. 15.Place a small amount of clean hydraulic oil in the inlet of the motor and rotate the drive shaft away from the inlet one revolution. If any binding is noted, disassemble the motor and check for assembly problems. Page 4 -- 126 Groundsmaster 4000--D/4010--D Cutting Deck Motors Removal 2 1 1. Park machine on a level surface, lower cutting decks, stop engine, apply parking brake and remove key from the ignition switch. 27 to 33 ft--lb (37 to 44 N--m) 2. Read the General Precautions for Removing and Installing Hydraulic System Components at the beginning of the Service and Repairs section of this chapter. 4 5 6 7 3 3. Thoroughly clean exterior of deck motor and fittings. Disconnect hydraulic lines from motor. Put caps or plugs on fittings and hoses to prevent contamination. Label hydraulic lines for proper installation. 4. Remove two (2) flange head screws that secure hydraulic motor to motor mount (Fig. 92). 5. Carefully remove hydraulic motor from cutting deck taking care not to damage spider hub attached to motor. Locate and remove spider from the deck. 7. If hydraulic fittings are to be removed from motor, mark fitting orientation to allow correct assembly. Remove fittings from motor and discard O--rings (Fig. 93). Figure 92 1. 2. 3. 4. Cutting deck motor Flange screw (2 used) Nut Tab washer Installation 5 1. If fittings were removed from motor, lubricate and place new O--rings onto fittings. Install fittings into port openings using marks made during the removal process to properly orientate fittings. Tighten fittings (see Hydraulic Fitting Installation in the General Information section of this chapter). 1 4. Secure motor to cutting deck with two (2) flange head screws (Fig. 92). 6 2 7 3 2. If removed, install spider hub on motor shaft. Secure with tab washer and nut. Torque nut from 27 to 33 ft--lb (37 to 44 N--m). Bend small tab of washer into keyway and large tab against nut. 3. Position spider in spindle pulley. Carefully install hydraulic motor to the cutting deck taking care not to damage spider hub attached to motor. 5. Spider hub 6. Woodruff key 7. Spider Hydraulic System 6. If necessary, straighten tab washer and remove nut, tab washer and spider hub from motor shaft. 4 8 9 10 Figure 93 1. 2. 3. 4. 5. Motor (center deck) O--ring Hydraulic fitting O--ring O--ring 6. 7. 8. 9. 10. Hydraulic fitting O--ring O--ring Hydraulic fitting O--ring 5. Remove caps or plugs from fittings and hoses. Connect hydraulic hoses to deck motor (see Hydraulic Hose and Tube Installation in the General Information section of this chapter). 6. After assembly is completed, verify that hydraulic hoses and fittings are not contacted by moving components. Groundsmaster 4000--D/4010--D Page 4 -- 127 Hydraulic System Cutting Deck Motor Service (Sauer--Danfoss) 9 15 10 12 10 15 14 13 9 8 7 15 6 1 33 to 40 ft--lb (45 to 55 N--m) 2 11 5 8 4 3 Figure 94 1. 2. 3. 4. 5. Rear cover Drive gear Seal Woodruff key Nut 6. 7. 8. 9. 10. Tab washer Spider hub Pressure seal Back--up ring O--ring NOTE: Internal components for a cutting deck motor are not available separately. Disassemble motor for cleaning, inspection and seal replacement only. Disassembly (Fig. 94) 11. 12. 13. 14. 15. Body Idler gear Cap screw (4 used) Front flange Dowel pin 5. Take motor from the vise and remove cap screws. 6. Remove front flange from the body, then remove rear cover. Locate and remove dowel pins from body. 1. Plug motor ports and clean the outside of the motor thoroughly. After cleaning, remove plugs and drain any oil out of the motor. 2. Use a marker or scribe to make a diagonal mark across the front flange, body and rear cover for reassembly purposes (Fig. 95). DIAGONAL MARK IMPORTANT: Prevent damage when clamping the deck motor into a vise; clamp on the front flange only. Also, use a vise with soft jaws. 3. Clamp mounting flange of motor in a vise with the shaft end down. Figure 95 4. Loosen cap screws on the rear cover. Hydraulic System Page 4 -- 128 Groundsmaster 4000--D/4010--D IMPORTANT: Mark the relative positions of the gear teeth and the bearing blocks so they can be reassembled in the same position. Do not touch the gear surfaces as residue on hands may be corrosive to gear finish. 1 7. Place the motor on its side and push on the rear bearing block to remove the bearing block and gear set (Fig. 96). 8. Carefully remove and discard O--rings, pressure seals and back--up rings (Fig. 97) from motor. Do not cause any damage to the machined grooves during the removal process. IMPORTANT: Make sure not to damage the counter bore when removing the shaft seal from the front plate. 2 Figure 96 1. Motor body 2. Bearing block & gear set 9. Position front flange with seal side up. Carefully remove shaft seal taking care to not damage seal bore. Inspection Hydraulic System 1. Remove any nicks and burrs from all motor components with emery cloth. CAUTION Use eye protection such as goggles when using compressed air. Figure 97 2. Clean all motor components with solvent. Dry all parts with compressed air. 3. Inspect drive gear, idler gear and bearing blocks (Fig. 98) for the following: A. Gear shafts should be free of rough surfaces and excessive wear at bushing points and sealing areas. Scoring, rough surfaces or wear on gear shafts indicates need for replacement. 1 2 B. Gear teeth should be free of excessive scoring and wear. Any broken or nicked gear teeth must be replaced. 3 C. Inspect gear face edge for sharpness. Sharp edges of gears will mill into bearing blocks and, thus, must be replaced. D. Bearing areas of bearing blocks should not have excessive wear or scoring. 3 E. Face of bearing blocks that are in contact with gears should be free of wear, roughness or scoring. 4. Inspect front flange, body and rear cover for damage or wear. Groundsmaster 4000--D/4010--D Figure 98 1. Drive gear 2. Idler gear Page 4 -- 129 3. Bearing block Hydraulic System Assembly (Fig. 94) 8. Install dowel pins in body. NOTE: When assembling the motor, check the identification marks made during disassembly to make sure the parts are properly aligned during assembly. IMPORTANT: Do not dislodge O--rings, pressure seals or back--up rings during final assembly. 1. Lubricate O--rings, pressure seals, back--up gaskets and seal grooves with a thin coat of petroleum jelly. Lubricate all other internal parts freely with clean hydraulic oil. 2. Install new shaft seal into front flange. 3. Install lubricated pressure seals into the grooves in the front flange and rear cover. Follow by carefully placing the back--up rings into the grooves. 4. Install new O--rings to the body. 5. Lubricate gear faces and bearing surfaces of drive gear, idler gear and bearing blocks. Carefully assemble bearing blocks and gears noting identification marks made during disassembly. 6. Position the motor body on its side. Carefully slide bearing block and gear assembly into the body cavity using identification marks made during disassembly. 7. Remove any excess lubrication from mating surfaces of body, rear cover and front flange. Make sure that these surfaces are clean and dry. Hydraulic System 9. Gently slide the rear cover onto the assembly using marker or scribe mark for proper location. Firm hand pressure should be sufficient to engage the dowel pins. 10.Position the motor with rear cover downwards. Carefully slide the front flange onto the assembly using marker or scribe mark for proper location. 11. Install the four (4) cap screws and hand tighten. IMPORTANT: Prevent damage when clamping the deck motor into a vise; clamp on the front flange only. Also, use a vise with soft jaws. 12.Place motor front flange in a vise and alternately torque the screws from 33 to 40 ft--lb (45 to 55 N--m). 13.Put a small amount of hydraulic oil in port on motor and rotate driveshaft one revolution. Protect the shaft if using a pliers. If drive shaft binds, disassemble motor and repeat assembly process. 14.Remove motor from vise. Page 4 -- 130 Groundsmaster 4000--D/4010--D Hydraulic System This page is intentionally blank. Groundsmaster 4000--D/4010--D Page 4 -- 131 Hydraulic System Cutting Deck Motor Service (Casappa) 17 2 14 11 9 15 6 3 1 10 7 16 13 14 8 2 33 to 40 ft--lb (45 to 55 N--m) 12 8 5 9 4 Figure 99 1. 2. 3. 4. 5. 6. Flange washer O--ring Front flange Dust seal Retaining ring Front wear plate 7. 8. 9. 10. 11. 12. Shaft seal Backup gasket Pressure seal Rear wear plate Body Idler gear 13. 14. 15. 16. 17. The Casappa cutting deck motors have similar construction as the cooling fan motor (also a Casappa brand) used on the Groundsmaster 4000--D and 4010--D. The deck motors have a separate rear cover (item 17 in Fig. 99) which is a difference from the cooling fan motor which includes the rear cover with the motor body. Orientation of the dust seal (item 4 in Fig. 99) is different in the deck motors than in the cooling fan motor. Cap screw (4 used) Dowel (4 used) Drive gear Washer (4 used) Rear cover 1 2 3 4 For disassembly, inspection and assembly procedures of the Casappa cutting deck motors, refer to Engine Cooling Fan Motor Service in this section. When installing the seals into the front flange in a cutting deck motor, use the orientation shown in Figure 100. NOTE: Internal components for a cutting deck motor are not available separately. Disassemble motor for cleaning, inspection and seal replacement only. Figure 100 1. Dust seal 2. Retaining ring Hydraulic System Page 4 -- 132 3. Flange washer 4. Shaft seal Groundsmaster 4000--D/4010--D Hydraulic System This page is intentionally blank. Groundsmaster 4000--D/4010--D Page 4 -- 133 Hydraulic System PTO Manifold 8 18 4 18 2 12 16 7 4 1 10 4 2 17 20 6 9 7 18 13 13 5 11 4 12 4 19 6 8 7 10 18 8 7 14 6 7 13 RIGHT FRONT 4 8 9 2 3 12 8 15 7 Figure 101 1. 2. 3. 4. 5. 6. 7. Hydraulic PTO manifold (center deck) Quick fitting (1 used per manifold) Flange screw (2 used per manifold) O--ring Hydraulic tee fitting O--ring O--ring 8. 9. 10. 11. 12. 13. 14. O--ring Hydraulic adapter Straight fitting Flange screw (2 used per manifold) Dust cap 45o hydraulic fitting Hydraulic PTO manifold (LH deck) 15. 16. 17. 18. 19. 20. 90o hydraulic fitting Hydraulic PTO manifold (RH deck) Hex head plug 45o hydraulic fitting Hydraulic tee fitting 90o hydraulic fitting NOTE: The ports on the manifold are marked for easy identification of components. Example: PRV is the proportional relief valve and P1 is a gear pump connection port (see Hydraulic Schematic in Chapter 10 -- Foldout Drawings to identify the function of the hydraulic lines and cartridge valves at each port). Hydraulic System Page 4 -- 134 Groundsmaster 4000--D/4010--D Removal (Fig. 101) 1. Read the General Precautions for Removing and Installing Hydraulic System Components at the beginning of the Service and Repairs section of this chapter. 2 2. To prevent contamination of hydraulic system during manifold removal, thoroughly clean exterior of PTO manifold and fittings. 3. Disconnect wire harness connector from the proportional relief valve coil on the PTO manifold. 1 4. Disconnect hydraulic lines from manifold and put caps or plugs on open hydraulic lines and fittings. Label disconnected hydraulic lines for proper installation. 3 5. Remove PTO manifold from the frame using Figure 101 as a guide. NOTE: The flange head screws that secure the right side PTO manifold also secures the controller mount to the frame (Fig. 102). Support controller mount before removing the right side PTO manifold. Figure 102 1. RH PTO manifold 2. Controller mount 3. Flange screw (2 used) Hydraulic System 6. If hydraulic fittings are to be removed from manifold, mark fitting orientation to allow correct assembly. Remove fittings from manifold and discard O--rings. Installation (Fig. 101) 1. If fittings were removed from manifold, lubricate and place new O--rings onto fittings. Install fittings into manifold openings using marks made during the removal process to properly orientate fittings. Tighten fittings (see Hydraulic Fitting Installation in the General Information section of this chapter). 2. Install PTO manifold to the frame using Figure 101 as a guide. NOTE: Make sure that the controller mount is secured when installing the right side PTO manifold (Fig. 102). 3. Remove caps and plugs from fittings and hoses. Using labels placed during manifold removal, properly connect hydraulic lines to manifold (see Hydraulic Hose and Tube Installation in the General Information section of this chapter). 4. Connect wire harness connector to the proportional relief valve coil on the PTO manifold. 5. Make sure hydraulic tank is full. Add correct oil if necessary before returning machine to service. Groundsmaster 4000--D/4010--D Page 4 -- 135 Hydraulic System PTO Manifold Service 20 ft--lb (27 N--m) 5 10 25 ft--lb (34 N--m) 35 ft--lb (47 N--m) 9 20 ft--lb (27 N--m) 1 6 7 3 8 20 ft--lb (27 N--m) 5 ft--lb (6.7 N--m) 2 25 ft--lb (34 N--m) 4 Figure 103 1. 2. 3. 4. PTO manifold body NWD SAE #4 plug with O--ring Orifice (0.025) (port OR) #6 zero leak plug with O--ring 5. Relief valve (port RV1) 6. Proportional relief valve (port PRV) 7. Solenoid coil 8. Nut 9. Logic cartridge valve (port LC1) 10. Pilot directional valve (port PD1) NOTE: The ports on the manifold are marked for easy identification of components. Example: RV is the relief valve port and P1 is the gear pump connection port (see Hydraulic Schematic in Chapter 10 -- Foldout Drawings to identify the function of the hydraulic lines and cartridge valves at each port location). Hydraulic System Page 4 -- 136 Groundsmaster 4000--D/4010--D The manifolds for the three (3) cutting decks are very similar. The front and right side PTO manifolds are identical. The left side PTO manifold uses the same cartridges and plugs as the front and right side manifolds but also includes an additional orifice that threads into the manifold OR2 port (Fig. 104). NOTE: When servicing the PTO manifolds, DO NOT interchange parts from one manifold to another. 1 NOTE: The PTO manifold assembly includes zero leak plugs. These plugs have a tapered sealing surface on the plug head that is designed to resist vibration induced plug loosening. The zero leak plugs also have an O--ring as a secondary seal. If zero leak plug removal is necessary, lightly rap the plug head using a punch and hammer before using an allen wrench to remove the plug: the impact will allow plug removal with less chance of damage to the socket head of the plug. 2 PTO Manifold Service (Fig. 103) Figure 104 2. Orifice (OR2 port) Hydraulic System For PTO manifold solenoid and control valve service procedures, see Control Manifold Cartridge Valve Service in this section. Refer to Figure 103 for PTO manifold cartridge valve and plug installation torque. 1. LH PTO manifold Groundsmaster 4000--D/4010--D Page 4 -- 137 Hydraulic System Side Deck Lift Cylinders 5 6 8 7 10 11 9 3 4 2 1 RIGHT FRONT Figure 105 1. 2. 3. 4. Lift arm assembly (LH shown) Shoulder screw Flange nut Pin assembly Hydraulic System 5. 6. 7. 8. Lock nut Flat washer Cylinder pin Spring pin Page 4 -- 138 9. Lift cylinder 10. 90o hydraulic fitting 11. 90o hydraulic fitting Groundsmaster 4000--D/4010--D Removal (Fig. 105) Installation (Fig. 105) 1. Park machine on a level surface, lower cutting decks, stop engine, apply parking brake and remove key from the ignition switch. 1. If fittings were removed from lift cylinder, lubricate and place new O--rings onto fittings. Install fittings into cylinder port openings using marks made during the removal process to properly orientate fittings. Tighten fittings (see Hydraulic Fitting Installation in the General Information section of this chapter). 2. Read the General Precautions for Removing and Installing Hydraulic System Components at the beginning of the Service and Repairs section of this chapter. 3. To prevent contamination of hydraulic system during lift cylinder removal, thoroughly clean exterior of cylinder and fittings. WARNING Make sure that side cutting deck is fully lowered before loosening hydraulic lines from side deck lift cylinder. If deck is not fully lowered as hydraulic lines are loosened, deck may drop unexpectedly. NOTE: To ease installation, label the hydraulic hoses to show their correct position on the lift cylinder. 2. Position cylinder barrel clevis to frame and insert cylinder pin (item 7) through the frame and cylinder barrel clevis. Secure pin with flat washer and lock nut. 3. Insert pin assembly (item 4) through the lift arm and cylinder rod clevis. Secure pin assembly to lift arm with shoulder screw and flange nut. 4. Attach hydraulic hoses to lift cylinder (see Hydraulic Hose and Tube Installation in the General Information section of this chapter). 5. Fill reservoir with hydraulic fluid as required. 6. After installation is completed, operate lift cylinder to verify that lift cylinder, hydraulic hoses and fittings are not contacted by anything. Hydraulic System 4. Disconnect hydraulic hoses from lift cylinder. 5. Remove shoulder screw and flange nut that secure the pin assembly (item 4) to the lift arm. Remove pin assembly from lift arm and cylinder rod clevis. 6. Remove lock nut and flat washer from the cylinder pin (item 7). Remove cylinder pin with spring pin from the frame and cylinder barrel clevis. 7. Remove lift cylinder from machine. 8. If hydraulic fittings are to be removed from lift cylinder, mark fitting orientation to allow correct assembly. Remove fittings from cylinder and discard O--rings. Groundsmaster 4000--D/4010--D Page 4 -- 139 Hydraulic System Center Deck Lift Cylinders 1 6 RIGHT 7 FRONT 6 9 8 10 7 5 3 4 2 11 Figure 106 1. 2. 3. 4. Front frame Flange head screw Flange nut Pin assembly Hydraulic System 5. 6. 7. 8. Grease fitting Cotter pin (2 used per pin) Flat washer (4 used per pin) Clevis pin Page 4 -- 140 9. Lift cylinder (2 used) 10. RH lift arm assembly 11. LH lift arm assembly Groundsmaster 4000--D/4010--D Removal (Fig. 106) Installation (Fig. 106) 1. Park machine on a level surface, lower cutting decks, stop engine, apply parking brake and remove key from the ignition switch. 1. If fitting was removed from lift cylinder, lubricate and place new O--rings onto fitting. Install fitting into cylinder port. Tighten fitting (see Hydraulic Fitting Installation in the General Information section of this chapter). 2. Read the General Precautions for Removing and Installing Hydraulic System Components at the beginning of the Service and Repairs section of this chapter. 3. To prevent contamination of hydraulic system during lift cylinder removal, thoroughly clean exterior of cylinder and fitting. 2. Make sure that cotter pin and two (2) flat washers are installed on one end of the clevis pin (item 8). 3. Position cylinder barrel to frame and insert clevis pin through frame and cylinder barrel. Secure clevis pin with two (2) flat washers and cotter pin. 4. Insert pin assembly (item 4) through lift arm and cylinder rod end. Secure pin to lift arm with flange nut and flange head screw. Make sure that front cutting deck is fully lowered before loosening hydraulic lines from center deck lift cylinders. If deck is not fully lowered as hydraulic lines are loosened, deck may drop unexpectedly. 4. Disconnect hydraulic hose from lift cylinder. 5. Remove flange nut and flange head screw that secure the pin assembly (item 4) to the lift arm. Remove pin assembly from lift arm and cylinder rod end which will free lift cylinder from lift arm. 5. Attach hydraulic hose to lift cylinder (see Hydraulic Hose and Tube Installation in the General Information section of this chapter). 6. Fill reservoir with hydraulic fluid as required. 7. After assembly is completed, operate center deck lift cylinders to verify that lift cylinders, hydraulic hoses and fittings are not contacted by anything. Hydraulic System WARNING 2 6. Remove one (1) cotter pin and two (2) flat washers from one end of the clevis pin (item 8) that secures barrel end of lift cylinder to front frame. Pull clevis pin from frame and cylinder barrel. 3 4 7. Remove lift cylinder from machine. 8. If necessary, remove hydraulic fitting from cylinder and discard O--rings (Fig. 107). 1 Figure 107 1. Lift cylinder 2. O--ring Groundsmaster 4000--D/4010--D Page 4 -- 141 3. Straight fitting 4. O--ring Hydraulic System Lift Cylinder Service 100 to 120 ft--lb (136 to 162 N--m) 1 13 12 11 6 2 8 3 10 9 16 15 SIDE DECK LIFT CYLINDER 7 5 13 14 4 Figure 108 1. 2. 3. 4. 5. 6. Barrel with clevis Retaining ring Shaft with clevis Dust seal Rod seal O--ring 9 7. 8. 9. 10. 11. Back--up ring Head O--ring Wear ring Piston 6 5 1 12. 13. 14. 15. 16. 7 Lock nut Grease fitting Bushing O--ring Seal 2 4 8 3 40 ft--lb (54 N--m) 12 11 10 CENTER DECK LIFT CYLINDER Figure 109 1. 2. 3. 4. Barrel Seal Shaft with clevis Dust seal Hydraulic System 5. 6. 7. 8. Retaining ring O--ring Back--up ring Head Page 4 -- 142 9. 10. 11. 12. Grease fitting Wear ring Piston Lock nut Groundsmaster 4000--D/4010--D Disassembly (Figs. 108 and 109) Assembly (Figs. 108 and 109) 1. Remove oil from lift cylinder into a drain pan by slowly pumping the cylinder shaft. Plug both ports and clean the outside of the cylinder. 1. Make sure all cylinder components are clean before assembly. 2. Mount lift cylinder securely in a vise by clamping on the clevis end of the barrel. Use of a vise with soft jaws is recommended. 3. Loosen head from barrel: A. Use a spanner wrench to rotate head clockwise until the edge of the retaining ring (item 2 in Figure 108 or item 5 in Figure 109) appears in the barrel opening. B. Insert a screwdriver under the beveled edge of the retaining ring to start the retaining ring through the opening. Then, rotate the head counter--clockwise to remove retaining ring from barrel and head. 4. Extract shaft with head and piston by carefully twisting and pulling on the shaft. 2. Coat new seal kit components with clean hydraulic oil. Install new lubricated seals and O--rings to the piston and head. IMPORTANT: Do not clamp vise jaws against the shaft surface. 3. Mount shaft securely in a vise by clamping on the clevis of the shaft. Use of a vise with soft jaws is recommended. A. Coat shaft with clean hydraulic oil. B. Carefully slide head and then piston onto the shaft. Secure piston to shaft with lock nut. C. Torque lock nut to specification in Figure 108 (side deck cylinder) or Figure 109 (center deck cylinder). 4. Remove shaft assembly from vise. IMPORTANT: Do not clamp vise jaws against the shaft surface. IMPORTANT: Prevent damage when clamping the hydraulic cylinder into a vise; clamp on the clevis end of the barrel ONLY. 5. Mount shaft securely in a vise by clamping on the clevis of the shaft. Use of a vise with soft jaws is recommended. 5. Mount barrel securely in a vise by clamping on the clevis end of the barrel. Use of a vise with soft jaws is recommended. 6. Remove lock nut and piston from the shaft. Slide head off the shaft. IMPORTANT: When installing the head into the barrel of the lift cylinder, pay careful attention to the retaining ring slot in the barrel to insure that the piston and head seals do not lodge in the slot. 7. Remove and discard all seals and O--rings from the piston and the head. CAUTION 7. Secure head in barrel: Use eye protection such as goggles when using compressed air to dry cylinder components. 8. Wash cylinder parts in clean solvent. Dry parts with compressed air. Do not wipe parts dry with paper towels or cloth. Lint in a hydraulic system will cause damage. 9. Carefully inspect internal surface of barrel for damage (deep scratches, out--of--round, etc.). Inspect shaft and piston for evidence of excessive scoring, pitting or wear. Replace lift cylinder if internal components are found to be worn or damaged. Groundsmaster 4000--D/4010--D 6. Coat all internal parts with a light coat of clean hydraulic oil. Slide piston, shaft and head assembly into the barrel being careful to not damage the seals. A. Align retaining ring hole in the head with the access slot in the barrel. B. Insert the retaining ring hook into the hole and rotate head clockwise until the retaining ring is completely pulled into the barrel and the ring ends are covered. C. Apply silicone sealer to barrel access slot. Page 4 -- 143 Hydraulic System Hydraulic System IMPORTANT: Prevent damage when clamping the cylinder in a vise; clamp on the clevis only. This page is intentionally blank. Hydraulic System Page 4 -- 144 Groundsmaster 4000--D/4010--D Chapter 5 Electrical System Table of Contents Groundsmaster 4000--D/4010--D Cruise Control Switch . . . . . . . . . . . . . . . . . . . . . . . Seat Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Parking Brake Switch . . . . . . . . . . . . . . . . . . . . . . . Service Brake Switches . . . . . . . . . . . . . . . . . . . . . Headlight Switch (Groundsmaster 4010--D) . . . . Windshield Wiper/Washer Switch (Grounds-master 4010--D) . . . . . . . . . . . . . . . . . . . . . . . . . . Air Conditioning Switch (Groundsmaster 4010--D) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Turn Signal Switch (Groundsmaster 4010--D) . . Flasher Switch (Groundsmaster 4010--D) . . . . . Traction Pedal Position Sensor . . . . . . . . . . . . . . Relays with Four (4) Terminals . . . . . . . . . . . . . . . Relays with Five (5) Terminals . . . . . . . . . . . . . . . Toro Electronic Controllers (TEC) . . . . . . . . . . . . Hydraulic Solenoid Valve Coils . . . . . . . . . . . . . . . Piston (Traction) Pump Control Solenoid Coils . CAN--bus Termination Resistor . . . . . . . . . . . . . . Diode Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . Resistor Assembly . . . . . . . . . . . . . . . . . . . . . . . . . Fuel Sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel Pump (Models 30603 and 30605) . . . . . . . . Fuel Pump (Models 30607 and 30609) . . . . . . . . Cutting Deck Position Switches . . . . . . . . . . . . . . Hydraulic Oil Temperature Sender . . . . . . . . . . . . Audio Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SERVICE AND REPAIRS . . . . . . . . . . . . . . . . . . . . . Battery Care . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Battery Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . Battery Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 5 -- 1 36 37 38 39 40 41 42 43 44 45 46 48 50 52 54 55 56 56 57 58 59 60 61 62 63 63 63 64 Electrical System Electrical System GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . 2 Operator’s Manual . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Toro Electronic Controllers (TEC) . . . . . . . . . . . . . 2 Yanmar Engine Electronic Control Unit (ECU) . . . 3 Yanmar Engine Electrical Components . . . . . . . . . 3 CAN--bus Communications . . . . . . . . . . . . . . . . . . . 4 Electrical Drawings . . . . . . . . . . . . . . . . . . . . . . . . . . 4 SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 INFOCENTER DISPLAY . . . . . . . . . . . . . . . . . . . . . . . 8 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . 15 Operator Advisories . . . . . . . . . . . . . . . . . . . . . . . . 15 Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Starting Problems . . . . . . . . . . . . . . . . . . . . . . . . . . 18 General Run & Transport Problems . . . . . . . . . . . 20 Cutting Deck Operating Problems . . . . . . . . . . . . 21 Cutting Deck Lift/Lower Problems . . . . . . . . . . . . 23 ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Cutting Deck Position Switch Adjustment . . . . . . 25 Traction Pedal Adjustment . . . . . . . . . . . . . . . . . . 26 Traction Pedal Position Sensor Calibration . . . . 28 ELECTRICAL SYSTEM QUICK CHECKS . . . . . . . 29 Battery Test (Open Circuit) . . . . . . . . . . . . . . . . . . 29 Charging System Test . . . . . . . . . . . . . . . . . . . . . . 29 Check Operation of Interlock Switches . . . . . . . . 29 COMPONENT TESTING . . . . . . . . . . . . . . . . . . . . . . 30 Ignition Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 Operator Cab Fuses (Groundsmaster 4010--D) 32 Fusible Link Harness . . . . . . . . . . . . . . . . . . . . . . . 33 PTO Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 HI/LOW Speed, Engine Speed and Cutting Deck Lift Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 General Information Operator’s Manual The Operator’s Manual provides information regarding the operation, general maintenance and maintenance intervals for your Groundsmaster machine. Refer to that publication for additional information when servicing the machine. Toro Electronic Controllers (TEC) Groundsmaster 4000--D and 4010--D machines use two (2) Toro Electronic Controllers (TEC) to manage machine electrical functions. The controllers are microprocessor controlled that sense the condition of various switches and sensors (inputs). The controllers then direct electrical power to control appropriate machine functions (outputs) based on the input state. Communication between the two (2) TEC controllers, the Yanmar engine electronic control unit (ECU) and the machine InfoCenter Display is provided with a CAN--bus system. The status of inputs to the controllers as well as outputs from the controllers can be monitored with the InfoCenter Display. The TEC controllers are attached to the machine under the power center cover next to the operator seat. The TEC controllers are visually identical but they have different software and therefore cannot be interchanged. 3 1 2 Figure 1 1. Front TEC controller 2. Rear TEC controller 3. Operator seat IMPORTANT: To prevent machine electrical system damage while welding on the machine, disconnect the battery cables from the batteries, disconnect the wire harness connectors from both Toro Electronic Controllers, disconnect the wire harness connectors from the engine electronic control unit and disconnect the terminal connector from the alternator. Also, disconnect and remove the engine ECU from the machine before welding. Electrical System Page 5 -- 2 Groundsmaster 4000--D/4010--D Yanmar Engine Electronic Control Unit (ECU) The Yanmar engine that powers the Groundsmaster 4000--D and 4010--D uses an electronic control unit (ECU) for engine management and also to communicate with the TEC controllers and the InfoCenter Display on the machine. All engine ECU electrical connectors should be plugged into the controller before the machine ignition switch is moved from the OFF position to either the RUN or START position. If the engine ECU is to be disconnected for any reason, make sure that the ignition switch is in the OFF position with the key removed for a minimum of thirty (30) seconds before disconnecting the engine ECU. See Chapter 3 -- Yanmar Diesel Engine for additional engine ECU information. 2 1 Figure 2 1. Electronic control unit (model 30603 / 30605) 2. Alternator 1 Electrical System 2 Figure 3 1. Electronic control unit (model 30607 / 30609) 2. Alternator Yanmar Engine Electrical Components When servicing or troubleshooting the engine electrical components, use the correct engine service manual and troubleshooting manual. Also, the Yanmar SMARTASSIST--Direct electronic control diagnostics service system is available to support the error diagnosis and maintenance services of engine electrical control devices. Groundsmaster 4000--D/4010--D Page 5 -- 3 Electrical System CAN--bus Communications The two (2) TEC controllers, the Yanmar engine electronic control unit and the InfoCenter Display used on the Groundsmaster 4000--D and 4010--D communicate with each other on a CAN--bus system. Using this system allows the traction unit to fully integrate all the different electrical components of the tractor and bring them together as one. The CAN--bus system reduces the number of electrical components and connections used on the machine and allows the number of wires in the wire harness to be significantly reduced. The integration of electrical functions also allows the InfoCenter Display to assist with electrical system diagnostics. CAN identifies the Controller Area Network that is used between the controllers on the Groundsmaster. Two (2) specially designed, twisted wires form the bus. These wires provide the data pathways between the controllers (the TEC controllers and the Yanmar electronic control unit) and the InfoCenter Display used on the machine. The engineering term for these wires are CAN High and CAN Low. At the ends of the twisted pair of bus wires are 120 ohm termination resistors. One of these resistors is included in the wire harness and the second is inside the engine ECU. Each of the components that is controlled by the CAN-bus link needs only four (4) wires to operate and communicate to the system: CAN High, CAN Low, B+ (power) and ground. The CAN--bus needs the ignition switch ON input for both the TEC and engine ECU to be activated. Electrical Drawings The electrical schematics and wire harness drawings for Groundsmaster 4000--D and 4010--D machines are located in Chapter 10 -- Foldout Drawings. Electrical System Page 5 -- 4 Groundsmaster 4000--D/4010--D Electrical System This page is intentionally blank. Groundsmaster 4000--D/4010--D Page 5 -- 5 Electrical System Special Tools Order special tools from your Toro Distributor. Some tools may also be available from a local supplier. Multimeter The multimeter can test electrical components and circuits for current, resistance or voltage. NOTE: Toro recommends the use of a DIGITAL Volt-Ohm--Amp multimeter when testing electrical circuits. The high impedance (internal resistance) of a digital meter in the voltage mode will make sure that excess current is not allowed through the meter. This excess current can cause damage to circuits not designed to carry it. Figure 4 Dielectric Gel Dielectric gel should be used to prevent corrosion of connection terminals. To ensure complete coating of terminals, liberally apply gel to both component and wire harness connector, plug connector to component, unplug connector, reapply gel to both surfaces and reconnect harness connector to component. Connectors should be thoroughly packed with gel for effective results. Toro Part Number: 107--0342 Figure 5 Battery Terminal Protector Aerosol spray that should be used on battery terminals to reduce corrosion problems. Apply terminal protector after the battery cable has been secured to the battery terminal. Toro Part Number: 107--0392 Figure 6 Electrical System Page 5 -- 6 Groundsmaster 4000--D/4010--D Battery Hydrometer Use the Battery Hydrometer when measuring specific gravity of battery electrolyte. Obtain this tool locally. Electrical System Figure 7 Groundsmaster 4000--D/4010--D Page 5 -- 7 Electrical System InfoCenter Display The InfoCenter Display used on your Groundsmaster is a LCD device that is located on the console. The InfoCenter provides information for the machine operator during machine operation, provides electrical system diagnostic assistance for technicians and allows inputs for adjustable machine settings. Power for the InfoCenter is available when energized by the main power relay (ignition switch in the RUN or START position). A CAN--bus system involving the machine TEC controllers, the Yanmar engine electronic control unit and the InfoCenter is used to provide necessary machine communication for InfoCenter operation. Splash Screen The two (2) InfoCenter splash screens (Figs. 8 and 9) are displayed when the ignition switch is initially turned to the RUN or START position. The splash screens allow basic machine information to be reviewed by the operator. After each of the splash screens has been on the InfoCenter for several seconds, the main information screen will be displayed on the InfoCenter. 2 T 1 The splash screens can be used to identify machine battery voltage, fuel level, hourmeter reading, hydraulic oil temperature and engine status. 12.6V 95.2 6 3 4 5 Figure 8 4. Right button 5. Down button 6. Menu/back button 1. Battery voltage 2. Fuel gauge 3. Hour meter 2 3 140 180 o 220 F 12.6V 1 0 RPM 4 7 5 6 Figure 9 1. 2. 3. 4. Electrical System Page 5 -- 8 Battery voltage Hydraulic oil temperature Fuel gauge Engine RPM 5. Right button 6. Down button 7. Menu/back button Groundsmaster 4000--D/4010--D Main Information Screen The two (2) InfoCenter main information screens (Figs. 10 and 11) are displayed after the initial splash screen has been displayed for several seconds. During normal machine operation, the main information screens provide machine information for the operator. Toggling between the main information screens is done by pressing the right button on the InfoCenter. 4 100 The main information screens can be used to monitor engine coolant temperature, fuel level, hydraulic oil temperature, battery voltage, engine RPM and traction speed range. The screens will also identify if the parking brake is applied, if the PTO is engaged or if the cruise control is activated. 240 P 1 8 6 7 Figure 10 1. 2. 3. 4. 5. 6. 7. 8. Parking brake applied Traction speed Coolant temperature Fault indicator If a machine fault occurs during machine operation, the InfoCenter fault indicator will blink to notify the operator. Accessing the fault log is described below in Faults Screen. Fuel gauge Right button Down button Menu/back button 3 4 140 180 220 o 12.6V 1 The main menu and additional information screens can be accessed from the InfoCenter main information screen by pressing and releasing the menu/back button (left button) on the display. Information on the main menu and menu item screens is included below. 8 2120 RPM 5 6 7 Figure 11 1. 2. 3. 4. Page 5 -- 9 Battery voltage Hydraulic oil temperature Fault indicator Fuel gauge 5. 6. 7. 8. Engine RPM Right button Down button Menu/back button Electrical System Electrical System 2 If an electrical engine fault occurs during machine operation, the fault will be displayed on the InfoCenter to notify the operator. The engine fault will be retained in the engine ECU and can be viewed using the engine diagnostic tool. Engine faults are not stored in the TEC controller so they cannot be viewed using the InfoCenter Faults Screen. Groundsmaster 4000--D/4010--D 170 L 2 The main information screens will also display arrows whenever the cutting decks are either raising (up arrows) or lowering (down arrows). If controls are not selected properly to allow certain machine operations, an advisory will be displayed on the InfoCenter Display. Typically, an advisory can be eliminated with a change in controls by the operator. 5 3 Main Menu Screen The main menu screen can be accessed from the InfoCenter main information by pressing and releasing the menu/back button (left button) on the display. Once to the main menu screen (Fig. 12), navigation to the five (5) different menu items can occur. Pressing the move to menu item button (center button) allows a different menu item to be highlighted. Selection of the highlighted item is completed by pressing the choose item button (right button). 1 Main Menu Faults Service Diagnostics 2 4 5 3 The main menu items include faults, service, diagnostics, settings and about. These menu items are described below. 5 4 3 To return to the main information screen from the main menu screen, press the back button (left button). Figure 12 1. Main menu 2. Menu items 3. Move to menu items 4. Choose menu item 5. Back button Faults Screen The faults screen (Fig. 13) will list all machine electrical faults that have occurred since the faults were last cleared from the InfoCenter. The faults will be identified by a fault number and when the fault occurred. Faults that might occur on the machine are listed in Fault Codes in the Troubleshooting section of this chapter. 1 After entry of the PIN code, the InfoCenter fault log can be cleared by selecting the clear system faults menu item. The cleared faults will be removed from the InfoCenter list but will be retained in the TEC controller memory. If a fault occurs during machine use, there may be a change in machine functionality due to the fault. Should there be machine operation issues due to a fault, a first step to remedy the issue would be to disengage the cutting decks, release the traction pedal, turn the ignition switch OFF and allow all machine functions to stop. Then, attempt to restart the machine to see if operation has returned to normal. Some faults will be reset during the restart and will then allow normal function. If a fault continues to occur, further system evaluation and possible component repair or replacement will be necessary. Faults #39 --57.3 Ago Clear System Faults 2 5 3 5 4 3 Figure 13 1. Fault menu 2. Fault items 3. Move to menu items 4. Choose menu item 5. Back button To return to the main menu screen from the faults screen, press the back button (left button). Electrical System Page 5 -- 10 Groundsmaster 4000--D/4010--D Service Screen The service screen (Fig. 13) contains machine operational information including hours and counts. Values listed for these service menu items cannot be changed. If the machine PIN has been entered to allow access to protected menu items in the settings screen, the protected service menu items will be listed and available in the service screen. NOTE: If the protected menu items are available, PIN will be shown in the upper right corner of the InfoCenter display. The options listed for hours include the following: D Key On identifies the number of hours that the ignition switch has been in the RUN position. D Machine Run identifies the number of hours that the engine has been running. D PTO On identifies the number of hours that the machine has been operated with the cutting decks engaged. D Fan -- Oil identifies the number of times that hydraulic oil temperature caused the engine cooling fan speed to change. D Inlet identifies the temperature of the inlet air into the engine intake system. The protected menu items include the following: D DPF Regeneration provides the necessary procedure for stationary regeneration for the exhaust system DPF (diesel particulate filter) on machines with a Tier 4 engine (models 30607 and 30609). If the engine ECU identifies that a stationary DPF regeneration is necessary, an advisory will occur on the InfoCenter and the necessary steps will be listed in the service screen menu. D Traction Pedal allows the traction pedal sensor to be calibrated (see Traction Pedal Position Sensor Calibration in the Adjustments section of this chapter for calibration procedure). D High Range identifies the number of hours that the machine has been operated in HI range speed (transport). D Fan Reverse provides the necessary inputs to cause the cooling fan to reverse direction. This protected menu item allows the demonstration of the fan reversal and would never be necessary to use on a normally functioning machine. D Service Due identifies the number of hours before the next scheduled maintenance is due. To return to the main menu screen from the service screen, press the back button (left button). 1 D Starts identifies the number of times that the engine has been started. D Left Deck identifies the number of times that the left side cutting deck has been energized. 5 3 D Right Deck identifies the number of times that the right side cutting deck has been energized. D Fan Reversals identifies the number of times that the engine cooling fan has been operated in the reverse direction. Groundsmaster 4000--D/4010--D Hours Key On: 92.5 Hours Machine Run: 88.4 Hours PTO On: 63.7 Hours 2 D Center Deck identifies the number of times that the center cutting deck has been energized. D Fan -- Coolant identifies the number of times that engine coolant temperature caused the engine cooling fan speed to change. Electrical System The options listed for counts include the following: 5 4 3 Figure 13 1. Service menu 2. Service items 3. Move to menu items Page 5 -- 11 4. Choose menu item 5. Back button Electrical System Diagnostics Screen The diagnostics screen (Fig. 16) lists the various states of machine electrical components. The diagnostics screen should be used to check operation of machine controls and to verify that switches and circuit wiring are functioning correctly. For each of the diagnostics screen items, inputs, qualifiers and outputs are identified. The diagnostics screen includes the following: D Left Deck identifies machine requirements to allow the left deck to raise and lower. Inputs indicate the state of the left deck lift/lower switch and whether the machine is in LOW range speed. Qualifiers include the LOW range speed, seat switch and parking brake position. Identified outputs consist of master, lower, raise and float solenoids. D Center Deck identifies machine requirements to allow the center deck to raise and lower. Inputs indicate the state of the center deck lift/lower switch. Qualifiers include the LOW range speed, seat switch and parking brake position. Identified outputs consist of master, raise and float solenoids. D Right Deck identifies machine requirements to allow the right deck to raise and lower. Inputs indicate the state of the right deck lift/lower switch. Qualifiers include the LOW range speed, seat switch and parking brake position. Identified outputs consist of master, lower, raise and float solenoids. D Traction Pedal identifies position of the traction pedal. Inputs indicate the state of the traction pedal position sensor. Outputs indicate whether the traction circuit is in forward, neutral or reverse. D PTO identifies machine requirements to allow the PTO to be engaged. Inputs indicate the state of the PTO switch. Qualifiers identify whether LOW speed range is selected, if the seat is occupied and if the cutting decks are lowered. Outputs indicate which cutting decks are engaged. D Engine Run identifies whether necessary TEC outputs exists to allow the engine to run. Inputs indicate the state of the ignition switch. Qualifiers identify whether the PTO is off, if the traction pedal is in neutral, if the seat is occupied (or parking brake is applied) and if all deck lift switches are not activated. Outputs indicate that requirements have been met to allow engine to run or start. NOTE: The components for engine operation (i.e. glow plugs, starter) are controlled by the Yanmar engine electronic control unit. D Cruise Control identifies machine requirements to allow the cruise control to be engaged. Inputs indicate the state of the cruise control switch and service brakes. Qualifiers identify whether the seat is occupied, if the parking or service brakes are applied and if the traction pedal is not in neutral. Outputs indicate that the cruise function is engaged. D Light Kit identifies machine requirements to allow machine lights (if equipped) to be energized. Inputs indicate the state of the light switches. Outputs indicate that the lights are energized. To return to the main menu screen from the diagnostics screen, press the back button (left button). 1 D Traction identifies machine requirements to allow the traction system to be engaged. Inputs indicate the state of the traction pedal. Qualifiers include the seat switch and parking brake position. Outputs indicate whether the piston (traction) pump is engaged in forward or reverse. Diagnostics Left Deck Center Deck Right Deck 2 5 4 3 D Hi/Low Range identifies machine requirements to allow HI or LOW speed range to be engaged. Inputs indicate the state of the hi/low switch. Qualifiers identify the position of the PTO switch and the cutting decks (raised or lowered). Outputs indicate whether HI range is engaged (solenoid S12 is energized). 5 Figure 16 1. Diagnostics menu 2. Diagnostics items 3. Move to menu items Electrical System 4 3 Page 5 -- 12 4. Choose menu item 5. Back button Groundsmaster 4000--D/4010--D Settings Screen If either the backlight (brightness) or contrast items are selected, the center button (--) or right button (+) can be used to change the display settings. Protected menus allows the machine PIN to be entered so that hidden machine service screen items can be viewed and modified. The protected service items include traction pedal sensor calibration, cooling fan reversal demonstration, Smart PowerTM ON/OFF and exhaust system DPF regeneration (Tier4 engines). If the protect settings is ON (see below), auto idle, mow speed, transport speed and counterbalance are also included in the protected menu. To allow access to the protected menu items, enter the four (4) digit pin PIN using the center and right InfoCenter buttons. After PIN has been entered, a check mark should be visible above center InfoCenter button. Press center button and the InfoCenter display screen should indicate “PIN” in the upper right hand corner if the correct PIN number was entered. Use back button to return to Settings menu. The protected menu items should be available in the Service menu and can be changed as long as the ignition switch remains in RUN. Trans. (Transport) Speed allows the maximum traction speed to be adjusted when in HI (transport) speed. HI speed can be adjusted to 40%, 70% or 100%. Smart Power allows the Smart PowerTM feature to be turned OFF and ON. To return to the main menu screen from the settings screen, press the back button (left button). 1 2 5 3 5 4 3 Figure 17 1. Settings menu 2. Settings items 3. Move to menu items NOTE: The initial PIN will either be 1234 or 0000. If the PIN has been changed and is forgotten, a temporary PIN can be obtained from your Toro distributor. 4. Change menu item 5. Back button 7 3 1 Protect settings allows the settings for auto idle, mow speed and transport speed to be hidden so they cannot be changed unless the PIN is entered. If the protect settings is ON, these settings will not be seen when using the InfoCenter until the protected menus is selected and the machine PIN is entered. If protect settings is OFF (default setting), settings for these functions will be visible on the InfoCenter and can be adjusted by the operator. PIN 20s 70 % 70 % -- Settings Auto Idle: Mow Speed: Trans. Speed: + 2 6 5 4 6 Reset Defaults allows machine settings to be returned to factory defaults. Auto Idle causes the engine speed to decrease to low idle after the machine has not been in use for the set time delay in seconds. Auto idle can be adjusted to 8, 10, 15, 20 or 30 seconds or the auto idle feature can be turned OFF. Settings English Units: English Language: 40% LCD Backlight: +/-- Electrical System The settings screen identifies the InfoCenter language and units (English or Metric). The settings screen also allows the operator to customize the backlight (brightness) and contrast settings for the InfoCenter display. 5 4 Figure 18 1. 2. 3. 4. Settings menu Settings items Current setting Increase setting 5. Decrease setting 6. Back button 7. PIN activated Mow Speed allows the maximum traction speed to be adjusted when in LOW (mow) speed. Mow speed can be adjusted to 40%, 70% or 100%. Groundsmaster 4000--D/4010--D Page 5 -- 13 Electrical System About Screen The about screen (Fig. 17) identifies the machine model number, serial number and software revisions for the TEC controllers, InfoCenter and engine electronic control unit (if available). The about screen also lists the CAN--bus status. Additional information is identified if the about screen is accessed after the protected menus have been accessed by entering the PIN. 1 About Model: SN: S/W Rev: 2 30607 313000103 120--6363C 5 To return to the main menu screen from the about screen, press the back button (left button). 3 5 4 3 Figure 17 1. About menu 2. About items 3. Move to menu items Electrical System Page 5 -- 14 4. Choose menu item 5. Back button Groundsmaster 4000--D/4010--D Troubleshooting If the machine has any interlock switches by--passed, reconnect the switches for safety and efficient troubleshooting. CAUTION Remove all jewelry, especially rings and watches, before doing any electrical troubleshooting or testing. Also, disconnect the battery cables unless the test requires battery voltage. NOTE: Check the InfoCenter Display for possible operator advisories or faults whenever diagnosing machine electrical problems. For effective troubleshooting and repairs, you must have a good understanding of the electrical circuits and components used on this machine (see electrical schematics and wire harness drawings in Chapter 10 -Foldout Drawings). Operator Advisories The list below identifies the operator advisories that are generated by the TEC controller. An advisory will be displayed on the InfoCenter Display. Typically, an advisory can be eliminated with a change in machine controls by the operator. Advisory Description 160 Inhibit start 161 Inhibit PTO 162 Inhibit cutting unit lower 163 Inhibit traction HIGH speed range 164 Inhibit traction LOW speed range 165 Inhibit traction 166 Inhibit cruise control 167 Derate traction setting 168 Inhibit traction teach (traction pedal calibration) 169 Engine shutdown 170 Recycle keyswitch (ignition switch) 171 Auto idle engaged 172 Calibrate (traction pedal) 173 Master address claim (front TEC controller) 174 Slave address claim (rear TEC controller) 175 Derate engine Groundsmaster 4000--D/4010--D Page 5 -- 15 Electrical System Advisory Electrical System Fault Codes The list below identifies the fault codes that are generated by the TEC controller to identify an electrical system malfunction (fault) that occurred during machine operation. Use the InfoCenter Display for fault retrieval. NOTE: The following list of fault codes identifies electrical problems that typically will prevent normal machine operation. The InfoCenter Display will identify existing faults if they should occur. Fault codes 13 through 25 identify problems with inputs (e.g. switches, sensors) to the TEC controllers. For input problems, use the InfoCenter Display to check the different switch positions before removing or replacing the component. NOTE: Fault codes 26 through 62 identify problems with outputs (e.g. solenoid coils, light bulbs) from the TEC controllers. These output problems might involve issues with the wire harness or the actual output device (solenoid coil or bulb). Fault Code Fault Description 1 Excessive engine coolant temperature (above 105oC) caused PTO to disengage 2 Excessive engine coolant temperature (above 115oC) caused engine to stop 3 One of the TEC output fuses (7.5 Amp) is faulty 4 IPE voltage too low indicating that TEC controller is faulty 5 Main power relay is faulty 6 Ignition switch was held in the START position for more than 30 seconds or the ignition switch is faulty 7 TEC software needs to be reprogrammed (contact Toro Distributor) 8 Alternator charging is too high 9 Alternator charging is too low 10 Engine has not been seen on CAN--bus for 10 seconds 11 Rear TEC controller has not been seen on CAN--bus for 1 second 12 InfoCenter has not been seen on CAN--bus for 1 second 13 Ignition switch is faulty (check ignition switch) 14 Traction pedal position sensor is faulty (check traction sensor) 15 Engine speed switch is faulty (check engine speed switch) 16 Traction system HI/LOW speed switch is faulty (check HI/LOW speed switch) 17 Traction pedal position sensor is out of range 18 Hydraulic temperature sensor circuit has open or short 21 Center cutting deck lift switch is faulty (check center lift switch) 22 Left cutting deck lift switch is faulty (check left lift switch) 23 Right cutting deck lift switch is faulty (check right lift switch) 25 Cruise control switch is faulty (check cruise control switch) 26 Engine START output has open or short to ground 27 Engine RUN output has open or short to ground 28 Traction system HIGH range output has open or short to ground 29 RH turn/warning light output has open or short to ground 30 LH turn/warning light output has open or short to ground Electrical System Page 5 -- 16 Groundsmaster 4000--D/4010--D Fault Description 31 Brake/RH turn light output has open or short to ground 32 Brake/LH turn light output has open or short to ground 33 Forward piston (traction) pump output has open or short to ground 34 Reverse piston (traction) pump output has open or short to ground 35 Reverse engine cooling fan output (solenoid valve S10) has open or short to ground 36 Disable dual engine cooling fan output (solenoid valve S11) has open or short to ground 38 Center PTO output has open or short to ground 39 LH PTO output has open or short to ground 40 RH PTO output has open or short to ground 41 Solenoid valve S1 (lift/lower enable) output has open or short to ground 42 Solenoid valve S2 (LH deck raise) output has open or short to ground 43 Solenoid valve S3 (LH deck lower) output has open or short to ground 44 Solenoid valve S4 (LH deck float) output has open or short to ground 45 Solenoid valve S5 (center deck raise) output has open or short to ground 46 Solenoid valve S6 (center deck float) output has open or short to ground 47 Solenoid valve S7 (RH deck raise) output has open or short to ground 48 Solenoid valve S8 (RH deck lower) output has open or short to ground 49 Solenoid valve S9 (RH deck float) output has open or short to ground 52 Engine cooling fan output has open or short to ground 63 Traction pedal position sensor is returning a voltage higher than 4.75V or lower than 0.25V (replace the traction pedal position sensor) 64 Traction pedal position sensor neutral switches do not align with calibrated sensor values (recalibrate traction pedal position sensor) 65 Traction pedal position sensor forward/reverse switches are indicating the pedal is in both positions at the same time (replace the traction pedal position sensor) 66 TEC controller overcurrent in traction circuit 67 Traction current validation failure: make sure TEC forward traction output is connected to the piston pump forward traction solenoid coil. If circuit is connected, replace the front TEC controller. Groundsmaster 4000--D/4010--D Page 5 -- 17 Electrical System Electrical System Fault Code Starting Problems NOTE: Check InfoCenter Display for possible operator advisories or faults whenever diagnosing machine electrical problems. Problem Possible Causes No electrical power to machine. The battery is discharged. The battery cables are loose or corroded. Fuse F--D1 (2 Amp) is faulty. Fuse F--D2 (2 Amp) is faulty. Fuse M1 (60 Amp) is faulty. A faulty ground connection exists on machine. The ignition switch or circuit wiring is faulty. Starter solenoid clicks, but starter will not crank. The battery is discharged. NOTE: If the solenoid clicks, the problem is not in the in- The battery cables are loose or corroded. terlock circuit. A ground wire or cable is loose or corroded. The wiring at the starter motor is faulty. The starter solenoid is faulty. The starter motor is faulty. Nothing happens when start attempt is made. InfoCenter display operates with the ignition switch in the RUN position. The traction pedal is not in the neutral position. The operator seat is unoccupied OR the parking brake is not applied. NOTE: Use InfoCenter Display to assist with identifying problem. The PTO switch is ON (engaged). Fuses for TEC are faulty. The ignition switch or circuit wiring is faulty. Traction pedal position sensor is out of adjustment. Traction pedal position sensor or circuit wiring is faulty. The seat switch or circuit wiring is faulty. The parking brake switch or circuit wiring is faulty. The start relay or circuit wiring is faulty. The starter solenoid or starter motor is faulty. The engine or fuel system is malfunctioning (see Yanmar Service Manual). Electrical System Page 5 -- 18 Groundsmaster 4000--D/4010--D Starting Problems (Continued) Problem Possible Causes Starter cranks, but should not, when the traction pedal is depressed. Traction pedal position sensor is out of adjustment. Engine cranks, but does not start. The fuel tank is empty. Traction pedal position sensor or circuit wiring is faulty. The engine is not cranking fast enough. The fuel pump or circuit wiring is faulty. Electrical System The engine or fuel system is malfunctioning (see Yanmar Service Manual). Groundsmaster 4000--D/4010--D Page 5 -- 19 Electrical System General Run and Transport Problems NOTE: Check InfoCenter Display for possible operator advisories or faults whenever diagnosing machine electrical problems. Problem Possible Causes Engine continues to run, but should not, when the ignition switch is turned off. The ignition switch or circuit wiring is faulty. The alternator circuit is faulty (machines with 80 Amp alternator) The engine or fuel system is malfunctioning (see Yanmar Service Manual). Machine continues to run without an InfoCenter Advisory, but should not, when the traction pedal is depressed with no operator in the seat. The seat switch or circuit wiring is faulty. Traction pedal position sensor is out of adjustment. Traction pedal position sensor or circuit wiring is faulty. Engine stops during operation, but is able to restart. The operator is lifting off the seat switch while mowing. NOTE: Excessive engine coolant temperature will cause the cutting decks to be disengaged and can lead to engine shutdown. If excessive coolant temperature causes engine shutdown, the operator can restart the engine to allow the machine to be moved a short distance. After a restart in this condition, the engine will run for approximately ten (10) seconds before the engine shuts down again. The seat switch or circuit wiring is faulty. The ignition switch or circuit wiring is faulty. The engine coolant temperature is excessive. Machine is being operated on a slope with a low fuel level. The engine or fuel system is malfunctioning (see Yanmar Service Manual). Battery does not charge. Loose, corroded or broken wire(s) exist in charging circuit. The engine alternator belt is out of adjustment. The battery is faulty. The alternator is faulty. Electrical System Page 5 -- 20 Groundsmaster 4000--D/4010--D Cutting Deck Operating Problems NOTE: Check InfoCenter Display for possible operator advisories or faults whenever diagnosing machine electrical problems. NOTE: To engage the mow circuit, the operator must be in the operator seat, the traction speed must be in the LOW speed (mow) position, the PTO switch must be ON and the cutting deck(s) must be fully lowered and in float. Problem Possible Causes The cutting decks remain engaged, but should not, with no operator in the seat. The seat switch or circuit wiring is faulty. A hydraulic problem in the mow circuit exists (see Troubleshooting section of Chapter 4 -- Hydraulic System). The TEC controller is faulty. Cutting deck runs, but should not, when raised. Decks shut off with PTO switch. The deck position switch or circuit wiring is faulty. A hydraulic problem in the mow circuit exists (see Troubleshooting section of Chapter 4 -- Hydraulic System). The TEC controller is faulty. Cutting decks run, but should not, when raised. Decks do not shut off with the PTO switch. Both the deck position switch or circuit wiring and PTO switch or circuit wiring are faulty. Electrical System A hydraulic problem in the mow circuit exists (see Troubleshooting section of Chapter 4 -- Hydraulic System). Groundsmaster 4000--D/4010--D Page 5 -- 21 Electrical System Cutting Deck Operating Problems (Continued) Problem Possible Causes Cutting decks run, but should not, when lowered with PTO switch in the OFF (disengage) position. The PTO switch or circuit wiring is faulty. Cutting deck(s) do not operate. The operator is lifting off the seat switch. The TEC controller is faulty. The cutting decks are not fully lowered. Traction circuit is not in LOW speed (mow) mode. High temperature of engine coolant or hydraulic oil has disabled the cutting decks. Fuse is faulty preventing PTO manifold solenoids from being energized. The seat switch or circuit wiring is faulty. The PTO switch or circuit wiring is faulty. The deck position switch or circuit wiring is faulty. The HI/LOW speed switch or circuit wiring is faulty. Hydraulic valve solenoid(s) or circuit wiring to the affected deck(s) is faulty. A hydraulic problem in the mow circuit exists (see Troubleshooting section of Chapter 4 -- Hydraulic System). The TEC controller is faulty. Electrical System Page 5 -- 22 Groundsmaster 4000--D/4010--D Cutting Deck Lift/Lower Problems NOTE: Check InfoCenter Display for possible operator advisories or faults whenever diagnosing machine electrical problems. NOTE: To lower a cutting deck, the operator must be in the operator seat and the traction speed must be in the LOW speed (mow) position. To raise a cutting deck, the operator must be in the operator seat. Problem Possible Causes None of the cutting decks will lower. The HI/LOW speed switch is in the HI speed position. Operator is not fully depressing the seat switch. TEC fuse(s) are faulty. The seat switch or circuit wiring is faulty. The HI/LOW speed switch or circuit wiring is faulty. Combination control manifold solenoid coil S1 or circuit wiring is faulty. A hydraulic problem in the lift/lower circuit exists (see Troubleshooting section of Chapter 4 - Hydraulic System). The TEC controller is faulty. None of the cutting decks will raise. TEC fuse(s) are faulty. A hydraulic problem in the lift/lower circuit exists (see Troubleshooting section of Chapter 4 - Hydraulic System). The TEC controller is faulty. Center cutting deck will not raise or lower, but both side cutting decks will raise and lower. The center deck lift switch or circuit wiring is faulty. Combination control manifold solenoid coils S5 or S6 or circuit wiring is faulty. A hydraulic problem in the lift/lower circuit exists (see Troubleshooting section of Chapter 4 - Hydraulic System). The TEC controller is faulty. Groundsmaster 4000--D/4010--D Page 5 -- 23 Electrical System Electrical System Combination control manifold solenoid coil S1 or circuit wiring is faulty. Cutting Deck Lift/Lower Problems (Continued) Problem Possible Causes Right side cutting deck will not raise or lower, but the center and left side cutting decks will raise and lower. The RH deck lift switch or circuit wiring is faulty. Fuse is faulty. Combination control manifold solenoid coils S7, S8 or S9 or circuit wiring is faulty. A hydraulic problem in the lift/lower circuit exists (see Troubleshooting section of Chapter 4 - Hydraulic System). The TEC controller is faulty. Left side cutting deck will not raise or lower, but the The LH deck lift switch or circuit wiring is faulty. center and right side cutting decks will raise and lower. Combination control manifold solenoid coils S2, S3 or S4 or circuit wiring is faulty. A hydraulic problem in the lift/lower circuit exists (see Troubleshooting section of Chapter 4 - Hydraulic System). The TEC controller is faulty. Electrical System Page 5 -- 24 Groundsmaster 4000--D/4010--D Adjustments Cutting Deck Position Switch Adjustment Adjustment 4 1. Park machine on a level surface with front cutting deck raised and side cutting decks lowered. Stop engine, engage parking brake and remove key from the ignition switch. 3 2 2. There should be from 0.070” to 0.130” (1.8 to 3.3 mm) clearance between the target surface end of position switch and the sensing plate on lift arm. 3. If necessary, loosen jam nuts on switch and adjust switch location to allow proper clearance between switch and sensing plate. 1 4. After adjustment, torque jam nuts from 165 to 195 in--lb (18.7 to 22.0 N--m). Check that proper clearance between switch and sensing plate still exists after tightening jam nuts. 1. Front lift arm 2. Position switch Figure 18 3. Sensing plate 4. Switch LED 3 2 1 4 5 Figure 19 1. Side lift arm (RH shown) 2. Position switch 3. Sensing plate Groundsmaster 4000--D/4010--D Page 5 -- 25 4. Switch LED 5. Clearance Electrical System Electrical System NOTE: The cutting deck position switches include a LED on the cable end of the switch body. The switch LED should be illuminated when the cutting decks are fully lowered. Traction Pedal Adjustment The traction pedal includes a neutral assembly that is used to adjust the traction neutral position (Fig. 20). Traction pedal adjustment may be necessary to make sure that traction pedal movement provides the correct full reverse and full forward positions for the traction pedal position sensor. The InfoCenter display can be used to check traction pedal adjustment using the following procedure. 1 1. Park machine on a level surface, lower cutting decks, engage parking brake and stop engine. 3 4 2. Turn ignition switch to RUN but do not start engine. 3. Use the InfoCenter Display Diagnostics menu (see InfoCenter Display in this chapter) to obtain and select the Traction Pedal menu item. Choose Inputs and the InfoCenter display should identify sensor voltage (Fig. 21). 5 4. Move traction pedal from full reverse to full forward positions while noting the range of voltage displayed on the InfoCenter. A. Voltage in full reverse should be from 0.5 to 1.75V (approximate). 2 Figure 20 1. Traction pedal 2. Pedal position sensor 3. Spring shaft 4. Hex nut 5. Rod end bearing B. Voltage in full forward should be from 3.5 to 4.5V (approximate). 5. If voltage range from full reverse to full forward is incorrect, adjustment of the spring shaft and rod end bearing is necessary (Fig. 20). Traction Pedal Sensor: 2.407V A. Remove steering cover to access traction pedal components (see Steering Tower in the Service and Repairs section of Chapter 7 -- Chassis). B. Loosen hex nut that secures rod end bearing in spring shaft. C. Rotate spring shaft which changes traction pedal position in relation to traction pedal position sensor. D. Check range of voltage as described in step 4 above and make additional adjustments to the spring shaft until range of voltage is within specifications. Figure 21 E. Tighten hex nut to secure rod end bearing. Check that traction pedal range of voltage is still correct after hex nut is tightened. F. Install steering cover (see Steering Tower in the Service and Repairs section of Chapter 7 -- Chassis). Electrical System Page 5 -- 26 Groundsmaster 4000--D/4010--D 6. After any adjustment of the spring shaft and rod end bearing, use the InfoCenter Display Diagnostics menu (see InfoCenter Display in this chapter) to obtain and select the Traction Pedal menu item. Choose Outputs and the InfoCenter display will identify the traction pedal position (Fig. 22). Traction Pedal Forward Range: Neutral Reverse Range: OFF ON OFF A. When the traction pedal is in the neutral position, the InfoCenter should display Neutral as ON and both Forward Range and Reverse Range as OFF. B. Move traction pedal in the forward direction and the InfoCenter should display the Forward Range as ON and both Neutral and Reverse Range as OFF. C. Return the traction pedal to neutral and then move pedal in the reverse direction. The InfoCenter should display the Reverse Range as ON and both Neutral and Forward Range as OFF. Figure 22 D. If outputs are incorrect, additional adjustment of the spring shaft and rod end bearing are necessary. Electrical System 7. After completing all adjustments and before returning the machine to operation, calibrate traction pedal position sensor (see Traction Pedal Position Sensor Calibration in this section of this chapter). Groundsmaster 4000--D/4010--D Page 5 -- 27 Electrical System Traction Pedal Position Sensor Calibration IMPORTANT: A properly installed and calibrated traction pedal position sensor is critical to accurate traction system response and for reliable sensor life. Use care when removing, installing and calibrating the traction pedal position sensor. 1 Calibration of the traction pedal position sensor ensures that the TEC controller can identify the traction neutral, forward and reverse positions. 2 1. Park machine on a level surface, lower cutting decks, engage parking brake and stop engine. 2. Turn ignition switch to RUN but do not start engine. 3. Use the InfoCenter Display Settings menu (see InfoCenter Display in this chapter) to obtain and select Protected Menus. Enter valid PIN for the machine to allow access to protected menu items including calibration of the traction pedal position sensor. The InfoCenter display screen should indicate “PIN” in the upper right hand corner when the correct PIN number has been entered. Figure 23 1. Traction pedal 4. Use the InfoCenter Display Service menu (see InfoCenter Display in this chapter) to obtain and select the Traction Pedal menu item. The InfoCenter display should indicate that the traction pedal calibration process is engaged (Fig. 24). 5. Follow the prompts on the InfoCenter display screen to calibrate the traction pedal position sensor. The calibration steps are listed below: 2. Pedal position sensor ADVISORY #172 Calibrate Teach Is Engaged A. Slowly press traction pedal to the forward direction. B. Press and hold traction pedal to the full forward position. C. Allow traction pedal to return to the neutral position. Figure 24 D. Slowly press traction pedal to the reverse direction. E. Press and hold traction pedal to the full reverse position. ADVISORY #172 F. Check that InfoCenter display indicates a successful calibration process (Fig. 25). Calibrate. Exit Good 6. Turn ignition switch to OFF which exits the traction pedal calibration menu. Figure 25 Electrical System Page 5 -- 28 Groundsmaster 4000--D/4010--D Electrical System Quick Checks Battery Test (Open Circuit) Use a multimeter to measure the voltage between the battery terminals. Set multimeter to the DC volts setting. The battery should be at a temperature of 60o to 100oF (16o to 38oC). The ignition key should be off and all accessories turned off. Connect the positive (+) multimeter lead to the positive battery post and the negative (--) multimeter lead to the negative battery post. The multimeter will display battery voltage. Voltage Measured Battery Charge Level 12.68 V (or higher) Fully charged (100%) 12.45 V 75% charged 12.24 V 50% charged 12.06 V 25% charged 11.89 V 0% charged NOTE: This test provides a relative condition of the battery. Load testing of the battery will provide additional and more accurate information. Charging System Test This is a simple test used to determine if a charging system is functioning. It will tell you if the charging system has an output, but not its capacity. Start the engine and run at high idle. Allow the battery to charge for at least three (3) minutes. Record the battery voltage. NOTE: The InfoCenter display can be used to identify battery voltage during machine operation. After running the engine for at least three (3) minutes, battery voltage should be at least 0.50 volt higher than initial battery voltage. NOTE: Upon starting the engine, the battery voltage will drop and then should increase once the engine is running. An example of a charging system that is functioning: At least 0.50 volt over initial battery voltage. Initial Battery Voltage = 12.30 v Battery Voltage after 3 Minute Charge = 12.95 v Difference = +0.65 v NOTE: Depending upon the condition of the battery charge and battery temperature, the battery voltage will increase at different rates as the battery charges. Check Operation of Interlock Switches CAUTION Do not disconnect safety switches. They are for the operator’s protection. Check the operation of the interlock switches daily for proper operation. Replace any malfunctioning switches before operating the machine. Groundsmaster 4000--D/4010--D Interlock switch operation is described in the Traction Unit Operator’s Manual. Your Groundsmaster is equipped with two (2) Toro Electronic Controllers (TEC) which monitor interlock switch operation. Testing of individual interlock switches and relays is included in the Component Testing section of this Chapter. NOTE: Use the InfoCenter Display when troubleshooting an electrical problem on your Groundsmaster. Page 5 -- 29 Electrical System Electrical System Use a digital multimeter set to DC volts. Connect the positive (+) multimeter lead to the positive battery post and the negative (--) multimeter lead to the negative battery post. Keep the test leads connected to the battery posts and record the battery voltage. Component Testing For accurate resistance and/or continuity checks, electrically disconnect the component being tested from the circuit (e.g. unplug the ignition switch connector before checking continuity on the switch). NOTE: For engine component testing information, see the Yanmar Workshop Manual and Yanmar Troubleshooting Manual. CAUTION When testing electrical components for continuity with a multimeter (ohms setting), make sure that power to the circuit has been disconnected. Ignition Switch The ignition (key) switch is located on the control panel and has three (3) positions: STOP, RUN and START (Fig. 26). The Toro Electronic Controller (TEC) monitors the operation of the ignition switch. 7. If the ignition switch tests correctly and a circuit problem still exists, check wire harness (see Electrical Schematics and Wire Harness Drawings in Chapter 10 -Foldout Drawings). Testing 8. After testing is complete, connect machine wire harness connector to ignition switch. Secure control arm covers to machine with removed fasteners (see Control Arm in the Service and Repairs section of Chapter 7 -Chassis). 2. Before disconnecting the ignition switch for testing, the switch and its circuit wiring should be tested as a TEC electrical input using the InfoCenter Display (see InfoCenter Display in this chapter). If input testing verifies that the ignition switch and circuit wiring are functioning correctly, no further ignition switch testing is necessary. If, however, input testing determines that the ignition switch and circuit wiring are not functioning correctly, proceed with the following ignition switch testing procedure. STOP START REAR VIEW FRONT VIEW Figure 26 4. Make sure ignition switch is in the OFF position. Disconnect wire harness connector from ignition switch. SWITCH POSITION 5. The ignition switch terminals are identified in Figure 26 and the circuitry of the switch is shown in the chart in Figure 27. With the use of a multimeter (ohms setting), the switch functions can be tested to determine whether continuity exists between the various terminals for each switch position. Verify continuity between switch terminals. Electrical System 1 2 3 3. Remove control arm covers to gain access to ignition switch (see Control Arm in the Service and Repairs section of Chapter 7 -- Chassis). 6. Replace ignition switch if testing determines that it is faulty. RUN 6 5 4 1. Park machine on a level surface, lower cutting decks, engage parking brake and stop engine. Remove key from ignition switch. CIRCUITS STOP 1+6 RUN 1+3+4+5+6 START 1+2+4+5+6 Figure 27 NOTE: Ignition switch terminals 1 and 6 are connected internally. Terminals 4 and 5 are also connected internally. These terminals should have continuity regardless of switch position. Page 5 -- 30 Groundsmaster 4000--D/4010--D Fuses The fuse block is located under the controller cover next to the operator seat (Fig. 28). In addition to the fuses in the fuse block, a 60 Amp fuse is included in the wire harness to protect the power circuit for the operator cab. This fuse resides in a fuse holder near the fuse block (Fig. 28). Fuse Identification and Function Use Figure 29 to identify each individual fuse and its correct amperage in the fuse block. The fuses have the following functions. Fuse Testing Turn ignition switch to the RUN position (do not start engine). With the fuse installed in the fuse block, use a multimeter to verify that 12 VDC exists at both of the terminal test points on the fuse. If 12 VDC exists at one of the fuse test points but not at the other, the fuse is faulty. If fuse removal is necessary, make sure that ignition switch is OFF and key is removed from switch. Remove fuse from fuse block and check that fuse has continuity across the fuse terminals. Fuse A--1 (7.5 Amp) protects power supply for the outputs of the front TEC controller. Fuse A--2 (7.5 Amp) protects power supply for the outputs of the rear TEC controller. 3 Fuse A--3 (10 Amp) protects turn signal light circuit (if equipped on models 30603 and 30605). Fuse A--4 (10 Amp) protects headlight circuit (if equipped). 2 Fuse B--1 (7.5 Amp) protects power supply for the outputs of the front TEC controller. Fuse B--3 (10 Amp) protects power supply to the engine ECU. Figure 28 1. Fuse block 2. 60 Amp fuse Fuse B--4 (10 Amp) protects operator air--ride seat circuit. 3. Operator seat FRONT A B C Fuse C--1 (7.5 Amp) protects power supply for the outputs of the front TEC controller. D 1 Fuse C--2 (7.5 Amp) protects power supply for the outputs of the rear TEC controller. 2 3 Fuse C--3 (10 Amp) protects main power supply circuit. 4 Fuse C--4 (10 Amp) protects power point circuit. 5 Fuse D--1 (2 Amp) protects logic power circuit to the front TEC controller. Fuse D--2 (2 Amp) protects logic power circuit to the rear TEC controller. Figure 29 Fuse D--3 (2 Amp) protects power supply for the InfoCenter display. Fuse D--4 (10 Amp) protects power supply for the horn (if equipped). Groundsmaster 4000--D/4010--D Page 5 -- 31 Electrical System Electrical System Fuse B--2 (7.5 Amp) protects power supply for the outputs of the rear TEC controller. 1 Operator Cab Fuses (Groundsmaster 4010--D) The operator cab fuse blocks are located in the cab headliner (Fig. 30). Identification and Function (Figs. 30 and 31) Fuse F1--2 (15 Amp) protects the cab fan circuit. Fuse F1--3 (30 Amp) protects the air conditioner circuit. Fuse F2--1 (15 Amp) protects the windshield wiper/ washer circuit. 2 Fuse F2--2 (15 Amp) protects the cab dome light circuit. Fuses F1--1, F1--4, F2--3 and F2--4 are available for optional equipment. 1 Figure 30 Testing 1. Cab headliner Turn ignition switch to the RUN position (do not start engine). With the fuse installed in the fuse block, use a multimeter to verify that 12 VDC exists at both of the terminal test points on the fuse. If 12 VDC exists at one of the fuse test points but not at the other, the fuse is faulty. If necessary, make sure that ignition switch is OFF and key is removed from switch. Remove fuse from fuse block and check that fuse has continuity across the fuse terminals. 2. Cab fuse blocks F1 1 F2 15 A 2 15 A 3 30A 15 A 4 Figure 31 Figure 32 Electrical System Page 5 -- 32 Groundsmaster 4000--D/4010--D Fusible Link Harness Your Groundsmaster uses two (2) fusible links for circuit protection. These fusible links are located in a harness that connects the starter B+ terminal to the wire harness (Fig. 33). If either of these links should fail, current to the protected circuits will cease. Refer to wire harness drawings in Chapter 10 -- Foldout Drawings for additional fusible link information. 1 2 Testing Make sure that ignition switch is OFF. Disconnect negative battery cable from battery terminal and then disconnect positive cable from battery (see Battery Service in the Service and Repairs section of this chapter). Locate and unplug fusible link connector from machine wire harness. Use a multimeter to make sure that continuity exists between the fusible link terminals. If either fusible link is open, replace the fusible link harness. Figure 33 1. Starter motor 2. Fusible link harness NOTE: It is not recommended to replace individual fusible link conductors of the fusible link harness. If any of the harness links are open (failed), replace the entire fusible link harness. After fusible link testing is complete, make sure that fusible link harness is securely attached to starter B+ terminal and wire harness. Connect positive battery cable to battery terminal first and then connect negative cable to battery. P02 TO MAIN HARNESS P01 STARTER B+ FUSIBLE LINK (14 GAUGE) FUSIBLE LINK (16 GAUGE) Groundsmaster 4000--D/4010--D Page 5 -- 33 Electrical System Figure 34 Electrical System PTO Switch The PTO switch is located on the control arm (Fig. 35). The PTO switch is pulled up to engage the PTO and pushed in to disengage the PTO. The TEC controller monitors the position of the PTO switch (up or down). Using inputs from the PTO switch and other switches in the interlock system, the TEC controller controls the energizing of the hydraulic solenoid valves used to drive the cutting deck motors. NOTE: To engage the PTO, the seat has to be occupied, traction speed has to be in LOW range and the cutting decks have to be fully lowered. 6. If PTO switch tests correctly and circuit problem still exists, check wire harness (see Electrical Schematics and Wire Harness Drawings in Chapter 10 -- Foldout Drawings). 7. After testing is completed, connect the wire harness connector to the PTO switch. 8. Assemble control arm (see Control Arm in the Service and Repairs section of Chapter 7 -- Chassis). 1 2 Testing 1. Before disconnecting the PTO switch for testing, the switch and its circuit wiring should be tested as a TEC input with the InfoCenter Display (see InfoCenter Display in this chapter). If the InfoCenter verifies that the PTO switch and circuit wiring are functioning correctly, no further switch testing is necessary. If, however, the InfoCenter determines that the PTO switch and circuit wiring are not functioning correctly, proceed with test. 2. Make sure ignition switch is OFF. Remove key from ignition switch. 3. Disassemble control arm to gain access to PTO switch (see Control Arm in the Service and Repairs section of Chapter 7 -- Chassis). Figure 35 1. Control arm 2. PTO switch 4. Disconnect harness electrical connector from the PTO switch. 4 5. The switch terminals are marked as shown in Figure 36. The circuit logic of the PTO switch is shown in the chart below. With the use of a multimeter (ohms setting), the switch functions can be tested to determine whether continuity exists between the various terminals for each switch position. Verify continuity between switch terminals. Replace PTO switch if testing identifies that switch is faulty. CLOSED CIRCUITS OPEN CIRCUITS OFF (DOWN) COM B + NC B COM C + NC C COM B + NO B COM C + NO C ON (UP) COM B + NO B COM C + NO C COM B + NC B COM C + NC C Electrical System 2 5 6 3 Figure 36 1. COM B terminal 2. NO B terminal 3. NC B terminal SWITCH POSITION 1 4. COM C terminal 5. NO C terminal 6. NC C terminal NOTE: Only PTO switch terminals COM C and NO C are used on Groundsmaster 4000--D and 4010--D machines. Page 5 -- 34 Groundsmaster 4000--D/4010--D HI/LOW Speed, Engine Speed and Cutting Deck Lift Switches The HI/LOW, engine speed and cutting deck lift switches are all identical momentary switches. These switches are located on the control arm (Fig. 37). The HI/LOW speed switch is used as an input for the TEC controller to select either the HI (transport) or LOW (mow) traction speed. The engine speed switch is used as an input for the engine electronic control unit to raise or lower the engine speed. When the switch is depressed and held in the forward position, the engine speed will increase. Conversely, when the rear of the switch is depressed, engine speed will decrease. The cutting deck lift switches are used as inputs for the TEC controller to raise or lower the cutting decks. When the front of a lift switch is depressed, the controlled decks will lower. When the rear of a lift switch is depressed and held, the controlled decks will raise. NOTE: To raise or lower the decks, the operator seat has to be occupied. Also, to lower the cutting decks, the traction speed has to be in LOW (mow) range. SWITCH POSITION CLOSED CIRCUITS OPEN CIRCUITS FRONT OF SWITCH PRESSED 2+3 5+6 2+1 5+4 NEUTRAL NONE ALL REAR OF SWITCH PRESSED 2+1 5+4 2+3 5+6 6. If switch tests correctly and circuit problem still exists, check wire harness (see Electrical Schematics and Wire Harness Drawings in Chapter 10 -- Foldout Drawings). 7. After testing is completed, connect wire harness connector to the switch. 8. Assemble control arm (see Control Arm in the Service and Repairs section of Chapter 7 -- Chassis). 3 4 Testing 1. Before disconnecting a switch for testing, the switch and its circuit wiring should be tested as a TEC input with the InfoCenter Display (see InfoCenter Display in this chapter). If the InfoCenter verifies that the switch and circuit wiring are functioning correctly, no further switch testing is necessary. If, however, the InfoCenter determines that the switch and circuit wiring are not functioning correctly, proceed with test. Electrical System 1 2. Make sure ignition switch is OFF. Remove key from ignition switch. 3. Disassemble control arm to gain access to switch that is to be tested (see Control Arm in the Service and Repairs section of Chapter 7 -- Chassis). 2 5 Figure 37 1. HI/LOW speed switch 2. Engine speed switch 3. RH deck lift switch 4. Center deck lift switch 5. LH deck lift switch 4. Disconnect harness electrical connector from the switch that is to be tested. 5. The switch terminals are marked as shown in Figure 38. The circuit logic of the switch is shown in the chart below. With the use of a multimeter (ohms setting), the switch functions may be tested to determine whether continuity exists between the various terminals for each position. Verify continuity between switch terminals. Replace switch if testing identifies a faulty switch. Groundsmaster 4000--D/4010--D Page 5 -- 35 BACK OF SWITCH Figure 38 Electrical System Cruise Control Switch The cruise control switch is used as an input for the TEC controller to maintain ground speed when engaged. The cruise control function is enabled when the switch is in the ON (center) position. Pressing the front of the switch to the momentary position sets the desired ground speed. The cruise control function is disengaged when the rear of the cruise control switch is depressed. On machine with serial numbers below 314000000, the cruise control switch is located on the operator side of the console arm (as shown in Fig. 39). On machine with serial numbers above 314000000, the cruise control switch is located on the outside the console arm. 6. If switch tests correctly and circuit problem still exists, check wire harness (see Electrical Schematics and Wire Harness Drawings in Chapter 10 -- Foldout Drawings). 7. After testing is completed, connect wire harness connector to the cruise control switch. 8. Assemble control arm (see Control Arm in the Service and Repairs section of Chapter 7 -- Chassis). NOTE: The cruise control function can also be disengaged if either brake pedal is pressed or if the traction pedal is pressed and held in the reverse direction. Testing 1. Before disconnecting the cruise control switch for testing, the switch and its circuit wiring should be tested as a TEC input with the InfoCenter Display (see InfoCenter Display in this chapter). If the InfoCenter Display verifies that switch and circuit wiring are functioning correctly, no further switch testing is necessary. If, however, the Display determines that the switch and circuit wiring are not functioning correctly, proceed with test. 2. Make sure ignition switch is OFF. Remove key from ignition switch. 2 1 Figure 39 1. Control arm 2. Cruise control switch 3. Disassemble control arm to gain access to the cruise control switch (see Control Arm in the Service and Repairs section of Chapter 7 -- Chassis). 4. Disconnect harness electrical connector from the switch. 5. With the use of a multimeter (ohms setting), the switch functions may be tested to determine whether continuity exists between the various terminals for each position. The switch terminals are marked as shown in Figure 40. The circuitry of the cruise control switch is shown in the chart below. Verify continuity between switch terminals. SWITCH POSITION CLOSED CIRCUITS OPEN CIRCUITS CRUISE DISENGAGE NONE ALL CRUISE ON (CENTER) 2+3 5+6 SPEED SET (MOMENTARY) 2+3 5+6 NONE Electrical System Page 5 -- 36 BACK OF SWITCH Figure 40 Groundsmaster 4000--D/4010--D Seat Switch The seat switch is normally open and closes when the operator is on the seat. This switch is used as an input for the TEC controller. The seat switch and its electrical connector are located in the seat assembly. If the traction system or PTO switch is engaged when the operator raises out of the seat, an operator advisory will be displayed on the InfoCenter. Testing of the switch can be done without seat removal by disconnecting the switch wire from the machine wire harness (Fig. 41). 2 1 Testing 1. Before disconnecting the seat switch for testing, the switch and its circuit wiring should be tested as a TEC input with the InfoCenter Display (see InfoCenter Display in this chapter). If the InfoCenter verifies that the seat switch and circuit wiring are functioning correctly, no further switch testing is necessary. If, however, the InfoCenter determines that the seat switch and circuit wiring are not functioning correctly, proceed with test. Figure 41 1. Seat switch electrical connector 2. Operator seat 2. Make sure ignition switch is OFF. Remove key from ignition switch. 3. Disconnect seat switch connector from the machine wire harness connector. Electrical System 4. Check the continuity of the switch by connecting a multimeter (ohms setting) across the seat switch connector terminals. 5. With no pressure on the seat, there should be no continuity between the seat switch terminals. 6. Press directly onto the seat switch through the seat cushion. There should be continuity as the seat cushion approaches the bottom of its travel. 7. If testing determines that seat switch is faulty, replace seat switch (see Operator Seat Service in the Service and Repairs section of Chapter 7 -- Chassis). 8. Connect seat switch connector to wire harness connector after testing is complete. Groundsmaster 4000--D/4010--D Page 5 -- 37 Electrical System Parking Brake Switch The switch used for the parking brake is a normally open proximity switch that is located under the steering tower cover (Fig. 42). The parking brake switch is an input for the TEC controller. When the parking brake is not applied, a tab on the brake rod is positioned near the switch sense zone which causes the switch to close (continuity). When the parking brake is applied, the brake rod tab is positioned away from the switch allowing the switch to be in its normal, open position (no continuity). 34 to 42 in--lb (3.9 to 4.7 N--m) 6 Switch Testing 1 1. Before disconnecting the parking brake switch for testing, the switch and its circuit wiring should be tested as a TEC input with the InfoCenter Display (see InfoCenter Display in this chapter). If the InfoCenter verifies that the brake switch and circuit wiring are functioning correctly, no further switch testing is necessary. If, however, the InfoCenter determines that the brake switch and circuit wiring are not functioning correctly, proceed with test. 2 3 5 2. Make sure ignition switch is OFF. Remove key from ignition switch. 3. Remove front steering tower cover (see Steering Tower in the Service and Repairs section of Chapter 7 -- Chassis). 4 Figure 42 1. Lock nut 2. Parking brake switch 3. Switch plate 4. Carriage bolt 5. Parking brake rod 6. Steering tower cover 4. Locate parking brake switch and unplug wire harness connector from switch. 5. Check the continuity of the switch by connecting a multimeter (ohms setting) across the connector terminals. 6. When the parking brake is not applied (brake rod tab close to brake switch), there should be continuity (zero resistance) between the switch terminals. 7. When the parking brake is applied (brake rod tab away from brake switch), there should be no continuity (infinite resistance) between the switch terminals. 8. Replace parking brake switch if necessary. 9. Correctly connect the wire harness connector to the parking brake switch after testing is completed. 10.Install front steering tower cover (see Steering Tower in the Service and Repairs section of Chapter 7 -- Chassis). Switch Adjustment With the parking brake not applied (brake rod tab near the switch), there should be a 0.062” (1.6 mm) gap between the switch and the brake rod tab. Electrical System Page 5 -- 38 Groundsmaster 4000--D/4010--D Service Brake Switches The two (2) switches used for the service brakes are normally open switches that are located under the footrest panel (Fig. 43). The service brake switches provide inputs for the TEC controller. When a brake pedal is not depressed, the brake pedal assembly contacts the switch plunger to close the switch. When a brake is applied, the brake pedal assembly moves away from the switch plunger, allowing the switch plunger to extend and the switch to open. 13 to 17 in--lb (1.5 to 1.9 N--m) 3 2 1 5 4 Testing 6 1. Before disconnecting a service brake switch for testing, the switch and its circuit wiring should be tested as a TEC input with the InfoCenter Display (see InfoCenter Display in this chapter). If the InfoCenter verifies that the brake switch and circuit wiring are functioning correctly, no further switch testing is necessary. If, however, the InfoCenter determines that the brake switch and circuit wiring are not functioning correctly, proceed with test. 7 2. Make sure ignition switch is OFF. Remove key from ignition switch. 3. Remove brake cover and switch plate on operator platform to access service brake switches (Fig. 43). Figure 43 1. 2. 3. 4. Flange screw (3 used) Cover Switch bracket Brake switch (2 used) 5. Screw (2 per switch) 6. Switch nut (2 used) 7. Clip (3 used) 4. Disconnect switch electrical connector from the machine wire harness. Electrical System 5. Check the continuity of the switch by connecting a multimeter (ohms setting) across the connector terminals. 6. When the service brake switch plunger is depressed, there should be continuity (zero resistance) between the switch terminals. 7. When the service brake switch plunger is extended, there should be no continuity (infinite resistance) between the switch terminals. 8. Replace service brake switch if necessary. 9. Connect switch electrical connector to the machine wire harness after testing. Secure brake cover and switch plate to operator platform. Adjustment Adjust the service brake switch so that the switch plunger always makes full contact with the brake pedal. Tighten fasteners from 13 to 17 in--lb (1.5 to 1.9 N--m). Groundsmaster 4000--D/4010--D Page 5 -- 39 Electrical System Headlight Switch (Groundsmaster 4010--D) The Groundsmaster 4010--D headlight switch is a two (2) position rocker switch that is located on the inside of the control arm. The headlight switch allows the headlights and taillights to be turned on and off. 2 Testing 1. Make sure ignition switch is OFF. Remove key from ignition switch. 1 2. Disassemble control arm to gain access to headlight switch (see Control Arm in the Service and Repairs section of Chapter 7 -- Chassis). 3. Disconnect harness electrical connector from the headlight switch. 4. With the use of a multimeter (ohms setting), the switch functions may be tested to determine whether continuity exists between the various terminals for each switch position. The switch terminals are marked as shown in Figure 45. The circuitry of the switch is shown in the chart below. Verify continuity between switch terminals. Replace switch if testing identifies a faulty switch. SWITCH POSITION CIRCUIT 1 CIRCUIT 2 ON 2+3 5+6 OFF 2+1 5+4 Figure 44 1. Control arm 2. Headlight switch BACK OF SWITCH Figure 45 5. If the headlight switch tests correctly and circuit problem still exists, check wire harness (see Electrical Schematics and Wire Harness Drawings in Chapter 10 -Foldout Drawings). NOTE: Switch terminals 1, 4, 5 and 6 are not used on Groundsmaster 4010--D machines. 6. After testing is completed, connect wire harness connector to the headlight switch. 7. Assemble control arm (see Control Arm in the Service and Repairs section of Chapter 7 -- Chassis). Electrical System Page 5 -- 40 Groundsmaster 4000--D/4010--D Windshield Wiper/Washer Switch (Groundsmaster 4010--D) The windshield wiper/washer switch is used to control operation of the windshield wiper and washer pump on the Groundsmaster 4010--D. The windshield wiper/washer switch is located in the cab headliner (Fig. 46). 2 Testing 1. Make sure ignition switch is OFF. Remove key from ignition switch. 2. Remove switch plate from cab headliner. 3. Locate windshield wiper/washer switch and unplug wire harness connector from switch. 4. The switch terminals are marked as shown in Figure 47. The circuit logic of the wiper/washer switch is shown in the chart below. With the use of a multimeter (ohms setting), the switch functions may be tested to determine whether continuity exists between the various terminals for each position. Verify continuity between switch terminals. Replace wiper/washer switch if testing identifies a faulty switch. CLOSED CIRCUITS OPEN CIRCUITS OFF 2+1 5+6 WIPER ON 2+3 5+6 WASHER and WIPER ON (MOMENTARY) 2+3 5+6 2+1 Figure 46 1. Cab headliner 2. Wiper/washer switch BACK OF SWITCH Electrical System SWITCH POSITION 1 Figure 47 5. If switch tests correctly and circuit problem still exists, check wire harness (see Electrical Schematics and Wire Harness Drawings in Chapter 10 -- Foldout Drawings). 6. Connect the wire harness connector to the switch after testing. 7. Install switch plate to cab headliner after switch testing is complete. Groundsmaster 4000--D/4010--D Page 5 -- 41 Electrical System Air Conditioning Switch (Groundsmaster 4010--D) The air conditioning switch is used to control operation of the air conditioning system on the Groundsmaster 4010--D. The switch is located in the cab headliner (Fig. 48). Testing 1. Make sure ignition switch is OFF. Remove key from ignition switch. 2 2. Remove switch plate from cab headliner. 3. Locate air conditioning switch and unplug wire harness connector from switch. 4. The switch terminals are marked as shown in Figure 49. The circuit logic of the air conditioning switch is shown in the chart below. With the use of a multimeter (ohms setting), the switch functions may be tested to determine whether continuity exists between the various terminals for each position. Verify continuity between switch terminals. Replace switch if testing identifies a faulty switch. SWITCH POSITION CLOSED CIRCUITS OPEN CIRCUITS AC OFF 2+1 5+4 2+3 5+6 AC ON 2+3 5+6 2+1 5+4 1 Figure 48 1. Cab headliner 2. Air conditioning switch BACK OF SWITCH 5. If switch tests correctly and circuit problem still exists, check wire harness (see Electrical Schematics and Wire Harness Drawings in Chapter 10 -- Foldout Drawings). Figure 49 6. Connect the wire harness connector to the air conditioning switch after testing. 7. Install switch plate to cab headliner after switch testing is complete. Electrical System Page 5 -- 42 Groundsmaster 4000--D/4010--D Turn Signal Switch (Groundsmaster 4010--D) On Groundsmaster 4010--D machines, the turn signal switch is used as an input for the TEC controller to provide power for the turn signals. The switch is located on the steering tower (Fig. 50). Testing 1. Before disconnecting the turn signal switch for testing, the switch and its circuit wiring should be tested as a TEC input with the InfoCenter Display (see InfoCenter Display in this chapter). If the InfoCenter verifies that the turn signal switch and circuit wiring are functioning correctly, no further switch testing is necessary. If, however, the InfoCenter determines that the turn signal switch and circuit wiring are not functioning correctly, proceed with test. 2. Make sure ignition switch is OFF. Remove key from ignition switch. 1 2 Figure 50 1. Steering column 2. Turn signal switch 3. Remove front steering tower cover (see Steering Tower in the Service and Repairs section of Chapter 7 -- Chassis). 4. Locate turn signal switch and unplug wire harness connector from switch. SWITCH POSITION CLOSED CIRCUITS OPEN CIRCUITS RIGHT TURN 2+3 5+6 2+1 5+4 NEUTRAL NONE ALL LEFT TURN 2+1 5+4 2+3 5+6 BACK OF SWITCH Figure 51 Electrical System 5. The switch terminals are marked as shown in Figure 51. The circuit logic of the turn signal switch is shown in the chart below. With the use of a multimeter (ohms setting), the switch functions may be tested to determine whether continuity exists between the various terminals for each position. Verify continuity between switch terminals. Replace turn signal switch if testing identifies a faulty switch. 6. Connect the harness connector to the switch after testing. 7. If switch tests correctly and circuit problem still exists, check wire harness (see Electrical Schematics and Wire Harness Drawings in Chapter 10 -- Foldout Drawings). 8. Install front steering tower cover (see Steering Tower in the Service and Repairs section of Chapter 7 -- Chassis). Groundsmaster 4000--D/4010--D Page 5 -- 43 Electrical System Flasher Switch (Groundsmaster 4010--D) On Groundsmaster 4010--D machines, the flasher switch is used as an input for the TEC controller to provide power for the four way flashers. The switch is located on the steering tower (Fig. 52). 2 Testing 1. Before disconnecting the flasher switch for testing, the switch and its circuit wiring should be tested as a TEC input with the InfoCenter Display (see InfoCenter Display in this chapter). If the InfoCenter verifies that the flasher switch and circuit wiring are functioning correctly, no further switch testing is necessary. If, however, the InfoCenter determines that the flasher switch and circuit wiring are not functioning correctly, proceed with test. 2. Make sure ignition switch is OFF. Remove key from ignition switch. 1 Figure 52 1. Steering column 2. Flasher switch 3. Remove front steering tower cover (see Steering Tower in the Service and Repairs section of Chapter 7 -- Chassis). 4. Locate flasher switch and unplug wire harness connector from switch. 5. The switch terminals are marked as shown in Figure 53. The circuit logic of the flasher switch is shown in the chart below. With the use of a multimeter (ohms setting), the switch functions may be tested to determine whether continuity exists between the various terminals for each position. Verify continuity between switch terminals. Replace flasher switch if testing identifies a faulty switch. SWITCH POSITION CLOSED CIRCUITS OPEN CIRCUITS ON (LIGHT END DEPRESSED) 2+3 5+6 2+1 5+4 OFF 2+1 5+4 2+3 5+6 BACK OF SWITCH Figure 53 6. Connect the harness connector to the switch after testing. 7. If switch tests correctly and circuit problem still exists, check wire harness (see Electrical Schematics and Wire Harness Drawings in Chapter 10 -- Foldout Drawings). 8. Install front steering tower cover (see Steering Tower in the Service and Repairs section of Chapter 7 -- Chassis). Electrical System Page 5 -- 44 Groundsmaster 4000--D/4010--D Traction Pedal Position Sensor The traction pedal position sensor is connected to the traction pedal assembly (Fig. 54). This position sensor determines the neutral band for the traction pedal, the direction of travel desired by the operator and the traction speed. The position sensor is a single analog, dual digital signal electronic device. The position sensor portion is a variable resistor that provides an analog signal for the TEC controller to determine the desired ground speed based on how far the traction pedal is moved. The traction pedal position sensor also houses two (2) switches that are used to determine the neutral position (deadband) and the indicated direction of travel (forward or reverse). As the traction pedal is depressed, the internal wiper of the position sensor moves and sends the analog signal to the TEC controller to determine machine direction and speed. The traction pedal position sensor must be calibrated with the TEC controller to determine the neutral and full speed set points for both the forward and reverse directions. The position sensor calibration process can be completed using the InfoCenter display. 1 2 Figure 54 1. Traction pedal 2. Pedal position sensor A properly installed and calibrated traction pedal position sensor is critical to accurate traction response and position sensor life. Use care when installing and calibrating the position sensor. Groundsmaster 4000--D/4010--D Page 5 -- 45 Electrical System Before suspecting a faulty position sensor, the sensor and its circuit wiring should be tested as a TEC input with the InfoCenter Display (see InfoCenter Display in this chapter). If necessary, follow calibration procedures for the traction pedal position sensor found in the Adjustments section of this chapter. If position sensor replacement is necessary, refer to Traction Pedal in the Service and Repairs section of Chapter 7 -- Chassis. Electrical System Relays with Four (4) Terminals Your Groundsmaster uses a number of electrical relays that have four (4) terminals. A tag near the wire harness relay connector can be used to identify each relay. The main power relay is used to provide current to most of the fuse protected circuits (operator seat, InfoCenter display, power point and optional electric equipment). The main power relay is energized when the ignition switch is in the RUN or START position. 4 3 The TEC power relay is used to provide current to the fuse protected circuits for the TEC controller. The TEC power relay is energized when the ignition switch is in the RUN or START position. The cab power relay is used on Groundsmaster 4010--D machines to provide current to the operator cab electrical components. The cab power relay is energized when the ignition switch is in the RUN or START position. The start relay is used to provide current to the engine starter motor solenoid. The start relay is energized by the engine ECU. 1 2 Figure 55 1. Main power relay 2. TEC power relay MODELS 30603 AND 30605 2 The air heater relay is used on models 30603 and 30605 to provide current for the engine air heater used for starting a cold engine. When necessary, the air heater relay is energized by the engine ECU. 4 The glow relay is used on models 30607 and 30609 to provide current to the engine glow plugs when energized by the engine ECU. The main power, TEC power and cab power relays are located under the controller cover next to the operator seat (Fig. 55). The start, air heater and glow relays are attached to the controller mount on the right side of the engine (Fig. 56 or 57). 3. Cab power relay 4. Operator seat 1 3 Figure 56 1. Controller mount 2. Engine ECU 3. Start relay 4. Air heater relay MODELS 30607 AND 30609 Testing 1. Park machine on a level surface, lower cutting decks, stop engine, engage parking brake and remove key from the ignition switch. 4 2. To make sure that machine operation does not occur unexpectedly, disconnect negative (--) cable from battery and then disconnect positive (+) cable from battery (see Battery Service in the Service and Repairs section of this chapter). 2 1 3 3. Locate relay that is to be tested. 4. Disconnect wire harness connector from relay. Remove relay from mounting bracket for testing. Electrical System Figure 57 1. Controller mount 2. Engine ECU Page 5 -- 46 3. Start relay 4. Glow relay Groundsmaster 4000--D/4010--D 5. Using a multimeter, verify that coil resistance between terminals 86 and 85 is approximately 72 ohms. 6. Connect multimeter (ohms setting) leads to relay terminals 30 and 87. Ground terminal 86 and apply +12 VDC to terminal 85. The relay should make and break continuity between terminals 30 and 87 as +12 VDC is applied and removed from terminal 85. 86 87 30 85 85 30 86 87 7. Disconnect voltage and test leads from the relay terminals. 8. Secure relay to mounting bracket and connect wire harness connector to relay. Figure 58 9. Secure all removed components to machine. Electrical System 10.Connect positive (+) cable to battery and then connect negative (--) cable to battery (see Battery Service in the Service and Repairs section of this chapter). Groundsmaster 4000--D/4010--D Page 5 -- 47 Electrical System Relays with Five (5) Terminals Your Groundsmaster uses a number of electrical relays that have five (5) terminals. A tag near the wire harness relay connector can be used to identify each relay. The air conditioning relay is used to control the air conditioning electrical power circuit on the Groundsmaster 4010--D. When energized by the air conditioning switch, the relay provides current for the air conditioning components. MODELS 30603 AND 30605 2 4 The main relay is used on models 30603 and 30605 to provide current for several engine components when energized by the engine ECU. The rack actuator relay is used on models 30603 and 30605 to provide current for the engine rack actuator when energized by the engine ECU. The EGR relay is used on models 30607 and 30609 to provide current to the engine EGR valve when energized by the engine ECU. 3 1 Figure 59 1. Controller mount 2. Engine ECU 3. Main relay 4. Rack actuator relay MODELS 30607 AND 30609 The air conditioning relay is attached to the cab headliner above the switch panel. The main, rack actuator and EGR relays are attached to the controller mount on the right side of the engine (Fig. 59 or 60). Testing 1. Park machine on a level surface, lower cutting decks, stop engine, engage parking brake and remove key from the ignition switch. 2. To make sure that machine operation does not occur unexpectedly, disconnect negative (--) cable from battery and then disconnect positive (+) cable from battery (see Battery Service in the Service and Repairs section of this chapter). 3 2 1 Figure 60 1. Controller mount 2. Engine ECU 3. EGR relay 3. Locate relay that is to be tested. 4. Disconnect wire harness connector from relay. Remove relay from mounting bracket for testing. 5. Using a multimeter, verify that coil resistance between terminals 85 and 86 is from 71 to 88 ohms. 86 6. Connect multimeter (ohms setting) leads to relay terminals 30 and 87. Ground terminal 86 and apply +12 VDC to terminal 85. The relay should make and break continuity between terminals 30 and 87 as +12 VDC is applied and removed from terminal 85. 7. Disconnect voltage from terminal 85 and multimeter lead from terminal 87. Electrical System 3 1 85 4 87A 87 30 2 1 Figure 61 1. Coil terminal 2. Common terminal Page 5 -- 48 3. Normally closed term. 4. Normally open term. Groundsmaster 4000--D/4010--D 8. Connect multimeter (ohms setting) leads to relay terminals 30 and 87A. Apply +12 VDC to terminal 85. The relay should make and break continuity between terminals 30 and 87A as +12 VDC is applied and removed from terminal 85. 10.Secure all removed components to machine. 11. Connect positive (+) cable first to battery and then connect negative (--) cable to battery (see Battery Service in the Service and Repairs section of this chapter). Electrical System 9. After testing, disconnect voltage and multimeter test leads from the relay terminals. Secure relay to mounting bracket and connect wire harness connector to relay. Groundsmaster 4000--D/4010--D Page 5 -- 49 Electrical System Toro Electronic Controllers (TEC) Groundsmaster 4000--D and 4010--D machines use two (2) Toro Electronic Controllers (TEC) to control electrical system operation. The controllers are attached to the operator platform under the controller cover (Figs. 64 and 65). 2 3 1 8 Logic power is provided to the controllers as long as the battery cables are connected to the battery. A pair of 2 Amp fuses (fuse D--1 for the front controller and fuse D--2 for the rear controller) provide circuit protection for this logic power to the controllers. 10 4 6 The front TEC controller monitors the states of the following components as inputs: ignition switch, traction pedal position sensor, parking brake switch, HI/LOW speed switch, service brake switches, seat switch, engine speed switch, hydraulic temperature sender, turn signal switch (if equipped) and hazard switch (if equipped). The front TEC controller controls electrical output to the engine ECU (start and run functions), fan drive solenoid coils (direction and flow source), traction (piston) pump solenoids (forward and reverse) and traction solenoid coil (HI/LOW speed). Additionally, electrical outputs for brake lights, turn lights and warning lights on Groundsmaster 4010--D machines are provided by the front TEC controller. Circuit protection for front TEC outputs is provided by three (3) 7.5 Amp fuses (fuse locations A--1, B--1 and C--1). The rear TEC controller monitors the states of the following components as inputs: ignition switch, cutting deck lift switches, PTO switch, cruise control switch and deck position switches. 7 9 11 5 FRONT Figure 64 1. 2. 3. 4. 5. 6. Controller cover Screw (2 used) Flat washer (2 used) Flange screw (2 used) Power mount Relay mount 7. 8. 9. 10. 11. Carriage screw (8 used) Flange nut (8 used) Front TEC controller Rear TEC controller Operator platform The rear TEC controller controls electrical output to the PTO solenoid coils, lift/lower solenoid coils and fan drive solenoid coil (speed). Circuit protection for rear TEC outputs is provided by three (3) 7.5 Amp fuses (fuse locations A--2, B--2 and C--2). 3 The InfoCenter display should be used to check inputs and outputs of the TEC controllers. Information on using the InfoCenter is included in the InfoCenter Display section of this chapter. The diagram in Figure 66 depicts the connection terminal functions for the TEC controllers. Note that electrical power for controller outputs is provided through three (3) connectors (PWR 2, PWR 3 and PWR 4) each protected with a 7.5 amp fuse. A fifty (50) pin wire harness connector attaches to the controller. The connector pins are identified in the diagram in Figure 66. The layout of the wire harness connectors that plug into the TEC controllers is shown in Fig. 67. Electrical System 1 2 Figure 65 1. Front TEC controller 2. Rear TEC controller Page 5 -- 50 3. Operator seat Groundsmaster 4000--D/4010--D 12V POWER (7.5A FUSES) 12V LOGIC POWER (2 AMP FUSE) VOLTAGE OUT The machine electrical schematic and wire harness drawings in Chapter 10 -- Foldout Drawings can be used to identify possible circuit problems between the controllers and the input/output devices (e.g. switches and solenoid coils). IGNITION SWITCH INPUTS Because of the solid state circuitry built into the TEC controllers, there is no method to test a controller directly. A controller may be damaged if an attempt is made to test it with an electrical test device (e.g. digital multimeter or test light). OUTPUTS (PWR 3) OUTPUTS (PWR 4) DIGITAL INPUTS (OPEN/ CLOSED) If removal of the TEC controllers is necessary, label the controllers to make sure they are properly connected to the machine. The two (2) TEC controllers are visually identical but they have different software and therefore cannot be interchanged. The power mount (item 5 in Fig. 64) can be separated from the operator platform and carefully lifted from the platform to access the controller fasteners. COMM PORT CAN BUS GROUND ANALOG INPUTS (VARIABLE) NOTE: The TEC controllers used on the Groundsmaster 4000--D and 4010--D are matched for correct machine operation. If either of these components are replaced for any reason, system software needs to be reprogrammed by your Toro Distributor. IMPORTANT: Before performing any welding on your Groundsmaster, disconnect both positive and negative battery cables from the battery, disconnect the wire harness connector from both of the TEC controllers and disconnect the terminal connector from the alternator. Also, disconnect and remove the engine ECU from the machine before welding. These steps will prevent damage to the machine electrical system. OUTPUTS (PWR 2) Figure 66 Electrical System IMPORTANT: When testing for wire harness continuity at the connector for the TEC controller, take care to not damage the connector pins with multimeter test leads. If connector pins are enlarged or damaged during testing, connector repair will be necessary for proper machine operation. WIRE HARNESS CONNECTOR FOR TEC CONTROLLERS 41 50 40 31 21 30 11 20 1 NOTE TAB POSITION 10 Figure 67 Groundsmaster 4000--D/4010--D Page 5 -- 51 Electrical System Hydraulic Solenoid Valve Coils 2 4 1 RIGHT FRONT 3 Figure 66 1. Front PTO manifold 2. RH PTO manifold 3. LH PTO manifold Several hydraulic solenoid valve coils are used on the hydraulic control manifolds of Groundsmaster 4000--D and 4010--D machines. When energized by the TEC controller, these coils provide hydraulic circuit control. Solenoid valve coils with two (2) different resistance specifications are used on the 4000--D and 4010--D. The correct resistance of a coil can be identified by measuring the height and diameter of the coil (Fig. 67). Resistance testing of the coils can be done with the coil remaining on the hydraulic valve. Electrical System 4. Combination manifold NOTE: To assist in troubleshooting, identical solenoid coils can be exchanged. If the problem follows the exchanged coil, a problem with the coil likely exists. If the problem remains unchanged, something other than the solenoid coil is the problem source (e.g. switch, circuit wiring, hydraulic problem). Refer to your parts catalog to determine if solenoid coils are identical. Page 5 -- 52 Groundsmaster 4000--D/4010--D Testing 1. Park machine on a level surface, lower cutting decks, stop engine, engage parking brake and remove key from the ignition switch. 2. Locate hydraulic solenoid valve coil to be tested (Fig. 66). Disconnect wire harness connector from coil. 3. Identify coil resistance specification by measuring the coil diameter and coil height (Fig. 67). COIL DIAMETER NOTE: Prior to taking small resistance readings with a digital multimeter, short the meter test leads together. The meter will display a small resistance value (usually 0.5 ohms or less). This resistance is due to the internal resistance of the meter and test leads. Subtract this value from from the measured value of the component you are testing. COIL HEIGHT 4. Using a multimeter (ohms setting), measure resistance between the two (2) connector terminals on the solenoid valve coil. The correct resistance for the solenoid coil is identified below: COIL DIAMETER COIL HEIGHT COIL RESISTANCE 1.34 in (34.0 mm) 1.53 in (38.9 mm) 5.4 ohm 1.84 in (46.7 mm) 1.96 in (49.9 mm) 7.1 ohm 1.41 in (35.8 mm) 1.43 in (36.3 mm) 8.8 ohm Figure 67 1 5 ft--lb (6.7 N--m) NOTE: Solenoid valve coil resistance should be measured with solenoid at approximately 68oF (20oC). Resistance may be slightly different than listed at different temperatures. Typically, a failed solenoid coil will either be shorted (very low or no resistance) or open (infinite resistance). 3 4 LH PTO MANIFOLD SHOWN 5. If solenoid valve coil resistance is incorrect, replace solenoid coil: A. Remove nut securing solenoid coil to the cartridge valve. Carefully slide coil off the valve. Electrical System 2 Figure 68 1. Hydraulic manifold 2. Cartridge valve 3. Solenoid coil 4. Nut B. Install new solenoid coil to the cartridge valve. Install and torque nut 5 ft--lb (6.7 N--m). Over--tightening may damage the solenoid coil or cause the cartridge valve to malfunction. 6. After testing is completed, connect wire harness connector to the solenoid coil. Groundsmaster 4000--D/4010--D Page 5 -- 53 Electrical System Piston (Traction) Pump Control Solenoid Coils The piston (traction) pump uses an electronic control assembly for swash plate rotation. Electrical outputs from the machine TEC controller are provided to two (2) solenoid coils for pump control. The piston pump control assembly is attached to the left side of the piston pump (Fig. 69). C. Slide new coil with O--rings onto the solenoid stem. NOTE: To assist in troubleshooting, the piston pump solenoid coils can be exchanged because they are identical. If the problem follows the exchanged coil, a problem with the coil likely exists. If the problem remains unchanged, something other than the solenoid coil is the problem source (e.g. traction pedal, circuit wiring, hydraulic problem). 5. After testing is completed, connect wire harness connector to the solenoid coil. D. Use a 12 point, 26 mm socket to install and torque coil nut to 44 in--lb (5 N--m) (do not over--tighten coil nut). 1 2 RIGHT FRONT Solenoid Coil Testing 1. Park machine on a level surface, lower cutting decks, stop engine, engage parking brake and remove key from the ignition switch. 2. Locate piston pump solenoid coil to be tested (Fig. 69). Disconnect wire harness connector from solenoid coil. NOTE: Prior to taking small resistance readings with a digital multimeter, short the meter test leads together. The meter will display a small resistance value (usually 0.5 ohms or less). This resistance is due to the internal resistance of the meter and test leads. Subtract this value from from the measured value of the component you are testing. 3 Figure 69 1. Piston pump 2. Forward solenoid coil 2 3. Using a multimeter (ohms setting), measure resistance between the two (2) connector terminals on the solenoid coil. Solenoid coil resistance should be 3.66 ohms. 3. Reverse solenoid coil 1 2 3 NOTE: Solenoid coil resistance should be measured with solenoid at approximately 68oF (20oC). Resistance may be slightly different than listed at different temperatures. Typically, a failed solenoid coil will either be shorted (very low or no resistance) or open (infinite resistance). 2 1 2 4. If solenoid coil resistance is incorrect, replace coil: A. Use a 12 point, 26 mm socket to loosen and remove the coil nut that secures solenoid coil. B. Slide solenoid coil and O--rings from valve stem. Clean all corrosion or dirt from the valve. Electrical System 3 Figure 70 1. Solenoid coil 2. O--ring Page 5 -- 54 3. Coil nut Groundsmaster 4000--D/4010--D CAN--bus Termination Resistor System communication between electrical components on Groundsmaster 4000--D and 4010--D machines is accomplished on a CAN--bus communication system. Two (2) specially designed, twisted wires form the bus for the network used on the machine. These wires provide the data pathways between machine components. At the end of the twisted pair of bus wires near the InfoCenter display is a 120 ohm termination resistor. The CAN--bus termination resistor plugs into the platform wire harness in the control arm. The resistor can be accessed by removing the cover plate on the right side of the control arm. The wire harness connector has a blue insert to identify the proper location for the termination resistor. Termination Resistor A B C Figure 73 NOTE: The Groundsmaster 4000--D and 4010--D engine ECU includes the second CAN--bus system termination resistor. This resistor cannot be accessed for testing. NOTE: Refer to the Electrical Schematics and Wire Harness Drawings in Chapter 10 -- Foldout Drawings for additional information on termination resistor location and wire connections. IMPORTANT: The termination resistor is required for proper electrical system operation. Termination Resistor Test Groundsmaster 4000--D/4010--D Page 5 -- 55 Electrical System The termination resistor (Fig. 73) can be tested using a digital multimeter (ohms setting). There should be 120 ohms resistance between terminals A and B of the termination resistor. Terminal C is not used on Groundsmaster 4000--D and 4010--D machines. Electrical System Diode Assemblies The Groundsmaster engine wire harness contains a diode assembly that is used for circuit protection from voltage spikes when the engine starter solenoid is de-energized. 1 4 2 Groundsmaster models 30607 and 30609 use an additional diode assembly in the engine wire harness that protects the engine EGR circuit from reverse polarity. The diode assemblies plug into the wiring harness near the engine starter motor (see engine wire harness drawing in Chapter 10 -- Foldout Drawings). The diode assemblies can be identified by a black color and diode symbol on end of diode assembly body. Testing The diode can be tested using a digital multimeter (diode test or ohms setting) and the table to the right. 3 Figure 72 1. Diode assembly 2. Male terminal 3. Female terminal 4. End of diode body Multimeter Red Lead (+) on Terminal Multimeter Black Lead (--) on Terminal Continuity Female Male YES Male Female NO Resistor Assembly On Groundsmaster machines with an 80 Amp alternator (see Engine Specifications in Chapter 3 -- Yanmar Diesel Engine), the engine wire harness contains a resistor that is necessary for ignition switch operation. The resistor plugs into the wiring harness near the engine starter motor (see engine wire harness drawing in Chapter 10 -- Foldout Drawings). 2 1 The resistor assembly can be identified by its gray color and resistor symbol on end of resistor assembly body. Testing The resistor can be tested using a digital multimeter (ohms setting). The resistance across the resistor terminals should be 1.6K ohms. Electrical System Figure 73 1. Resistor assembly Page 5 -- 56 2. End of resistor body Groundsmaster 4000--D/4010--D Fuel Sender The fuel sender is attached to the top of the fuel tank. The resistance of the fuel sender increases as the fuel level in the fuel tank decreases. The TEC controller uses the fuel sender as an input to generate an output for the InfoCenter fuel gauge. Two (2) styles of fuel senders have been used on Groundsmaster 4000--D and 4010--D machines. Early production machines are equipped with a pivoting float design that has two (2) wire harness terminals (shown in Fig. 74). Later machines have a sliding float design and a single harness connector. Testing 1. Make sure ignition switch is OFF. Remove key from ignition switch. 2. Disconnect wire harness connector(s) at fuel sender. 6. Using a multimeter, check resistance of the sender with the float in the full and empty positions. Expected resistance values are shown in the table below. CONNECTOR STYLE RESISTANCE (FULL) RESISTANCE (EMPTY) Two Terminals 27.5 to 39.5 Ohms 240 to 260 Ohms Single Connector 28 to 33 Ohms 240 to 250 Ohms 7. Replace sender as necessary. Carefully install sender into fuel tank and secure with removed fasteners. 8. Secure wire harness connector(s) to fuel sender. On two (2) terminal senders, apply skin--over grease (see Special Tools in this chapter) to sender terminals. 3 CAUTION 1 If testing circuit wiring, make sure wire connections at fuel sender are secure before turning ignition switch to RUN to prevent an explosion or fire from sparks. Figure 74 1. Fuel sender 2. White (+) lead 4. Remove screws and lock washers that secure the fuel sender to the fuel tank. 5. Carefully remove fuel sender and gasket from the fuel tank. Clean all fuel from the sender. NOTE: Before taking small resistance readings with a digital multimeter, short meter test leads together. The meter will display a small resistance value. This internal resistance of the meter and test leads should be subtracted from the measured value of the component. 3. Black (--) lead TWO TERMINAL SENDER SINGLE CONNECTOR SENDER FULL POSITION CAUTION Make sure fuel sender is completely dry (no fuel on it) before testing. Perform test away from the fuel tank to prevent an explosion or fire from sparks. Groundsmaster 4000--D/4010--D Page 5 -- 57 EMPTY POSITION SLIDING FLOAT Figure 75 Electrical System Electrical System 3. To test the circuit wiring and InfoCenter fuel gauge, use a jumper wire to connect the two (2) harness wires leading to the fuel sender and turn ignition switch to RUN. InfoCenter fuel gauge should indicate full. Turn ignition switch OFF and continue testing fuel sender if circuit wiring and gauge are acceptable. 2 Fuel Pump (Models 30603 and 30605) The fuel pump is attached to the fuel tank support above the fuel water separator (Fig. 76). 2 Operational Test 4 1. Park machine on a level surface, lower cutting decks, stop engine and apply parking brake. Raise hood to access fuel pump. 3 2. Disconnect fuel pump discharge hose from the fuel injection pump fitting on the engine (Fig. 77). 3. Make sure fuel hoses attached to the fuel pump are free of obstructions. 4. Place disconnected end of fuel pump discharge hose into a large, graduated cylinder sufficient enough to collect 1 quart (0.95 liter). IMPORTANT: When testing fuel pump output, do not turn ignition switch to the START position. 1 Figure 76 1. Fuel water separator 2. Fuel pump 3. Pump inlet hose 4. Pump discharge hose 5. Collect fuel in the graduated cylinder by turning ignition switch to the RUN position. Allow pump to run for fifteen (15) seconds, then turn switch to OFF. 1 4 6. The amount of fuel collected in the graduated cylinder should be approximately 16 fl oz (475 ml) after fifteen (15) seconds. 3 7. Replace fuel pump as necessary. 2 IMPORTANT: If fuel pump is replaced, make sure that replacement pump is the correct pump for your Groundsmaster by using your Parts Catalog. If incorrect pump is used, fuel system components can be damaged. 8. Install fuel hose to the water separator and secure with hose clamp. 9. Prime fuel system (see Fuel System in the Service and Repairs section of Chapter 3 -- Yanmar Diesel Engine). 10.Lower and secure hood. Figure 77 1. Tier 4i engine 2. Hose clamp Fuel Pump Specifications Pump Capacity Pressure Current Draw Electrical System 3. Fuel supply hose 4. Fuel return hose Page 5 -- 58 64 fl oz/min (1.9 l/min) 7 PSI (48.3 kPa) 2.0 Amp Groundsmaster 4000--D/4010--D Fuel Pump (Models 30607 and 30609) The fuel pump is attached to the fuel tank support above the fuel water separator (Fig. 78). Operational Test 2 1. Park machine on a level surface, lower cutting decks, stop engine and apply parking brake. Raise hood to access fuel pump. 2. Disconnect fuel pump discharge hose from the fuel filter attached to the engine (Fig. 79). 3 3. Make sure fuel hoses attached to the fuel pump are free of obstructions. 4. Place disconnected end of fuel pump discharge hose into a large, graduated cylinder sufficient enough to collect 1 quart (0.95 liter). IMPORTANT: When testing fuel pump output, do not turn ignition switch to the START position. 4 1 Figure 78 1. Fuel water separator 2. Fuel pump 3. Pump inlet hose 4. Pump discharge 5. Collect fuel in the graduated cylinder by turning ignition switch to the RUN position. Allow pump to run for thirty (30) seconds, then turn switch to OFF. 2 6. The amount of fuel collected in the graduated cylinder should be approximately 11.8 fl oz (350 ml) after thirty (30) seconds. 1 IMPORTANT: If fuel pump is replaced, make sure that replacement pump is the correct pump for your Groundsmaster by using your Parts Catalog. If incorrect pump is used, fuel system components can be damaged. 3 8. Install fuel hose to the engine mounted fuel filter and secure with hose clamp. 9. Prime fuel system (see Fuel System in the Service and Repairs section of Chapter 3 -- Yanmar Diesel Engine). Figure 79 1. Tier 4 engine 2. Hose clamp 3. Pump discharge hose 4. Fuel return hose Fuel Pump Specifications 10.Lower and secure hood. Pump Capacity Pressure Current Draw Groundsmaster 4000--D/4010--D Page 5 -- 59 23.5 fl oz/min (700 ml/min) 3.3 PSI (22.8 kPa) 0.9 Amp Electrical System Electrical System 4 7. Replace fuel pump as necessary. Cutting Deck Position Switches Three (3) cutting deck position switches are used on the Groundsmaster 4000--D and 4010--D. These switches are located on the traction unit frame (Figs. 80 and 81). The position switches are powered proximity switches that incorporate an internal reed switch and a LED. The deck position switches are used as inputs for the TEC controller to prevent deck operation when a cutting deck is raised. The switch sensing plates are attached to the cutting deck lift arms. The position switches for front and side decks are different. The single front cutting deck position switch is a normally closed switch. When the front cutting deck is lowered, the sensing plate on the lift arm is away from the position switch so the switch is in its normally closed state. When the front cutting deck is raised, the sensing plate is moved near the position switch and the switch opens. 4 3 2 1 Figure 80 1. Front lift arm 2. Position switch 3. Sensing plate 4. Switch LED The two (2) side cutting deck position switches are normally open switches. When a side cutting deck is lowered, the sensing plate on the lift arm is near the position switch and the switch closes. When a side cutting deck is raised, the sensing plate is moved away from the position switch so the switch is in its normally open state. 3 2 Testing 1. The cutting deck position switches and their circuit wiring should be tested as a TEC input with the InfoCenter Display (see InfoCenter Display in this chapter). If the InfoCenter verifies that the position switches and circuit wiring are functioning correctly, no further switch testing is necessary. If, however, the InfoCenter determines that a position switch and circuit wiring are not functioning correctly, proceed with test. 2. Park machine on a level surface, lower cutting decks, stop engine and apply parking brake. 1 4 5 Figure 81 1. Side lift arm (RH shown) 2. Position switch 3. Sensing plate 4. Switch LED 5. Clearance 3. Turn ignition switch to the RUN position (do not start engine) and check LED on cable end of position switches (Fig. 80 or 81). Switch LED should be illuminated when the cutting decks are fully lowered. C. Using a multimeter, verify that wire harness connector terminal for pink wire has 12 VDC when the ignition switch is RUN. 4. Start engine, fully raise cutting decks and then stop engine. Then, turn ignition switch to the RUN position (do not start engine) and check LED on cable end of position switches. Switch LED should not be illuminated when the cutting decks are fully raised. D. Make sure that clearance between end of position switch and sensing plate is from 0.070” to 0.130” (1.8 to 3.3 mm). If necessary, adjust position switch (see Cutting Deck Position Switches in the Adjustments section of this chapter). Recheck switch operation after adjustment. 5. If a position switch LED did not function correctly: A. Position cutting deck so sensing plate on the lift arm is near the position switch (front cutting deck raised and side cutting decks lowered). E. If pink wire has system voltage present and gap is correct but switch LED does not function, replace position switch. 6. After testing is complete, make sure that position switch connector is plugged into wire harness. B. Make sure that ignition switch is OFF and disconnect the switch connector from wire harness. Electrical System Page 5 -- 60 Groundsmaster 4000--D/4010--D Hydraulic Oil Temperature Sender The Groundsmaster 4000--D and 4010--D use a temperature sender as an input for the TEC controller to identify if the hydraulic oil temperature has reached an excessive level. The hydraulic oil temperature sender is attached to the bottom of the rear axle motor (Fig. 82). The InfoCenter will display fault code 18 if the hydraulic oil temperature sender inputs to the TEC controller are not in the normal range. 5. After allowing the sender to cool, install sender: A. Install new O--ring on sender. B. Install sender into port and torque from 9 to 11 ft-lb (12.3 to 14.9 N--m). C. Connect wire harness connector to sender. 6. Check and fill hydraulic system to proper level. Testing 1. Locate temperature sender in rear axle motor. Disconnect wire harness connector from sender. RIGHT 1 FRONT 2. Place suitable drain pan under temperature sender in rear axle motor. Thoroughly clean area around temperature sender and remove sender from axle motor. 3. Put sensing end of sender in a container of oil with a thermometer and slowly heat the oil (Fig. 83). CAUTION 2 Handle the hot oil with extreme care to prevent personal injury or fire. 2. Oil temp sender Electrical System NOTE: Prior to taking resistance readings with a digital multimeter, short the meter test leads together. The meter will display a small resistance value (usually 0.5 ohms or less). This resistance is due to the internal resistance of the meter and test leads. Subtract this value from from the measured value of the component you are testing. Figure 82 1. Rear axle motor 4. Check resistance of the sender with a multimeter (ohms setting) as the oil temperature increases. A. The meter should indicate from 11.6 to 13.5 kilo ohms at 68oF (20oC). B. The meter should indicate from 2.3 to 2.5 kilo ohms at 140oF (60oC). C. The meter should indicate from 605 to 669 ohms at 212oF (100oC). Figure 83 D. Replace sender if specifications are not met. Groundsmaster 4000--D/4010--D Page 5 -- 61 Electrical System Audio Alarm The audio alarm sounds to notify the operator when a machine problem exists. Electrical current for the alarm is provided as an output from the TEC controller. The alarm is attached to the control arm next to the operator seat. 4 Testing 1. Make sure ignition switch is OFF. Remove key from ignition switch. 2. Disassemble control arm to gain access to the audio alarm (see Control Arm in the Service and Repairs section of Chapter 7 -- Chassis). 1 3 2 Figure 84 1. Alarm top view 2. Alarm bottom view 3. Positive (+) terminal 4. Negative (--) terminal 3. Disconnect wire harness connector from alarm. IMPORTANT: Make sure to observe polarity on the alarm terminals when testing. Damage to the alarm may result from an improper connection. 4. Correctly connect 12VDC source to the alarm terminals (Fig. 84). 5. Alarm should sound as long as 12VDC is connected to the alarm terminals. 6. Disconnect voltage source from the alarm. Reconnect harness connector to alarm. 7. Assemble control arm (see Control Arm Assembly in the Service and Repairs section of Chapter 7 -- Chassis). Electrical System Page 5 -- 62 Groundsmaster 4000--D/4010--D Service and Repairs NOTE: For engine component repair information (e.g. starter motor), refer to the Yanmar Workshop Manual that is correct for your Groundsmaster model. Battery Care 1. The top of the battery must be kept clean. lf the machine is stored in a location where temperatures are extremely high, the battery will discharge more rapidly than if the machine is stored in a location where temperatures are cool. B. Coat battery posts and cable connectors with battery terminal protector (Toro Part No. 107--0392) or petroleum jelly to prevent corrosion. 3. Battery cables must be tight on terminals to provide good electrical contact. WARNING WARNING IMPORTANT: Do not remove fill caps (if equipped) while cleaning the battery. 2. Check battery condition weekly or after every 50 hours of operation. Keep terminals and entire battery case clean because a dirty battery will discharge slowly. Connecting battery cables to the wrong battery post could result in personal injury and/or damage to the electrical system. 4. If corrosion occurs at terminals, disconnect cables. Always disconnect negative (--) cable first. Clean clamps and terminals separately. Reconnect cables with positive (+) cable first. Coat battery posts and cable connectors with battery terminal protector (Toro Part No. 107--0392) or petroleum jelly to prevent corrosion. 5. If the battery electrolyte is accessible, check electrolyte level every 25 operating hours and every 30 days if machine is in storage. Maintain cell level with distilled water. Do not fill cells above the fill line. A. Clean battery by washing entire case with a solution of baking soda and water. Rinse with clear water. Battery Storage If the machine will be stored for more than 30 days: 1. Remove the battery and charge it fully (see Battery Service in this section). 2. Either store battery on a shelf or on the machine. 4. Store battery in a cool atmosphere to avoid quick deterioration of the battery charge. 5. To help prevent the battery from freezing, make sure it is fully charged (see Battery Service in this section). 3. Leave battery cables disconnected if the battery is stored on the machine. Groundsmaster 4000--D/4010--D Page 5 -- 63 Electrical System Electrical System Wear safety goggles and rubber gloves when working with electrolyte. Charge battery in a well ventilated place so gasses produced while charging can dissipate. Since the gases are explosive, keep open flames and electrical sparks away from the battery; do not smoke. Nausea may result if the gases are inhaled. Unplug charger from electrical outlet before connecting or disconnecting charger leads to or from battery posts. Battery Service The battery is the heart of the electrical system. With regular and proper service, battery life can be extended. Additionally, battery and electrical component failure can be prevented. 2 CAUTION 1 When working with batteries, use extreme caution to avoid splashing or spilling electrolyte. Electrolyte can destroy clothing and burn skin or eyes. Always wear safety goggles and a face shield when working with batteries. Battery Specifications BCI Group Size 34 690 CCA at 0oF (--18oC) 110 minutes reserve capacity at 80oF (27oC) Electrolyte Specific Gravity Fully charged: 1.265 corrected to 80oF (27oC) Discharged: less than 1.240 Battery Removal and Installation (Fig. 85) 3 Figure 85 1. Negative battery post 2. Positive battery post 3. Battery retainer Battery Inspection and Maintenance 1. Check battery for cracks. Replace battery if cracked or leaking. 1. Open battery cover to access battery. 2. Check battery terminal posts for corrosion. Use wire brush to clean corrosion from posts. 2. Loosen and remove negative cable from battery. After negative cable is removed, loosen and remove positive cable. IMPORTANT: Before cleaning the battery, tape or block vent holes to the filler caps and make sure the caps are on tightly. 3. Loosen battery retainer and then carefully remove battery from machine. 3. Check for signs of wetness or leakage on the top of the battery which might indicate a loose or missing filler cap, overcharging, loose terminal post or overfilling. Also, check battery case for dirt and oil. Clean the battery with a solution of baking soda and water, then rinse it with clean water. 4. Install battery in reverse order making sure to connect and tighten positive cable to battery before connecting negative cable. NOTE: Before connecting the negative (ground) cable to the battery, connect a digital multimeter (set to DC Amps) between the negative battery post and the negative (ground) cable connector. The reading should be less than 0.1 Amp. If the reading is 0.1 Amp or more, the machine’s electrical system should be tested for short circuits or faulty components and repaired. 5. Secure battery to machine with battery retainer. Close battery cover. Electrical System 4. Check that the cover seal is not broken away. Replace the battery if the seal is broken or leaking. 5. If the battery electrolyte is accessible, check the electrolyte level in each cell. If the level is below the tops of the plates in any cell, fill all cells with distilled water between the minimum and maximum fill lines. Charge at 15 to 25 Amps for fifteen (15) minutes to allow sufficient mixing of the electrolyte. Page 5 -- 64 Groundsmaster 4000--D/4010--D 1. Perform a high--discharge test with an adjustable load tester. This is one of the most reliable means of testing a battery as it simulates the cold--cranking test. A commercial battery load tester is required to perform this test. CAUTION Follow the manufacturer’s instructions when using a battery load tester. A. Check the voltage across the battery terminals prior to testing the battery. If the voltage is less than 12.4 VDC, charge the battery before performing a load test. B. If the battery has recently been charged, use a battery load tester following the manufacturer’s instructions to apply a 150 Amp load for fifteen (15) seconds. This step will remove the surface charge. 9.6 70oF (and up) 21oC (and up) 9.5 60oF 16oC 9.4 50oF 10oC 9.3 40oF 4oC 9.1 30oF --1oC 8.9 20oF --7oC 8.7 10oF --12oC 8.5 0oF --18oC 2. If the battery electrolyte is accessible, the specific gravity of the electrolyte can be used to determine the battery condition. IMPORTANT: Make sure the area around the cells is clean before opening the battery caps. C. Make sure battery terminals are free of corrosion. D. Estimate the internal temperature of the battery to the nearest 10 degrees F. E. Connect a battery load tester to the battery terminals following the manufacturer’s instructions. Connect a digital multimeter to the battery terminals. F. Apply a test load of 345 Amps (one half the cranking performance rating of the battery) to the battery for fifteen (15) seconds. G. Take a battery voltage reading at fifteen (15) seconds, then remove the load. H. Using the table in the column to the right, determine the minimum voltage for the battery temperature reading. If the test voltage is below the minimum voltage for the battery temperature, replace the battery. If the test voltage is at or above the minimum, return the battery to service. Groundsmaster 4000--D/4010--D Battery Temperature Minimum Voltage Page 5 -- 65 A. Measure the specific gravity of each cell with a hydrometer. Draw electrolyte in and out of the hydrometer barrel prior to taking a reading to warm-up the hydrometer. At the same time take the temperature of the cell. B. Temperature correct each cell reading. For each 10oF (5.5oC) above 80oF (26.7oC) add 0.004 to the specific gravity reading. For each 10oF (5.5oC) below 80oF (26.7oC) subtract 0.004 from the specific gravity reading. Example: Cell Temperature 100oF Cell Gravity 1.245 100oF minus 80oF equals 20oF (37.7oC minus 26.7oC equals 11.0oC) 20oF multiply by 0.004/10oF equals 0.008 (11oC multiply by 0.004/5.5oC equals 0.008) ADD (conversion above) 0.008 Correction to 80oF (26.7oC) 1.253 C. If the difference between the highest and lowest cell specific gravity is 0.050 or greater or the lowest cell specific gravity is less than 1.225, charge the battery. Charge at the recommended rate and time given in Charging or until all cells specific gravity is 1.225 or greater with the difference in specific gravity between the highest and lowest cell less than 0.050. If these charging conditions can not be met, replace the battery. Electrical System Electrical System Battery Testing Battery Charging To minimize possible damage to the battery and allow the battery to be fully charged, the slow charging method is presented here. This charging method can be accomplished with a constant current battery charger which is readily available. CAUTION Follow the manufacturer’s instructions when using a battery charger. NOTE: Using specific gravity of the battery electrolyte is the most accurate method of determining battery condition. 1. Determine the battery charge level from either its open circuit voltage or electrolyte specific gravity (if electrolyte is accessible). Battery Charge Level Open Circuit Voltage Specific Gravity 100% 12.6 1.265 75% 12.4 1.225 50% 12.2 1.190 25% 12.0 1.155 0% 11.8 1.120 CAUTION Do not charge a frozen battery because it can explode and cause injury. Let the battery warm to 60oF (16oC) before connecting to a charger. Charge the battery in a well--ventilated place to dissipate gases produced from charging. These gases are explosive; keep open flame and electrical spark away from the battery. Do not smoke. Nausea may result if the gases are inhaled. Unplug the charger from the electrical outlet before connecting or disconnecting the charger leads from the battery posts. 3. Following the battery charger manufacturer’s instructions, connect the charger cables to the battery. Make sure a good connection is made. 4. Charge the battery following the battery charger manufacturer’s instructions. 5. While charging, occasionally check the battery. If the electrolyte is violently gassing or spewing or if the battery case feels hot to the touch, the charging rate must be lowered or temporarily stopped. 6. Determine if battery is fully charged before removing battery from charger. Either of the following procedures can be used: 2. Determine the charging time and rate using the battery charger manufacturer’s instructions or the following table. Battery Reserve Capacity (Minutes) Battery Charge Level (Percent of Fully Charged) 75% 50% 25% 0% 80 or less 3.8 hrs @ 3 Amps 7.5 hrs @ 3 Amps 11.3 hrs @ 3 Amps 15 hrs @ 3 Amps 81 to 125 5.3 hrs 10.5 hrs 15.8 hrs 21 hrs @ @ @ @ 4 Amps 4 Amps 4 Amps 4 Amps 126 to 170 5.5 hrs @ 5 Amps 11 hrs @ 5 Amps 16.5 hrs @ 5 Amps 22 hrs @ 5 Amps 171 to 250 5.8 hrs @ 6 Amps 11.5 hrs @ 6 Amps 17.3 hrs @ 6 Amps 23 hrs @ 6 Amps above 250 6 hrs @ 10 Amps 12 hrs @ 10 Amps 18 hrs @ 10 Amps 24 hrs @ 10 Amps Electrical System Page 5 -- 66 A. Continue charging and reduce charging rate as needed until a two (2) hour period results in no increase in voltage. Open circuit voltage should be approximately 12.6 volts for a fully charged battery. B. If the battery electrolyte is accessible, three (3) hours prior to the end of the charging, measure the specific gravity of a battery cell once per hour. The battery is fully charged when the cells are gassing freely at a low charging rate and there is less than a 0.003 change in specific gravity for three (3) consecutive readings. Groundsmaster 4000--D/4010--D Chapter 6 Axles, Planetaries and Brakes Table of Contents Axles, Planetaries and Brakes SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . 3 Operator’s Manual . . . . . . . . . . . . . . . . . . . . . . . . . . 3 ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Planetary Wheel Drive Assembly Endplay . . . . . . 4 SERVICE AND REPAIRS . . . . . . . . . . . . . . . . . . . . . . 6 Brake Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Brake Inspection and Repair . . . . . . . . . . . . . . . . . 10 Planetary Wheel Drive Assembly . . . . . . . . . . . . . 12 Planetary Wheel Drive Service . . . . . . . . . . . . . . . 14 Rear Axle Assembly . . . . . . . . . . . . . . . . . . . . . . . . 18 Rear Axle Service . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Bevel Gear Case and Axle Case . . . . . . . . . . . . . 24 Differential Shafts . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Axle Shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Input Shaft/Pinion Gear . . . . . . . . . . . . . . . . . . . . . 30 Differential Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Pinion Gear to Ring Gear Engagement . . . . . . . 35 Groundsmaster 4000--D/4010--D Page 6 -- 1 Axles, Planetaries and Brakes Specifications Item Specification Tire pressure (front and rear) 25 to 30 PSI (172 to 207 kPa) Rear wheel toe--in 0.250 in (6 mm) Planetary gear drive oil System gear lube capacity (each wheel) SAE 85W--140 wt. gear lube 22 fl. oz. (0.65 liters) Rear axle lubricant System gear lube capacity SAE 85W--140 wt. gear lube 80 fl. oz. (2.4 liters) Rear axle gear box lubricant System gear lube capacity SAE 85W--140 wt. gear lube 16 fl. oz. (0.5 liters) Wheel lug nut torque 85 to 100 ft--lb (115 to 136 N--m), front and rear Steering cylinder castle nut torque 79 to 84 ft--lb (107 to 113 N--m) Planetary mounting screw torque 75 to 85 ft--lb (101 to 115 N--m) Brake housing mounting screw torque 75 to 85 ft--lb (101 to 115 N--m) Front wheel motor mounting screw torque 75 to 85 ft--lb (101 to 115 N--m) Axles, Planetaries and Brakes Page 6 -- 2 Groundsmaster 4000--D/4010--D General Information Operator’s Manual The Operator’s Manual provides information regarding the operation, general maintenance and maintenance intervals for your Groundsmaster machine. Refer to that publication for additional information when servicing the machine. Groundsmaster 4000--D/4010--D Page 6 -- 3 Axles, Planetaries and Brakes Adjustments Planetary Wheel Drive Assembly Endplay A front planetary wheel drive assembly that is properly operating should have no endplay. Any endplay in a planetary assembly indicates that there are potential problems with the planetary. Check planetary endplay at intervals specified in your Operator’s Manual. Endplay Checking Procedure 1. Park machine on a level surface, lower cutting decks, stop engine and remove key from the ignition switch. 3. Grasp front wheel and check for endplay in the planetary assembly as indicated by axial wheel movement. Make sure that there is no endplay in assembly. 4. If any endplay is detected, the planetary should be disassembled, inspected and serviced as necessary (see Planetary Wheel Drive Assembly in the Service and Repairs section of this chapter). 5. After planetary endplay checking is completed, lower machine to ground. CAUTION When raising and supporting machine, use correct jacks and supports. Make sure machine is parked on a solid, level surface such as a concrete floor. Prior to raising machine, remove any attachments that may interfere with the safe and proper raising of the machine. Always chock or block wheels. Use jack stands to support the raised machine. If the machine is not properly supported by jack stands, the machine may move or fall, which may result in personal injury. 2. Chock rear wheels and jack up front of machine (see Jacking Instructions in Chapter 1 -- Safety). Support machine with jack stands. Axles, Planetaries and Brakes Page 6 -- 4 Groundsmaster 4000--D/4010--D This page is intentionally blank. Groundsmaster 4000--D/4010--D Page 6 -- 5 Axles, Planetaries and Brakes Service and Repairs Brake Assembly 75 to 85 ft--lb (101 to 115 N--m) 19 4 1 15 13 3 8 11 7 6 14 20 12 1 13 8 10 2 22 6 RIGHT FRONT 5 17 7 16 75 to 85 ft--lb (101 to 115 N--m) 9 18 85 to 100 ft--lb (115 to 135 N--m) 21 Figure 1 1. 2. 3. 4. 5. 6. 7. 8. Front wheel motor Internal retaining ring Splined brake shaft RH brake assembly Planetary assembly (2 used) Cap screw (2 used per motor) Flat washer (2 used per motor) O--ring Axles, Planetaries and Brakes 9. 10. 11. 12. 13. 14. 15. LH brake assembly Hydraulic tee fitting 90o hydraulic fitting (2 used) Hydraulic connector Hydraulic tee fitting (2 used) 90o hydraulic fitting Straight hydraulic fitting Page 6 -- 6 16. 17. 18. 19. 20. 21. 22. Flange screw (4 used per brake) Jam nut Gasket Flange screw (6 used per side) Front wheel assembly Lug nut (8 used per wheel) Brake cable (RH shown) Groundsmaster 4000--D/4010--D Removal (Fig. 1) 1. Park machine on a level surface, lower cutting decks, stop engine and remove key from the ignition switch. 2. Drain oil from planetary wheel drive/brake assembly (Fig. 2). 2 CAUTION 1 When removing front wheel, use correct jacks and supports. Make sure machine is parked on a solid, level surface such as a concrete floor. Prior to raising machine, remove any attachments that may interfere with the safe and proper raising of the machine. Always chock or block wheels. Use jack stands 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. Figure 2 1. Planetary drain 3. Chock rear wheels and jack up front of machine (see Jacking Instructions in Chapter 1 -- Safety). Support machine with jack stands. 2. Brake drain 2 3 4. Remove front wheel assembly. 5. Remove hydraulic wheel motor (see Front Wheel Motors in the Service and Repairs section of Chapter 4 -- Hydraulic System). 6. Disconnect brake cable from pull rod on brake assembly. 1 Figure 3 1. Splined brake shaft step 2. Hydraulic motor end 7. Support brake assembly to prevent it from falling. 3. Planetary assembly end 0.340” to 0.400” (8.7 to 10.1 mm) 8. Remove flange head screws (item 16) that secure brake assembly to frame. 9. Remove brake assembly from machine. Be careful to not drop splined brake shaft (item 3) as brake assembly is removed. 10.Remove splined brake shaft from brake assembly. 1 11. Remove and discard gasket (item 18). Make sure that all gasket material is removed from both brake and planetary assemblies. 12.Complete brake inspection and repair (see Brake Inspection and Repair in this section). 3 2 Figure 4 1. Pull rod jam nut 2. Brake cable 3. Brake cable hex Installation (Fig. 1) 1. Install splined brake shaft (item 3) into brake assembly. NOTE: The stepped end of the splined brake shaft must be aligned toward the hydraulic wheel motor (Fig. 3). Groundsmaster 4000--D/4010--D Page 6 -- 7 Axles, Planetaries and Brakes 2. Apply gasket sealant to sealing surfaces of new gasket (item 18). Apply gasket to brake assembly. 9. Make sure drain plugs are installed in brake and planetary drive assemblies (Fig. 2). 3. Install brake assembly onto machine, aligning splined brake shaft with input shaft on planetary wheel drive. Make sure that brake pull rod is orientated toward rear of machine. 10.Fill planetary wheel drive/brake assembly with SAE 85W--140 gear lube (Fig. 5). Capacity is approximately 22 fl. oz. (0.65 liters) per wheel. 4. Secure brake assembly to planetary assembly with four (4) flange head screws (item 16). Tighten screws in a crossing pattern to a torque from 75 to 85 ft--lb (101 to 115 N--m). 5. Secure hex on end of brake cable to pull rod on brake assembly. Brake cable end should be completely threaded onto pull rod before tightening jam nut. 11. Check and adjust brake cables for proper brake operation. If necessary, adjust hex on end of brake cable so that pull rod jam nut is positioned from 0.340” to 0.400” (8.7 to 10.1 mm) from brake casting surface when brakes are disengaged (Fig. 4). Brakes should be adjusted so that both brake pedals have approximately 1” (25mm) of freeplay and have equal brake tension. 6. Install new O--ring on hydraulic wheel motor. Install wheel motor and torque cap screws from 75 to 85 ft--lb (101 to 115 N--m). 2 1 7. Install wheel assembly. NOTE: While front wheel is off the ground, check planetary wheel drive assembly for endplay (see Planetary Wheel Drive Assembly Endplay in the Adjustments section of this chapter). Figure 5 WARNING 1. Check plug 2. Fill plug Failure to maintain proper wheel lug nut torque could result in failure or loss of wheel and may result in personal injury. 8. Lower machine to ground. Torque lug nuts from 85 to 100 ft--lb (115 to 135 N--m). Axles, Planetaries and Brakes Page 6 -- 8 Groundsmaster 4000--D/4010--D This page is intentionally blank. Groundsmaster 4000--D/4010--D Page 6 -- 9 Axles, Planetaries and Brakes Brake Inspection and Repair 2 1 3 4 5 6 7 8 9 15 10 14 13 12 11 Figure 6 1. 2. 3. 4. 5. Brake housing (LH shown) Seal Pull rod Clevis pin (2 used) Link (2 used) 6. 7. 8. 9. 10. Hitch pin (2 used) Stationary disc (4 used) Rotating disc (3 used) Retaining ring Gasket 11. 12. 13. 14. 15. Rotating actuator Extension spring (3 used) Ball (3 used) Plug O--ring Brake Inspection and Repair (Fig. 6) 6. Remove seal (item 2) from brake housing. 1. Scrape gasket material (item 10) from brake housing and planetary wheel drive mounting surfaces. 7. Wash parts in cleaning solvent. Inspect components for wear or damage. 2. Remove retaining ring (item 9) from brake housing groove. 8. Reverse steps 2 through 6 to assemble brakes, installing new parts as necessary. Install a new seal (item 2). 3. Remove stationary discs (item 7) and rotating discs (item 8). 4. Remove extension springs (item 12). 9. Use a new gasket (item 10) when installing brake assembly to machine. 5. Remove actuator assembly (items 11, 6, 5, 4 and 3) and balls (item 13). Axles, Planetaries and Brakes Page 6 -- 10 Groundsmaster 4000--D/4010--D This page is intentionally blank. Groundsmaster 4000--D/4010--D Page 6 -- 11 Axles, Planetaries and Brakes Planetary Wheel Drive Assembly 75 to 85 ft--lb (101 to 115 N--m) 19 4 1 15 13 3 8 11 7 6 14 5 20 12 1 13 8 10 2 17 6 RIGHT FRONT 7 16 75 to 85 ft--lb (101 to 115 N--m) 9 18 85 to 100 ft--lb (115 to 135 N--m) 21 Figure 7 1. 2. 3. 4. 5. 6. 7. Front wheel motor Internal retaining ring Splined brake shaft RH brake assembly Planetary assembly (2 used) Cap screw (2 used per motor) Flat washer (2 used per motor) 8. 9. 10. 11. 12. 13. 14. O--ring LH brake assembly Hydraulic tee fitting 90o hydraulic fitting (2 used) Hydraulic connector Hydraulic tee fitting (2 used) 90o hydraulic fitting 15. 16. 17. 18. 19. 20. 21. Straight hydraulic fitting Flange screw (4 used per brake) Jam nut Gasket Flange screw (6 used per side) Front wheel assembly Lug nut (8 used per wheel) NOTE: The planetary wheel drive assembly can be serviced with the planetary installed to machine (see Planetary Wheel Drive Service in this section). Use the following procedure to remove and install planetary wheel drive assembly from machine. Axles, Planetaries and Brakes Page 6 -- 12 Groundsmaster 4000--D/4010--D Removal (Fig. 7) 1. Park machine on a level surface, lower cutting decks, stop engine and remove key from the ignition switch. 2. Drain oil from planetary wheel drive/brake assembly (Fig. 8). WARNING Failure to maintain proper wheel lug nut torque could result in failure or loss of wheel and may result in personal injury. 5. Lower machine from jack stands. Torque lug nuts from 85 to 100 ft--lb (115 to 135 N--m). CAUTION When removing front wheel, use correct jacks and supports. Make sure machine is parked on a solid, level surface such as a concrete floor. Prior to raising machine, remove any attachments that may interfere with the safe and proper raising of the machine. Always chock or block wheels. Use jack stands 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. 6. Make sure drain plugs are installed in brake and planetary drive assemblies (Fig. 8). 7. Fill planetary wheel drive/brake assembly with SAE 85W--140 gear lube (Fig. 9). Capacity is approximately 22 fl. oz. (0.65 liters) per wheel. 8. Check and adjust brake cables for proper brake operation. 3. Chock rear wheels and jack up front of machine (see Jacking Instructions in Chapter 1 -- Safety). Support machine with jack stands. 2 4. Remove front wheel assembly. 5. Remove hydraulic wheel motor (see Front Wheel Motors in the Service and Repairs section of Chapter 4 -- Hydraulic System). 1 6. Remove brake assembly (see Brake Assembly in this section). 7. Support planetary assembly to prevent it from falling. Loosen and remove flange head screws that secure planetary assembly to frame. Remove planetary assembly from machine. Figure 8 1. Planetary drain 2. Brake drain 2 Installation (Fig. 7) 1 1. Position planetary assembly to machine. Install flange head screws that secure planetary assembly. Torque screws in a crossing pattern from 75 to 85 ft--lb (101 to 115 N--m). 2. Install brake assembly (see Brake Assembly in this section). 3. Install hydraulic wheel motor (see Front Wheel Motors in the Service and Repairs section of Chapter 4 -Hydraulic System). Figure 9 1. Check plug 2. Fill plug 4. Install wheel assembly. Groundsmaster 4000--D/4010--D Page 6 -- 13 Axles, Planetaries and Brakes Planetary Wheel Drive Service 2 118 to 144 in--lb (13.3 to 16.3 N--m) 3 4 7 8 9 11 1 12 13 14 5 15 16 6 10 28 21 13 27 26 17 25 24 23 22 20 19 18 Figure 10 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. Spindle Boot seal Oil seal Inner bearing cone Inner bearing cup Wheel stud (8 used) Socket head screw (16 used) Lock washer (16 used) Housing Dowel pin (2 used) Axles, Planetaries and Brakes 11. 12. 13. 14. 15. 16. 17. 18. 19. Outer bearing cup Outer bearing cone O--ring Thrust washer Retaining ring (external) Ring gear Retaining ring (internal) Plug (2 used) O--ring (2 used) Page 6 -- 14 20. 21. 22. 23. 24. 25. 26. 27. 28. End cap Thrust plug Thrust washer Retaining ring Primary gear Drive shaft Primary carrier assembly Secondary gear Secondary carrier assembly Groundsmaster 4000--D/4010--D NOTE: The planetary wheel drive assembly can be serviced with the planetary installed to machine. If the spindle (item 1) needs to be removed from machine, see Planetary Wheel Drive Assembly in this section. Disassembly (Figs. 10 and 11) 1. If planetary wheel drive assembly is installed on machine: A. Park machine on a level surface, lower cutting units, stop engine and remove key from the ignition switch. B. Drain oil from planetary wheel drive/brake assembly. C. Chock rear wheels and jack up front of machine (see Jacking Instructions in Chapter 1 -- Safety). Support machine with jack stands. D. Remove front wheel assembly. Figure 11 2. Remove retaining ring (item 17). 3. Remove end cap (item 20). Thrust plug (item 21) and thrust washer (item 22) usually remain in end cap bore and should be removed for cleaning and inspection. 4. Remove drive shaft assembly (items 23, 24 and 25) If necessary, remove retaining ring and primary gear from shaft. 5. Remove primary carrier (item 26), secondary gear (item 27) and secondary carrier (item 28). NOTE: Steps 6 through 10 are necessary only if inspecting or replacing bearings and/or seals. Assembly (Figs. 10 and 11) 1. Thoroughly clean parts in solvent and dry completely after cleaning. Inspect parts for damage or excessive wear and replace as necessary. 2. If any wheel studs were removed, use a press to install new studs into housing. Make sure that stud shoulder is fully pressed against housing surface. NOTE: Use new seal and shim kits when assembling planetary wheel drive. 3. If spindle and housing were separated: IMPORTANT: Do not reuse retaining ring (item 10) after it has been removed. 6. Remove retaining ring (item 15) and thrust washer (item 14). Discard retaining ring. 7. Carefully remove housing (item 9) from spindle (item 1). Remove outer bearing cone (item 12). 8. Remove and discard seals (items 2 and 3) and O-rings (item 13) from housing. 9. Remove inner bearing cone (item 4) from housing. If necessary, remove bearing cups (items 5 and 11) from housing. 10.If wheel stud (item 6) removal is necessary, use press to extract stud(s) from housing. 11. If necessary, remove socket head screws (item 7) with lock washers (item 8) that secure ring gear (item 16) to housing. Remove ring gear and two (2) dowel pins (item 10) from housing. Groundsmaster 4000--D/4010--D Page 6 -- 15 A. Press bearing cups (items 5 and 11) into housing (item 9). Cups should be pressed fully to shoulder of the housing bore. B. Set inner bearing cone (item 4) into inner bearing cup. C. Make sure that seal bore in housing is thoroughly cleaned. If OD of seal (item 3) is not rubber or does not have a sealant coating, apply light coating of silicone sealant to seal bore in housing. Install seal into housing so it is flush with housing face. Lightly grease seal lips. D. Pack boot seal (item 2) with grease and install on housing. E. If ring gear was removed from housing, place dowel pins (item 10) in housing. Secure ring gear to housing with lock washers (item 8) and socket head screws (item 7). Torque socket head screws from 118 to 144 in--lb (13.3 to 16.3 N--m). Axles, Planetaries and Brakes F. Lightly oil bearing journals on spindle shaft. Slide housing assembly onto spindle (item 1) taking care to not damage seal or spindle. Make sure that inner bearing in housing fully seats against spindle shaft shoulder. G. Install outer bearing cone (item 12) onto spindle. NOTE: The planetary shim kit includes the retaining ring and several thrust washers with thickness in incremental steps of 0.004 inch (0.10 mm). Refer to your Parts Catalog to identify the correct part number for the planetary shim kit. H. Measure thickness of thrust washer (item 14) that was removed during disassembly. Choose new thrust washer of equal thickness or the next available thickness from thrust washers in the shim kit. I. Apply a light coating of oil to spindle shaft, thrust washer (item 14) and new retaining ring (item 15). Install thrust washer onto spindle shaft. WARNING If retaining ring (item 15) is not fully installed in spindle groove, loss of wheel and personal injury may result. J. Carefully install new retaining ring (item 15) into the spindle shaft groove taking care to not distort ring. If the proper thrust washer has been installed, the retaining ring should fit tightly between the thrust washer and spindle groove. Tap the OD of the retaining ring starting in the center and working out toward each end to ensure that the retaining ring is properly seated into the spindle groove. Make sure that retaining ring ID is fully seated to spindle shaft groove. 4. Install secondary carrier (item 28), secondary gear (item 27) and primary carrier (item 26) making sure that carrier gear teeth align with ring gear and spline on spindle shaft. 5. If primary gear (item 24) was removed from drive shaft, slide gear onto shaft and secure with retaining ring (item 23). 6. Install drive shaft assembly (items 25, 24 and 23) making sure that drive shaft spline aligns with carrier gears. 7. Install thrust plug (item 21) and thrust washer (item 22) into end cap (item 20). Make sure that thrust plug and thrust washer are captive on inside of end cap (item 20). 8. Install new O--ring (item 13) to end cap and then install end cap. Secure cap with retaining ring (item 17). 9. Check operation of planetary wheel drive. With a constant turning force applied, rotation of the planetary should be consistent. If there is more drag at certain points, gears are not rolling freely and the planetary should be examined for improper assembly or damaged components. 10.If planetary wheel drive assembly is installed on machine: A. Install front wheel assembly. WARNING Failure to maintain proper wheel lug nut torque could result in failure or loss of wheel and may result in personal injury. K. After retaining ring is installed, make sure that there is no endplay in assembly. If required, remove retaining ring and install a thrust washer of different thickness to adjust endplay. L. Install new O--ring (item 13) into groove in housing. Axles, Planetaries and Brakes Page 6 -- 16 B. Lower machine to ground. Torque wheel lug nuts in a crossing pattern from 85 to 100 ft--lb (115 to 135 N--m). C. Make sure drain plug is installed in bottom of brake assembly. Fill planetary wheel drive/brake assembly with SAE 85W--140 gear lube to proper level. Capacity is approximately 16 oz. (0.47 l) per wheel. Groundsmaster 4000--D/4010--D This page is intentionally blank. Groundsmaster 4000--D/4010--D Page 6 -- 17 Axles, Planetaries and Brakes Rear Axle Assembly 18 19 5 8 6 7 22 28 4 16 5 15 27 17 1 24 20 29 14 25 27 23 RIGHT 26 FRONT 3 12 21 135 to 165 ft--lb (184 to 223 N--m) 9 10 13 1 11 85 to 100 ft--lb (115 to 135 N--m) 2 Figure 12 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. Plug with O--ring Lug nut (5 used per wheel) Rear wheel assembly (2 used) Cap screw (2 used) Flat washer (8 used) Rear axle motor O--ring Steering cylinder Spacer Cotter pin (2 used) 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. Slotted hex nut (2 used) Washer Cap screw (4 used) Lock washer (4 used) Bulkhead mount plate Grommet (2 used) Bulkhead nut (2 used) Cap screw (6 used) Frame assembly Lock nut (6 used) 21. 22. 23. 24. 25. 26. 27. 28. 29. Rear axle mount Rear axle assembly Lock nut Thrust washer Rear axle pin Washer head screw Grease fitting Thrust washer (0.033”) Thrust washer (0.018”) CAUTION When changing attachments, tires or performing other service, use correct jacks and supports. Make sure machine is parked on a solid, level surface such as a concrete floor. Prior to raising machine, remove any attachments that may interfere with the safe and proper raising of the machine. Always chock or block wheels. Use jack stands to support the raised machine. If the machine is not properly supported by jack stands, the machine may move or fall, which may result in personal injury. Axles, Planetaries and Brakes Page 6 -- 18 Groundsmaster 4000--D/4010--D Removal (Fig. 12) 1. Park machine on a level surface, lower cutting decks, stop engine, apply parking brake and remove key from the ignition switch. 2. Drain oil from rear axle and axle gearbox (Figs. 13 and 14). 3. Chock front wheels and jack up rear of machine (see Jacking Instructions in Chapter 1 -- Safety). Support machine with appropriate jack stands. 1 2 4. Remove both wheels from rear axle. 5. Remove hydraulic motor from rear axle assembly (see Rear Axle Motor in the Service and Repairs section of Chapter 4 -- Hydraulic System). Figure 13 1. Center axle drain plug 2. Outside plug (2 used) 6. Remove steering cylinder from rear axle (see Steering Cylinder in the Service and Repairs section of Chapter 4 -- Hydraulic System). 7. Remove cap screws and lock washers that secure bulkhead mount plate (item 15) to rear axle. Separate mount plate from rear axle and support it along with attached hydraulic hoses and tubes to allow the rear axle to be lowered from machine. 8. If required, remove tie rod ends from steering arms on rear axle (Fig. 15). Remove the cotter pins and castle nuts from the tie rod ball joints. Use a ball joint fork and remove the tie rod ends from the axle steering arms. 9. Support rear axle to prevent it from falling. Remove six (6) cap screws, flat washers and lock nuts that secure rear axle mount to machine frame. Lower rear axle and rear axle mount from machine. 2 1 Figure 14 1. Gearbox drain plug 4 10.Remove lock nut and washer from rear axle pin that attaches rear axle to rear axle mount. Remove washer head screw that secures flange of rear axle pin to axle mount (Fig. 16). 2. Gearbox fill plug 2 3 5 1 11. Remove rear axle pin from rear axle and mount. Separate rear axle mount from rear axle. Note location of thrust washers (items 28 and 29) on both ends of axle mounting boss. 6 Installation (Fig. 12) 1. Position rear axle mount to axle. Install thrust washers (items 28 and 29) between axle boss and axle mount. The thicker thrust washer should be installed on the hydraulic motor end of the axle (toward the rear of the machine). With washers installed, there should be from 0.002” to 0.020” (0.05 mm to 0.51 mm) clearance between rear axle mount and axle mounting boss. Add thrust washers if needed to adjust clearance. Groundsmaster 4000--D/4010--D Figure 15 1. Tie rod 2. Dust cover 3. Cotter pin Page 6 -- 19 4. Castle nut 5. Tie rod end 6. Steering arm (LH) Axles, Planetaries and Brakes 2. Secure rear axle to rear axle mount. A. Slide rear axle pin through rear axle mount and rear axle. Install washer and lock nut onto rear axle pin. 2 1 B. Secure pivot pin to axle mount with washer head screw (Fig. 16). C. Torque lock nut from 135 to 165 ft--lb (184 to 223 N--m). After tightening the lock nut, makes sure that the rear axle pivots freely. 3. Position rear axle with attached mount under machine. With a jack, raise assembly to machine frame and align mounting holes of rear axle mount and machine frame. Figure 16 1. Rear axle pin 2. Washer head screw 2 4. Secure rear axle mount to frame with six (6) cap screws, flat washers and lock nuts. 5. If removed, install the tie rod to rear axle (Fig. 15). Tighten ball joint castle nuts and install new cotter pins. 1 6. Position bulkhead mount plate (item 15) with attached hydraulic hoses and tubes to rear axle. Secure mount plate to axle with cap screws and lock washers. 7. Install steering cylinder to rear axle assembly (see Steering Cylinder in the Service and Repairs section of Chapter 4 -- Hydraulic System). Figure 17 1. Rear axle check plug 2. Rear axle fill plug 1 8. Install hydraulic motor to rear axle assembly (see Rear Axle Motor in the Service and Repairs section of Chapter 4 -- Hydraulic System). WARNING Failure to maintain proper wheel lug nut torque could result in failure or loss of wheel and may result in personal injury. 2 9. Install rear wheels to axle. 10.Lower machine to ground. Torque wheel lug nuts from 85 to 100 ft--lb (115 to 135 N--m). Figure 18 1. Steering stop bolt 2. Bevel gear case (LH) 11. Fill gearbox and rear axle with SAE 85W--140 weight gear lube (Figs. 14 and 17). Lubricant capacity is approximately 16 fl. oz. (0.47 liters) for the gearbox and 80 fl. oz. (2.37 liters) for the rear axle assembly. 12.Check rear wheel toe--in and adjust if necessary. 13.Check steering stop bolt adjustment. When the steering cylinder is fully extended (right turn), a gap of 1/16” (1.6 mm) should exist between bevel gear case casting and stop bolt on left axle case. Figure 18 shows stop bolt location. Axles, Planetaries and Brakes Page 6 -- 20 Groundsmaster 4000--D/4010--D This page is intentionally blank. Groundsmaster 4000--D/4010--D Page 6 -- 21 Axles, Planetaries and Brakes Rear Axle Service 10 11 21 20 19 17 18 24 22 2 23 16 1 25 4 13 15 12 5 26 43 6 7 8 44 45 27 46 61 62 14 3 8 9 47 33 28 29 32 30 31 10 11 48 37 50 63 64 42 22 60 51 38 41 52 8 9 35 36 49 13 34 40 53 59 54 58 39 57 56 55 Figure 19 Axles, Planetaries and Brakes Page 6 -- 22 Groundsmaster 4000--D/4010--D Figure 19 (Continued) 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. LH axle support Flange bushing (2 used) Axle vent Filter Vent extension Cap screw (4 used per gear case) Shim set Seal washer Plug Lock nut Lock washer Grease fitting Ball bearing Screw (2 used per steering arm) Axle case support (LH shown) Bolt (2 used) Stud (2 used) Shim set Differential assembly O--ring Plug O--ring 23. 24. 25. 26. 27. 28. 29. 30. 31. 32. 33. 34. 35. 36. 37. 38. 39. 40. 41. 42. 43. RH axle support Input shaft assembly Bolt (8 used) O--ring Differential shaft (LH shown) Shim set Ball bearing Bevel gear (15 tooth) Retaining ring Bolt (4 used per knuckle) Shim set Dowel pin (2 used per axle case) Bushing Knuckle pin O--ring Bevel gear case (LH shown) Bushing Shaft seal Stud (2 used per gear case) Bolt (4 used per cover) Collar 44. 45. 46. 47. 48. 49. 50. 51. 52. 53. 54. 55. 56. 57. 58. 59. 60. 61. 62. 63. 64. Bevel gear (17 tooth) Bevel gear shaft Axle case (LH shown) Ball bearing Bevel gear (29 tooth) Shim set Clip (2 used per axle case) Axle cover Screw (6 used per cover) Wheel stud (5 used per axle) Axle Oil seal Ball bearing O--ring Retaining ring Spacer Axle case cover Seal washer Plug Bevel gear (17 tooth) O--ring NOTE: Figure 19 illustrates the rear axle used on the Groundsmaster 4000 and 4010. Service procedures for the rear axle is on the following pages of this section. Groundsmaster 4000--D/4010--D Page 6 -- 23 Axles, Planetaries and Brakes Bevel Gear Case and Axle Case The following procedures assume the rear axle assembly has been removed from the machine. 35 to 41 ft--lb (47 to 56 N--m) Removal 1 1. Remove the mounting screws, nuts and lock washers. Remove the bevel gear case/axle case assembly and O-ring from the axle support (Fig. 20). 4 5 6 2 2. Mark both right and left bevel gear case/axle case assemblies. 3 35 to 41 ft--lb (47 to 56 N--m) IMPORTANT: Do not interchange right and left bevel gear case/axle case assemblies. Figure 20 1. 2. 3. 4. Cap screw (4 used) Lock nut (2 used) Lock washer (2 used) Axle support 5. Bevel gear case/axle case assembly 6. O-ring 3. Remove the axle cover mounting screws. Remove the axle cover from the axle case as an assembly (Fig. 21). 17 to 20 ft--lb (23 to 27 N--m) 1 4 3 2 Figure 21 1. Axle case 2. Axle cover assembly 4. Remove the axle case support mounting screws, the axle case support and the support shims (Fig. 22). 3. Screw (6 used) 4. O-ring Threadlocking Compound 3 57 to 67 ft--lb (77 to 91 N--m) 2 4 1 Figure 22 1. Axle case 2. Axle case support Axles, Planetaries and Brakes Page 6 -- 24 3. Screw (2 used) 4. Support shim Groundsmaster 4000--D/4010--D 5. Remove the knuckle pin mounting screws and the knuckle pin. Remove the gasket and any remaining gasket material from either mating surface (Fig. 23). 6. While holding the bevel gear case, tap the upper end of the bevel gear shaft out of the upper bearing and upper bevel gear. 2 1 17 to 20 ft--lb (23 to 27 N--m) 3 4 Threadlocking Compound 7. Pull the bevel gear case from the axle case and remove the upper bevel gear and collar from the gear case. 5 14 8. Remove the axle case cover screws, cover and the O-ring from the axle case. 7 15 8 9. Remove the plug and sealing washer from the center of the axle case cover. While holding the axle case cover, lightly tap the lower end of the bevel gear shaft out of the lower bearing and lower bevel gear. 11 6 10.Remove and discard bevel gear shaft seal from axle case (Fig. 23). 13 9 12 10 17 to 20 ft--lb (23 to 27 N--m) Figure 23 1. 2. 3. 4. 5. 6. 7. 8. Knuckle pin Mounting screw (4 used) O--ring Bevel gear case Upper bearing Bevel gear shaft Collar Upper bevel gear 9. 10. 11. 12. 13. 14. 15. Lower bevel gear Lower bearing Axle case Axle case cover O-ring Shaft seal Bushing Inspection 1. Measure the knuckle pin O.D. and the axle case support bushing I.D. to determine the bushing to pin clearance (Fig. 24). Replace components as necessary. 1 2 BUSHING TO PIN CLEARANCE: 0.002 to 0.016 inch (0.05 to 0.40 mm) KNUCKLE PIN O.D. (Factory Spec.): 0.982 to 0.983 inch (24.95 to 24.98 mm) AXLE CASE SUPPORT BUSHING I.D. (Factory Spec.): 0.984 to 0.987 inch (25.00 to 25.08 mm) Figure 24 2. Inspect all gears, shafts, bearings, cases and covers for damage and wear. Replace components as necessary. Groundsmaster 4000--D/4010--D 1. Knuckle pin Page 6 -- 25 2. Axle case support Axles, Planetaries and Brakes Installation 1. Coat new shaft seal with grease and install in axle case as shown (Fig. 25). 3 2 1 Figure 25 1. Axle case 2. Bevel gear case 2. Install the lower bevel gear and bevel gear shaft in the axle case cover. Coat a new O-ring with grease and install the axle case cover (Fig. 26). Tighten cover screws from 17 to 20 ft-lb (23 to 27 N--m). 3. Shaft seal 7 8 3. Slide the bevel gear case over the bevel gear shaft and install the bevel gear and collar. Make sure the bevel gear shaft is completely seated in the upper and lower bearings (Fig. 26). 6 4. Install the knuckle pin. Use medium strength threadlocking compound and tighten the knuckle pin mounting screws from 17 to 20 ft-lb (23 to 27 N--m). 5 3 2 1 4 Figure 26 1. 2. 3. 4. Axles, Planetaries and Brakes Page 6 -- 26 Axle case cover Lower bevel gear Bevel gear shaft Lower bearing 5. 6. 7. 8. Upper bevel gear Collar Upper bearing Knuckle pin Groundsmaster 4000--D/4010--D 5. Determine necessary quantity of support shims. B. Position support shims that were removed during disassembly between axle case support and axle case. Install mounting screws into axle case. Slowly tighten screws while frequently checking for clearance (vertical endplay) between axle case support and knuckle pin. If binding of components is noted before screws are fully tightened, add additional support shims. Torque screws from 57 to 67 ft--lb (77 to 91 N--m). C. Use dial indicator to measure vertical endplay of axle case (Fig. 27). AXLE CASE ASSEMBLY ENDPLAY: 0.001 to 0.008 inch (0.02 to 0.20 mm) 57 to 67 ft--lb (77 to 91 N--m) 4 A. Lubricate the axle case support bushing with a thin coat of grease and slide axle case support onto knuckle pin. 1 VERTICAL ENDPLAY 6 5 2 3 Figure 27 1. Axle case support 2. Axle case 3. Bevel gearcase 3 D. Adjust endplay by increasing or reducing number of axle case support shims. 1 4. Dial indicator 5. Knuckle pin 6. Support shim location 2 NOTE: Axle case support shims are available in 0.004 inch (0.1 mm), 0.008 inch (0.2 mm) and 0.016 inch (0.4 mm) thickness. 4 6. After correct support shims have been determined, remove mounting screws, apply heavy strength threadlocking compound to screw threads, reinstall screws and torque from 57 to 67 ft--lb (77 to 91 N--m). 5 IMPORTANT: Correct engagement between bevel gears is critical to axle performance and durability. 7. Temporarily install the bevel gear case/axle case assembly on the axle support. Position a dial indicator at the tooths center. Prevent the axle from turning and measure the upper bevel gear to differential shaft gear backlash (Fig. 28). Figure 28 1. Axle support 2. Upper bevel gear 3. Differential shaft gear UPPER BEVEL GEAR BACKLASH: 0.004 to 0.016 inch (0.10 to 0.40 mm) 4. Dial indicator 5. Axle bearing shims 4 5 1 8. Adjust backlash by increasing or reducing axle bearing shim thickness (see Differential Shafts in this section of this manual). NOTE: Axle bearing shims are available in 0.004 inch (0.1 mm), 0.008 inch (0.2 mm) and 0.020 inch (0.5 mm) thickness. 2 3 Figure 29 1. Axle cover assembly 2. Lower bevel gear 3. Axle gear Groundsmaster 4000--D/4010--D Page 6 -- 27 4. Dial indicator 5. Axle bearing shims Axles, Planetaries and Brakes 9. Remove the bevel gear case/axle case assembly from the axle support. Coat a new O-ring with grease and temporarily install the axle cover assembly. Position a dial indicator at the tooths center. Prevent the axle from turning and measure the lower bevel gear to axle gear backlash (Fig. 29). LOWER BEVEL GEAR BACKLASH: 0.004 to 0.016 inch (0.10 to 0.40 mm) 10.Adjust backlash by increasing or reducing axle bearing shim thickness (see Axle Shafts in this section of this manual). NOTE: Axle bearing shims are available in 0.008 inch (0.2 mm), 0.012 inch (0.3 mm) and 0.020 inch (0.5 mm) thickness. 11. Tighten axle cover screws from 17 to 20 ft-lb (23 to 27 N--m). 12.Coat a new O-ring with grease and install the bevel gear case/axle case assembly on the axle support. Tighten mounting screws and nuts from 35 to 41 ft-lb (47 to 56 N--m) (Fig. 30). Differential Shafts The following procedures assume the rear axle assembly has been removed from the machine. 35 to 41 ft--lb (47 to 56 N--m) Removal 1 IMPORTANT: Do not interchange right and left differential shaft assemblies. 1. Remove the mounting screws, nuts and lock washers. Remove the bevel gear case/axle case assembly and O-ring from the axle support (Fig. 30). 4 7 35 to 41 ft--lb (47 to 56 N--m) 3. Remove the retaining ring and bevel gear (Fig 31). 5. Inspect all gears, shafts, bearings and cases for damage and wear. Replace components as necessary. 2 3 2. Mark and pull the differential shaft assembly from the axle support. 4. Drive the differential shaft out of the bearings. Remove the bearings and bearing shims. 5 6 Figure 30 1. 2. 3. 4. Cap screw (4 used) Lock nut (2 used) Lock washer (2 used) Axle support 5. Bevel gear/axle case assembly 6. O-ring 7. Stud (2 used) Installation 1. Press bearings onto differential shaft. Place correct combination of bearing shims in axle support and drive differential shaft and bearing assembly into axle support. 6 3 5 4 2. Install bevel gear and retaining ring. 2 1 3. Coat new O-ring with grease. Align differential shaft splines with differential gear assembly and slide differential shaft assembly onto axle support. 4. Install bevel gear case/axle case assembly (see Bevel Gear Case/Axle Case Assembly in this section of this manual). Figure 31 1. Retaining ring 2. Bevel gear 3. Differential shaft Axles, Planetaries and Brakes Page 6 -- 28 4. Bearing 5. Bearing shims 6. O-ring Groundsmaster 4000--D/4010--D Axle Shafts The following procedures assume the rear axle assembly has been removed from the machine. 1 Removal 4 1. Remove the axle cover mounting screws. Remove the axle cover from the axle case as an assembly (Fig. 32). 17 to 20 ft--lb (23 to 27 N--m) 3 2. Use a bearing puller to remove the bearing and bevel gear as shown (Fig. 33). 3. Remove the shims, spacer and retaining ring. Drive the axle out of the bearing and cover. Remove and discard the axle shaft seal. 4. Inspect all gears, shafts, bearings, spacers and cases for damage and wear. Replace components as necessary. 2 Figure 32 1. Axle case 2. Axle cover assembly 3. Screw (6 used) 4. O-ring Installation 1 1. Coat new axle shaft seal with grease and install in axle cover as shown (Fig. 34). 2 2. Press the axle cover and bearing assembly onto the axle shaft. Press only on the inner race of the cover bearing (Fig. 34). 4 3 5 3. Install retaining ring, spacer and correct combination of bearing shims. Install bevel gear and bearing. 4. Coat a new O-ring with grease and install the axle cover assembly. Tighten axle cover screws from 17 to 20 ft-lb (23 to 27 N--m). Figure 33 1. Bearing 2. Bevel gear 3. Shims 4. Spacer 5. Retaining ring 1 4 2 3 Figure 34 1. Axle shaft seal 2. Axle cover Groundsmaster 4000--D/4010--D Page 6 -- 29 3. Bearing 4. Axle shaft Axles, Planetaries and Brakes Input Shaft/Pinion Gear 20 35 to 41 ft--lb (47 to 56 N--m) 1 3 22 19 2 17 18 16 4 10 9 8 6 21 5 23 15 10 14 9 13 7 11 35 to 41 ft--lb (47 to 56 N--m) 12 Figure 35 1. 2. 3. 4. 5. 6. 7. 8. Nut (2 used) Lock washer (2 used) Stud (2 used) Lock nut Stake washer Oil seal O-ring Seal collar 9. 10. 11. 12. 13. 14. 15. 16. Bearing O-ring Input shaft/pinion gear Bearing case Shim Screw (2 used) Gear case Gasket The following procedures assume the rear axle assembly has been removed from the machine. Removal (Fig. 35) 1. Remove the cover plate, gasket and gear case assembly from the axle assembly. Remove the gasket and any remaining gasket material. 2. Remove the retaining rings, the driven gear and the needle bearing from the input shaft/pinion gear. 3. Remove input shaft/pinion gear assembly from the gear case. Remove the shims and bearing case Orings. 17. 18. 19. 20. 21. 22. 23. Cover plate Dowel pin (2 used) Lock washer (6 used) Cap screw (6 used) Retaining ring (2 used) Driven gear (45 tooth) Needle bearing NOTE: Replacement input shaft/pinion gear (item 11) is only available in matched set with differential ring gear. Installation (Fig. 35) NOTE: When installing bearing cones onto the input shaft/pinion gear, press only on the inner race of the bearing cone. 1. If the inner bearing cone was removed, press a new bearing cone all the way onto the input shaft/pinion gear. 2. Place the shaft and bearing assembly in the bearing case and install the outer bearing cone. 4. Release the stake washer and remove the lock nut. Remove and discard the stake washer. NOTE: The bearings must be completely seated. There should be no input shaft/pinion gear end play. 5. Drive the input shaft/pinion gear out from the outer bearing cone and bearing case. Remove and discard the oil seal and O-ring. 3. Coat a new oil seal with grease and install as shown in Figure 36. The seal should be installed with the garter spring towards the hydraulic motor location. 6. Inspect all gears, shafts, bearings, spacers and cases for damage and wear. Replace components as necessary. 4. Coat new O-ring with grease. Install O-ring in the oil seal collar and install the collar. Axles, Planetaries and Brakes Page 6 -- 30 Groundsmaster 4000--D/4010--D 5. Install a new stake washer. Install the lock nut finger tight. 6. Set the bearing preload by securing the bearing case in a vise. Thread a M12 x 1.5 hex head cap screw into the splined end of the input shaft/pinion gear and slowly tighten the lock nut until 4 to 6 in-lb (0.4 to 0.7 N--m) of force is required to rotate the input shaft/pinion gear in the bearing case. 0.040 in. (1.0 mm) 2 1 7. Secure the lock nut with the stake washer. 8. Use a depth gauge to measure the distance from the end face of the input shaft/pinion gear to the mating surface of the bearing case. Subtract the “Design Cone Center Distance” from this distance to determine initial shim thickness (Fig. 37). DESIGN CONE CENTER DISTANCE (distance from mating surface of axle support to end face of pinion gear): 1.870 + 0.002 inch (47.5 + 0.05 mm) 3 Figure 36 1. Oil seal 2. Bearing case 3. Seal garter spring 1 NOTE: Bearing case shims are available in 0.004 inch (0.1 mm) and 0.008 inch (0.2 mm) thickness. Design Cone Center Distance 9. Coat new O-rings with grease and install the bearing case in the gear case. Place shims on the gear case and temporarily install gear case assembly into axle case. Tighten mounting nuts and screws from 35 to 41 ft-lb (47 to 56 N--m). 2 10.Insert a screwdriver through the drain plug hole to hold ring gear and measure the pinion gear to ring gear backlash (Fig. 38). Figure 37 PINION GEAR TO RING GEAR BACKLASH: 0.004 to 0.016 inch (0.10 to 0.40 mm) 1. Input shaft/pinion gear 2. Bearing case 11. Adjust backlash by increasing or reducing gear case shim thickness. 1 12.Check pinion gear to ring gear engagement (see Pinion Gear to Ring Gear Engagement in this section of this manual). 13.Place the correct combination of shims on the gear case. Tighten mounting nuts and screws from 35 to 41 ft-lb (47 to 56 N--m). 2 3 14.Install retaining rings and driven gear on input shaft/ pinion gear. 4 15.If the drive gear (on drive motor shaft) was removed, install the retaining rings and drive gear on the motor shaft. 16.Use a new gasket and install the cover plate. Use a new O-ring and install the drive motor. Groundsmaster 4000--D/4010--D Figure 38 1. Axle case 2. Screwdriver Page 6 -- 31 3. Dial indicator 4. Input shaft/pinion gear Axles, Planetaries and Brakes Differential Gear The following procedures assume the rear axle assembly has been removed from the machine. 35 to 41 ft--lb (47 to 56 N--m) 1 Removal 1. Remove bevel gear case/axle case assemblies (see Bevel Gear Case/Axle Case Assembly in this section of this manual). IMPORTANT: Do not interchange right and left differential shafts assemblies. 2. Mark and pull the differential shaft assemblies from the axle support. 3. Remove input shaft/pinion gear assembly, shims and O-ring from the axle support (Fig. 39). 4. Remove the axle support case screws. Separate the axle support halves and remove the O-ring. 2 5 4 7 6 35 to 41 ft--lb (47 to 56 N--m) 3 Figure 39 1. 2. 3. 4. Gear Case Pinion Gear Axle support (left) Axle support (right) 5. Case screw (8 used) 6. Differential gear 7. O-ring 5. Remove the differential gear assembly, bearings and adjusting shims from the axle case. 2 6. Drive the spring pin from the differential case with a punch and hammer. Discard the spring pin (Fig. 40). 1 NOTE: Mark and arrange all components so they can be reassembled in their original position. 7. Remove the differential pinion shaft, pinion gears and pinion washers. Remove the differential side gears and side gear shims. Remove the ring gear only if it will be replaced (Fig. 41). NOTE: Replacement ring gears are only available in matched ring and pinion sets. Figure 40 1. Differential case 2. Spring pin 4 1 3 2 5 Threadlocking Compound 2 3 4 5 6 8 22 to 25 ft--lb (30 to 34 N--m) 7 Figure 41 1. 2. 3. 4. Axles, Planetaries and Brakes Page 6 -- 32 Differential pinion shaft Pinion gear Pinion washer Side gear 5. 6. 7. 8. Side gear shims Ring gear Differential case Bolt/washer (8 used) Groundsmaster 4000--D/4010--D Inspection 1. Measure the differential side gear O.D. and the differential case I.D. to determine the side gear to case clearance (Fig. 42). Replace components as necessary. SIDE GEAR TO CASE CLEARANCE: 0.002 to 0.012 inch (0.05 to 0.30 mm) 1 SIDE GEAR O.D. (Factory Spec.): 1.335 to 1.337 inch (33.91 to 33.95 mm) DIFFERENTIAL CASE I.D. (Factory Spec.): 1.339 to 1.341 inch (34.00 to 34.06 mm) 2 2. Measure the differential pinion shaft O.D. and the pinion gear I.D. to determine the pinion shaft to pinion gear clearance (Fig. 43). Replace components as necessary. PINION SHAFT TO PINION GEAR CLEARANCE: 0.001 to 0.010 inch (0.03 to 0.25 mm) PINION SHAFT O.D. (Factory Spec.): 0.550 to 0.551 inch (13.97 to 13.10 mm) Figure 42 1. Side gear PINION GEAR I.D. (Factory Spec.): 0.551 to 0.552 inch (13.10 to 14.02 mm) 2. Differential case 3. Inspect all gears, shafts, bearings, cases and covers for damage and wear. Replace components as necessary. 1 2 Figure 43 1. Pinion shaft Groundsmaster 4000--D/4010--D Page 6 -- 33 2. Pinion gear Axles, Planetaries and Brakes Installation 3 1. If the ring gear was removed from the differential case, use medium strength Loctite thread locker and tighten the mounting screws from 22 to 25 ft-lb (30 to 34 N--m). 2 1 2. Apply molybdenum disulfide lubricant (Three Bond 1901 or equivalent) to the splines and bearing surfaces of the differential pinion gears, pinion washers and side gears. 3. Install the side gear shims and side gears in their original location in the differential case. 4. Place the differential pinion gears and pinion washers in their original location in the differential case. Temporarily install the differential pinion shaft. 5. Secure the differential case in a soft jawed vise. Position a dial indicator on a tooth of the differential pinion gear. Press the pinion and side gear against the differential case and measure the pinion gear to side gear backlash (Fig. 44). Figure 44 1. Vise 2. Differential gear case 3. Dial indicator More than 35% total tooth contact PINION GEAR TO SIDE GEAR BACKLASH: 0.004 to 0.016 inch (0.10 to 0.40 mm) 1/3 to 1/2 of entire width from small end of tooth 6. Adjust backlash by increasing or reducing side gear shim thickness. Figure 45 NOTE: Side gear shims are available in 0.043 inch (1.10 mm), 0.047 inch (1.20 mm) and 0.051 inch (1.30 mm) thickness. 12.Install differential gear assembly in right side axle support half. 7. Apply gear marking compound, such as DyKemR Steel Blue lightly over several gear teeth. 13.Coat a new o-ring with grease and install left side axle support half. Tighten axle support case screws from 35 to 41 ft-lb (47 to 56 N--m). 8. While applying a light load to either side gear, rotate either pinion gear until the side gears have made one complete revolution. 14.Install input shaft/pinion gear assembly (see Input Shaft/Pinion Gear in this section of this manual). 9. Ideal tooth contact should cover more than 35% of each tooth surface. The contact area should be in the center of each tooth and extend 1/3 to 1/2 way across each tooth from the toe (small) end (Fig. 45). 10.Adjust side gear shims if necessary to correct tooth contact. Recheck differential pinion gear to side gear backlash if any changes are made. 15.Coat new o-rings with grease, align differential shaft splines with differential gear assembly and slide differential shaft assemblies onto axle support. 16.Install bevel gear case/axle case assemblies (see Bevel Gear Case/Axle Case Assembly in this section of this manual). 11. After backlash and tooth contact have been adjusted, align the hole in the differential pinion shaft with the hole in the differential case and install a new spring pin. Axles, Planetaries and Brakes Page 6 -- 34 Groundsmaster 4000--D/4010--D Pinion Gear to Ring Gear Engagement The final position of the pinion gear is verified by using the gear contact pattern method as described in the following procedure. PROFILE TOP LAND GEAR TOOTH DEFINITIONS (Fig. 46): Toe -- the portion of the tooth surface at the end towards the center. TOE HEEL Heel -- the portion of the gear tooth at the outer end. LENGTHWISE BEARING ARC Top Land -- top surface of tooth. 1. Paint the teeth of the ring gear, both drive and coast side, with a gear marking compound, such as DyKemR Steel Blue. ROOT Figure 46 2. Install the input shaft/pinion gear assembly into axle case. More than 35% total tooth contact 3. While applying a light load to the ring gear, rotate the pinion gear in the direction of forward travel until the ring gear has made one complete revolution. Ideal tooth contact observed on the ring gear should cover more than 35% of each tooth surface. The contact area should be in the center of each tooth and extend 1/3 to 1/2 way across each tooth from the toe end (Fig. 47). 1/3 to 1/2 of entire width from small end of tooth Figure 47 Adjustments to the gear contact position are made by moving the input shaft/pinion gear (bearing case shims) or by moving the differential gear case (differential bearing shims) (Fig. 48). 4 3 NOTE: Bearing case shims are available in 0.004 inch (0.10 mm) and 0.008 inch (0.20 mm) thickness. NOTE: Differential bearing shims are available in 0.004 inch (0.10 mm), 0.008 inch (0.20 mm) and 0.016 inch (0.40 mm) thickness. Study the different contact patterns (Figs. 49 and 50) and correct gear engagement as necessary. 2 NOTE: When making changes, note that two variables are involved (see Gear Pattern Movement Summary in this section of this manual). Example: If the pinion gear to ring gear backlash is set correctly to specifications and the bearing case shim is changed to adjust tooth contact, it may be necessary to readjust backlash to the correct specification before checking the contact pattern. Groundsmaster 4000--D/4010--D 1 Figure 48 1. Input shaft/pinion gear 2. Bearing case shims 3. Differential gear case Page 6 -- 35 4. Differential bearing shims Axles, Planetaries and Brakes Gear Pattern Movement Summary Heel Contact Base Contact Every gear has a characteristic pattern. The illustrations show typical patterns only and explain how patterns shift as gear location is changed. 1. If contact is toward the heel or base of the gear (Fig. 49): A. Install thicker or additional bearing case shim(s) to move pinion shaft toward ring gear. Figure 49 B. Install thinner or remove differential bearing shim(s) to move ring gear backward. C. Repeat until proper tooth contact and pinion gear to ring gear backlash are correct. Toe Contact Tip Contact 2. If contact is toward the toe or tip of the gear (Fig. 50): A. Install thinner or remove bearing case shim(s) to move pinion shaft away from ring gear. B. Install thicker or additional differential bearing shim(s) to move ring gear forward. Figure 50 C. Repeat until proper tooth contact and pinion gear to ring gear backlash are correct. Axles, Planetaries and Brakes Page 6 -- 36 Groundsmaster 4000--D/4010--D Chapter 7 Chassis Table of Contents GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . 1 Operator’s Manual . . . . . . . . . . . . . . . . . . . . . . . . . . 1 SERVICE AND REPAIRS . . . . . . . . . . . . . . . . . . . . . . 2 Steering Tower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Center Deck Lift Arms . . . . . . . . . . . . . . . . . . . . . . . 4 Side Deck Lift Arms . . . . . . . . . . . . . . . . . . . . . . . . . 8 Side Deck Rear Arm Assembly . . . . . . . . . . . . . . 10 Lift Arm Joint Yoke . . . . . . . . . . . . . . . . . . . . . . . . . 14 Control Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Traction Pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Operator Platform . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Operator Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Operator Seat Service . . . . . . . . . . . . . . . . . . . . . . 26 Operator Seat Suspension . . . . . . . . . . . . . . . . . . 28 Hood . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 General Information Operator’s Manual Chassis The Operator’s Manual provides information regarding the operation, general maintenance and maintenance intervals for your Groundsmaster machine. Refer to that publication for additional information when servicing the machine. Groundsmaster 4000--D/4010--D Page 7 -- 1 Chassis Service and Repairs Steering Tower 2 1 3 6 20 to 26 ft--lb (28 to 35 N--m) 4 7 27 to 33 ft--lb (37 to 44 N--m) 5 8 10 9 17 19 10 11 18 7 20 12 13 14 20 15 16 RIGHT FRONT 22 21 23 19 24 Figure 1 1. 2. 3. 4. 5. 6. 7. 8. Steering wheel cover Hex nut Flat washer Steering wheel Foam collar Steering seal External snap ring (2 used) Steering shaft Chassis 9. 10. 11. 12. 13. 14. 15. 16. Flange bushing Thrust washer (as needed) Cap screw (4 used) Washer (4 used) Washer (4 used) Mount (4 used) Valve mount plate Steering control valve Page 7 -- 2 17. 18. 19. 20. 21. 22. 23. 24. Steering column Cap screw (2 used) Pivot hub (3 used) Flange nut (3 used) Spacer Cap Tilt lever Cap screw Groundsmaster 4000--D/4010--D Disassembly (Fig. 1) 3 1. Park machine on a level surface, lower cutting decks, stop engine, apply parking brake and remove key from the ignition switch. 5 2. Remove steering tower covers to access steering tower components (Fig. 2). 2 3. Disassemble steering tower as needed using Figure 1 as a guide. Assembly (Fig. 1) 2 1. Assemble steering tower using Figures 1 and 2 as guides. 4 A. If steering column (item 17) was removed, torque cap screws (item 18) that secure steering column to frame bracket from 27 to 33 ft--lb (37 to 44 N--m). 1 2 B. Thrust washer(s) (item 10 in Fig. 1) on steering column are used as needed to remove end play of steering shaft. 1. Operator platform 2. Flange screw (10 used) 3. Front cover 4. Clip (2 used) 5. Rear cover Chassis C. If steering wheel was removed, torque hex nut that secures steering wheel from 20 to 26 ft--lb (28 to 35 N--m). Figure 2 Groundsmaster 4000--D/4010--D Page 7 -- 3 Chassis Center Deck Lift Arms 42 41 42 41 43 RIGHT 44 FRONT 90 to 100 ft--lb (123 to 135 N--m) 18 19 20 2 37 38 6 5 4 40 8 17 12 11 33 10 3 15 14 9 34 31 29 5 25 23 28 7 30 14 13 36 36 39 37 32 11 15 23 24 21 22 60 to 70 ft--lb (81 to 94 N--m) 12 27 26 150 to 175 ft--lb (203 to 237 N--m) 35 1 16 16 35 Figure 3 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. Center deck assembly Grease fitting Ball joint seal Hydraulic deck motor Flange head screw RH lift arm LH lift arm Lift cylinder (2 used) Pin (2 used) Flange nut (2 used) Jam nut (LH threads) (2 used) Ball joint (LH threads) (2 used) Cotter pin (2 used) Ball joint mount (2 used) Flange nut (2 per mount) Chassis 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. Cap screw (2 per mount) Sensor plate Carriage screw Flat washer Flange nut U--bolt (2 used) Height--of--cut chain (2 used) Flat washer (4 per u--bolt) Hex nut (2 per u--bolt) Lock nut (2 per u--bolt) Clevis pin (2 used) Hair pin (2 used) Cap screw Spherical rod end Damper Page 7 -- 4 31. 32. 33. 34. 35. 36. 37. 38. 39. 40. 41. 42. 43. 44. Clevis rod end Spring pin Grease fitting (2 used) Spacer Flat washer (2 used) Slotted hex nut Grease fitting Lock nut (2 used) Lift arm pin (2 used) Spring pin (2 used) Flat washer (4 used per pin) Cotter pin (2 used per pin) Clevis pin (2 used) Front frame Groundsmaster 4000--D/4010--D Removal (Fig. 3) 1. Park machine on a level surface, lower cutting decks, stop engine, apply parking brake and remove key from the ignition switch. 1 2. Remove center cutting deck (see Center Cutting Deck Removal in Chapter 8 -- Cutting Decks). CAUTION 1.200” (30.5 mm) When changing attachments, tires or performing other service, use correct jacks and supports. Make sure machine is parked on a solid, level surface such as a concrete floor. Prior to raising machine, remove any attachments that may interfere with the safe and proper raising of the machine. Always chock or block wheels. Use jack stands to support the raised machine. If the machine is not properly supported by jack stands, the machine may move or fall, which may result in personal injury. 2 Figure 4 1. U--bolt 2. Height of cut chain 2 3. Chock rear wheels and jack up front of machine. Support machine on jack stands. 4. Remove front wheel next to lift arm that is to be removed. 1 5. Remove cap screw, washers and lock nut that secure lift cylinder pin to lift arm. Remove pin and separate lift cylinder and lift arm. NOTE: The lift arm ball joint (item 12) and jam nut (item 11) have left hand threads. 7. Remove height--of--cut chain, ball joint mount and ball joint from removed lift arm as required. Installation (Fig. 3) 1. Position lift arm to frame and insert lift arm pin. Engage roll pin into frame slots and install lock nut on pin. Torque lock nut from 60 to 70 ft--lb (81 to 94 N--m). Make sure that lift arm pivots freely after installation. 2. Align lift cylinder with lift arm. Slide pin through lift arm and cylinder end. Secure pin with cap screw, washers and lock nut. 3. Install front wheel assembly and lower machine to the ground. Make sure that wheel lug nuts are torqued from 85 to 100 ft--lb (115 to 135 N--m). Groundsmaster 4000--D/4010--D Figure 5 1. Lift arm 2. Ball joint 4. If sensing plate (item 32) was removed from lift arm, secure plate fully forward in lift arm slot. 5. If height--of--cut chain u--bolt was removed from lift arm, assemble u--bolt so that threaded portion extends 1.200” (30.5 mm) above lift arm mounting plate (Fig. 4). This dimension is a starting point that might need additional adjustment for deck pitch correction (see step 12 below). NOTE: The lift arm ball joint (item 12) and jam nut (item 11) have left hand threads. 6. If removed, install ball joint to lift arm. Distance from end of lift arm to center of ball joint should be from 2.210” to 2.390” (56.1 to 60.7 mm) (Fig. 5). Make sure that ball joint is horizontal and that stud is centered in ball joint. Install deck before torquing ball joint jam nut (item 24). Page 7 -- 5 Chassis Chassis 6. Remove lock nut that secures lift arm pin. Support lift arm and slide pin from frame and lift arm. Remove lift arm from frame. 2.210” to 2.390” (56.1 to 60.7 mm) 7. Install ball joint mount to ball joint with slotted hex nut. Torque nut from 90 to 100 ft--lb (123 to 135 N--m) while aligning cotter pin holes. Install cotter pin. 8. Install center cutting deck (see Center Cutting Deck Installation in Chapter 8 -- Cutting Decks). 9. If ball joint was removed from lift arm, torque ball joint jam nut from 150 to 175 ft--lb (203 to 237 N--m). Chassis 10.Lubricate lift arm grease fittings. 11. After assembly is completed, raise and lower the cutting deck to verify that hydraulic hoses and fittings do not contact anything. 12.Check height--of--cut and deck pitch adjustment (refer to Operator’s Manual). Page 7 -- 6 Groundsmaster 4000--D/4010--D Chassis This page is intentionally blank. Groundsmaster 4000--D/4010--D Page 7 -- 7 Chassis Side Deck Lift Arms 33 13 34 13 33 35 1 Loctite #242 2 3 4 8 5 4 15 34 30 10 20 31 21 32 29 24 17 9 77 to 96 ft--lb (105 to 130 N--m) 10 27 19 22 23 26 25 6 12 14 28 RIGHT 7 Antiseize Lubricant 11 13 15 16 24 18 FRONT Figure 6 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. Lift cylinder pin Slotted roll pin Flange head screw Rubber bumper Rivet (2 per bumper) Cap screw Thrust washer Lift arm pivot shaft Pivot hub Thrust washer (as needed) Spring pin Tapped block 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. Flat washer (5 used per side) Flange head screw (3 used per block) Grease fitting Flange bushing (2 per hub) Flange bushing (2 per hub) Grease fitting Flange bushing (2 per lift arm) Jam nut (2 per switch) Washer (2 per switch) Lift arm (LH shown) Bushing (2 per lift arm) Flange nut (3 used per side) 25. 26. 27. 28. 29. 30. 31. 32. 33. 34. 35. Sensing plate Carriage screw (2 per plate) Shoulder screw Cylinder pin Lift cylinder Plastic grip Proximity switch Crossmember Lock nut (2 per side) Washer (2 per latch) Latch (LH shown) NOTE: There are not bushings in the frame to support the lift arm pivot shaft (item 8) because the shaft is fixed in place by a roll pin (item 11). The lift arm (item 22) and pivot hub (item 9) rotate on the pivot shaft and have bushings that can be serviced. NOTE: Allowable clearance between lift arm pivot shaft (item 8) and front frame bore (Fig. 7) is up to 0.025” (0.64 mm). Allowable clearance between lift arm pivot shaft and rear frame bore is up to 0.070” (1.78 mm). 2 1 Figure 7 1. Front frame bore Chassis Page 7 -- 8 2. Rear frame bore Groundsmaster 4000--D/4010--D Removal (Fig. 6) 1. Park machine on a level surface, lower cutting decks, stop engine, apply parking brake and remove key from the ignition switch. 2. Remove side deck from lift arm (see Side Cutting Deck Removal in Chapter 8 -- Cutting Decks). 3. Remove side deck rear arm assembly from pivot hub (see Side Deck Rear Arm Assembly Removal in this section). 6. Align lift cylinder with lift arm. Secure lift cylinder to lift arm with lift cylinder pin (item 28). After lift cylinder is secured, make sure that upper hydraulic fitting on lift cylinder does not contact frame. 7. Install side deck rear arm assembly (see Side Deck Rear Arm Assembly Installation in this section). 8. If sensing plate (item 25) was removed from lift arm, secure plate so it is rotated as far as possible toward center of machine. 4. Remove lift cylinder pin (item 28) that secures lift cylinder to lift arm. 9. Position and install side cutting deck to machine (see Side Cutting Deck Installation in Chapter 8 -- Cutting Decks). 5. Drive out slotted roll pin (item 11) that retains lift arm pivot shaft. Discard roll pin. 10.Lubricate lift arm grease fittings after assembly is complete. 6. Support lift arm and pull lift arm pivot shaft from lift arm and frame. Locate and remove thrust washers (item 10) during pivot shaft removal. Note location of thrust washers for assembly purposes. 11. After assembly is completed, raise and lower the cutting deck to verify that hydraulic hoses and fittings do not contact anything. A. If pivot shaft is difficult to remove, fabricate a puller as shown in Figure 8. 3” x 12” (3/8” to 1/2” thick) plate steel 9/16” hole B. Attach puller to end of pivot shaft using bolt and flat washer. C. Drive pivot shaft from lift arm and frame with hammer. Flat washer 1/2” -- 13 UNC bolt 7. Remove lift arm from machine. Installation (Fig. 6) 1” to 1 1/8” 1. Apply anti--seize lubricant to lift arm pivot shaft. 2. Position lift arm to frame with thrust washers properly placed (Fig. 6). Make sure that there is a thrust washer placed between the rear of the lift arm and frame. Additional thrust washers can be used to remove end play of lift arm. Use hammer to drive pivot shaft from lift arm 3. Slide pivot shaft into frame and lift arm until roll pin holes in shaft and frame align. Make sure that lift arm pivots freely after installation. 5. If pivot hub (item 9) was removed from pivot shaft, slide pivot hub onto shaft. Apply Loctite #242 (or equivalent) to cap screw threads and secure pivot hub with washer and cap screw. Torque cap screw from 77 to 96 ft--lb (105 to 130 N--m). Groundsmaster 4000--D/4010--D Page 7 -- 9 Chassis 4. Install new slotted roll pin (item 11) to secure lift arm pivot shaft. Figure 8 Chassis Side Deck Rear Arm Assembly Loctite #271 34 25 24 29 40 39 33 28 22 26 31 34 35 35 36 31 37 30 27 18 19 RIGHT 35 32 15 21 17 38 23 20 14 13 13 5 FRONT 270 to 330 in--lb (31 to 37 N--m) 12 4 11 3 6 1 9 2 8 16 10 41 7 43 42 Figure 9 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. Cutting deck (LH shown) Deck mount (LH shown) Cap screw Lock nut Clevis pin Hair pin Spacer Rod end Jam nut Cap screw (4 per arm) Straight bushing Spring shaft Flat washer Compression spring Plastic bearing Chassis 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. Plate Lock nut (2 per arm) Pivot shaft Retaining ring Thrust washer (2 per arm) Flange bushing Rear arm (LH shown) Lock nut (2 per damper) Lock washer Lock nut Grease fitting Jam nut Cap screw Bell crank (LH shown) Page 7 -- 10 30. 31. 32. 33. 34. 35. 36. 37. 38. 39. 40. 41. 42. 43. Damper Damper rod end (2 per damper) Cap screw (2 per damper) Link tube Lock nut Flat washer Bushing Damper spring Lock nut (4 per arm) Jam nut (2 per arm) Rod end (2 per arm) Cap screw (8 used) Lock washer (8 used) Flat washer (8 used) Groundsmaster 4000--D/4010--D Rear Arm Removal (Fig. 9) 1. Park machine on a level surface, lower cutting decks, stop engine, apply parking brake and remove key from the ignition switch. 10.If rod ends (item 31) were removed from damper (item 30), apply Loctite #271 (or equivalent) to damper shaft threads before installing rod ends. Secure damper to bellcrank and rear arm with cap screws and lock nuts. 2. Remove hair pin (item 6) and clevis pin (item 5) that connect damper link to cutting deck. 11. If damper link was disassembled, adjust the length of the link from 5.295” to 5.445” (134.5 to 138.3 mm) (Fig. 11). 3. Remove cap screw (item 3) and lock nut (item 4) that secures rod end of rear arm to cutting deck. Locate and remove spacer from each side of rod end. 12.If damper springs (item 37) were removed, tighten lock nuts so that bushings (item 36) are free to rotate. 4. Remove lock nut (item 25) and lock washer (item 24) that secures rear arm pivot shaft. Slide pivot shaft from hub and rear arm. Remove rear arm assembly from machine. 1 2 3 Rear Arm Disassembly (Fig. 9) 1. Disassemble rear arm assembly using Figure 9 as a guide. Rear Arm Assembly (Fig. 9) 1. Slide large flat washer, spring, plastic bearing, second large flat washer and small flat washer onto spring shaft. Thread one jam nut onto shaft and tighten so that spring is compressed to a length of 7.690” (195.3 mm). 3. Insert assembly into rear arm housing. 1 4. Secure plate to rear arm housing with two (2) cap screws and lock nuts. 2 IMPORTANT: All free play must be removed from assembly to allow proper operation and ensure long life. 3 5. Grasp end of spring shaft. Push inward and pull outward on shaft to determine free play in assembly. Loosen jam nut, 1/2 turn at a time, until there is no free play in spring assembly. 5.295” to 5.445” (134.5 to 138.3 mm) 2 6. Remove two (2) cap screws and nuts securing plate to rear arm housing. Remove spring shaft assembly from housing. 7. Thread remaining jam nut onto end of spring shaft and, while retaining inner jam nut to prevent it from moving, torque outer jam nut from 22 to 28 ft--lb (30 to 37 N--m) to lock adjustment. 3. Damper 1 Chassis 2. Slide the straight bushing and plate onto spring shaft. Figure 10 1. Lift arm (RH shown) 2. Rear arm Figure 11 1. Rod end (2 used) 2. Jam nut (2 used) 3. Link tube 8. Thoroughly pack spring with grease. Install spring shaft assembly into housing and secure plate with four (4) cap screws and lock nuts. 9. Thread rod end (item 8) with jam nut (item 9) into end of spring shaft. Do not tighten jam nut at this time. Groundsmaster 4000--D/4010--D Page 7 -- 11 Chassis Rear Arm Installation (Fig. 9) 1. Position rear arm assembly to cutting deck and frame. 2. Slide pivot shaft through rear arm clevis and hub. Secure pivot shaft with lock washer (item 24) and lock nut (item 25). 3. Connect damper link to cutting deck with clevis pin (item 5) and hair pin (item 6). 4. Position spacers on both sides of rod end of rear arm assembly. Secure rod end of rear arm assembly to deck mount with cap screw (item 3) and lock nut (item 4). Figure 12 5. Lubricate rear arm grease fittings. 6. Align cutting deck to traction unit as follows: A. Make sure the machine is on a level, hard surface. B. Place a square or straight edge against the deck weldment that contains the castor fork assembly (Fig. 12). Do not use the castor fork assembly itself. C. Measure from the inset bead of the rim (not the outer edge of the rim) to the straight edge at two locations as indicated in Figure 12. Rim and paint irregularities make the rim outer edge an unreliable point of measure. These two measurements should be the same within a tolerance of 1/8” (3 mm). D. Rotate spring shaft (item 12) in rear arm assembly until correct dimension is attained. Shaft should rotate freely inside the assembly. All adjustments must be made with the rod end of the rear arm bolted to the deck. E. Raise and lower the deck and recheck dimensions for correct alignment. F. When deck is properly aligned to traction unit, tighten rod end jam nut (item 9). NOTE: Due to differences in turf conditions and the counterbalance setting of traction unit, it is advised that turf be cut and appearance checked before formal cutting is started. Refer to Operator’s Manual for correcting cutting deck mismatch procedures. Chassis Page 7 -- 12 Groundsmaster 4000--D/4010--D Chassis This page is intentionally blank. Groundsmaster 4000--D/4010--D Page 7 -- 13 Chassis Lift Arm Joint Yoke 13 150 to 180 ft--lb (203 to 244 N--m) 14 12 21 17 11 11 9 10 1 20 18 18 5 19 6 8 3 RIGHT 16 2 4 15 FRONT 7 Figure 13 1. 2. 3. 4. 5. 6. 7. Side cutting deck (LH shown) Deck mount (LH shown) Retaining ring (2 used per deck) Lock nut Plate Rubber plate Cap screw 8. 9. 10. 11. 12. 13. 14. Flat washer (8 used per mount) Joint yoke Spacer Thrust washer (0.125” thickness) Hardened washer Cotter pin Slotted hex nut Removal (Fig. 13) 1. Park machine on a level surface, lower cutting decks, stop engine, apply parking brake and remove key from the ignition switch. 2. Remove cap screw (item 19) and lock nut (item 20) that secures rod end of rear arm assembly to cutting deck. Locate and remove spacer (item 18) from each side of rod end. 15. 16. 17. 18. 19. 20. 21. Cap screw (8 used per mount) Lock washer (8 used per mount) Rear arm assembly Spacer Cap screw Lock nut Thrust washer (0.032” thickness) 4. Remove cotter pin from joint yoke shaft. Make sure that deck mount is supported and remove slotted hex nut that secures joint yoke to lift arm. Take hardened washer (item 12) and thrust washers (items 21 and 11) from joint yoke shaft. Slowly raise lift arm enough to free joint yoke from lift arm. Remove thrust washer (item 11) and spacer (item 10) from yoke shaft. 5. Lift joint yoke and deck mount from lift arm and cutting deck. 3. Remove eight (8) cap screws, lock washers and flat washers that secure deck mount to cutting deck (Fig. 14). Chassis Page 7 -- 14 Groundsmaster 4000--D/4010--D Joint Yoke Disassembly 1. Remove retaining rings from yoke and deck mount. IMPORTANT: Support yoke when removing cross and bearings to prevent yoke damage. 2. Use a press to remove yoke from deck mount: 5. Install retaining rings to yoke and deck mount to secure bearings in place. 6. Make sure that assembled joint yoke moves without binding. Slight binding can usually be eliminated by lightly rapping the yoke lugs with a soft faced hammer. If binding continues, disassemble joint yoke and deck mount to identify and eliminate source of binding. A. Place a small socket against one bearing in the deck mount and a large socket on the opposite side of the mount. Installation (Fig. 13) B. While supporting the large socket, apply pressure on small socket to partially push the opposite bearing into the large socket. 2. Secure deck mount to deck with eight (8) cap screws, lock washers and flat washers (Fig. 14). C. Remove assembly from press, grasp partially removed bearing and tap on yoke to completely remove the bearing. D. Repeat process for remaining bearing. E. Remove yoke from mount. 3. Use a press and the above process to remove bearings and cross from yoke. 4. Thoroughly clean and inspect all components. 1. Position joint yoke with deck mount to cutting deck. 3. Place spacer washer (chamfered ID side down) and then thrust washer (item 11) onto joint yoke shaft. Insert yoke shaft up through lift arm bushings. Place additional thrust washers (items 11 and 21) and then hardened washer (item 12) on yoke shaft and secure with slotted hex nut. Torque nut from 150 to 180 ft--lb (203 to 244 N--m) while aligning hole in shaft with slot in nut. Install cotter pin. 4. Position spacers on both sides of rod end of rear arm assembly. Secure rod end of rear arm assembly to deck mount with cap screw and lock nut. 5. Grease joint yoke and lift arm bushings after installation on machine. Joint Yoke Assembly 1. Make sure that rubber plate (item 6) and plate (item 5) are positioned in bottom of deck mount. 2. Apply a coating of grease to bearing bores of yoke and deck mount. Also, apply grease to bearings and seal of bearing assembly. Make sure that all bearing rollers are properly seated in bearing cage. 6. After assembly is completed, raise and lower the cutting deck to verify that hydraulic hoses and fittings do not contact anything. 1 3. Use a press to install cross and bearings into yoke. 3 A. Press one bearing partially into yoke. 4 2 IMPORTANT: Take care when installing cross into bearing to avoid damaging bearing seal. B. Carefully insert cross into bearing and yoke. 5 D. Carefully place second bearing into yoke bore and onto cross shaft. Press bearing into yoke. 4. Use a press and the above process to install deck mount to yoke. Groundsmaster 4000--D/4010--D 5 Chassis C. Hold cross in alignment and press bearing in until it hits the yoke. Figure 14 1. Lift arm (RH shown) 2. Joint yoke 3. Rear arm assembly Page 7 -- 15 4. Deck mount 5. Cap screw/washers Chassis Control Arm 27 26 28 18 25 23 21 22 20 34 1 19 31 14 13 11 29 36 30 33 32 37 35 40 41 10 9 38 15 24 39 2 16 17 7 3 12 6 RIGHT 4 8 42 FRONT 5 43 Figure 15 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. Flange nut (3 used) Flange head screw (2 used) Washer head screw (10 used) LH cover Lock nut Control arm panel Ignition switch InfoCenter display R--clamp Audio alarm PTO switch Nut Bracket U--nut (5 used) Clip (2 used) Chassis 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. Flange head screw (6 used) Flange nut (2 used) Hole plug Rivet (2 used) Switch panel Arm rest Power point Cap Nut Flange spacer (2 used) Cover plate Flange head screw (2 used) Plug (2 used) Screw Page 7 -- 16 30. 31. 32. 33. 34. 35. 36. 37. 38. 39. 40. 41. 42. 43. RH cover Cruise control switch Cover plate Cap screw (2 used) Lift/lower switch (3 used) Ignition key Nut Screw (2 used) Switch step Hex nut Hi--low speed switch Engine speed switch Hole plug (GM4000--D) Headlight switch (GM4010--D) Groundsmaster 4000--D/4010--D Disassembly (Fig. 15) 1. Park machine on a level surface, lower cutting units, stop engine and engage parking brake. Remove key from ignition switch. 2. Remove two (2) flange head screws (item 27) and then cover plate (item 26) from outside of control arm. Locate and retrieve two (2) spacers (item 25). 3. At front of control arm, remove screw (item 29) and lock nut (item 5) that secure control arm covers to each other. 8 6 6. Remove electrical components from control arm as needed using Figure 15 as a guide. 7. If necessary, remove control arm panel and supports from machine using Figures 15 and 16 as guides. 2 3 9 1 1 5 5 12 11 10 4. Remove five (5) washer head screws (item 3) that secure each cover to control arm panel. 5. Remove control arm covers from machine. As LH cover (item 4) is removed from control arm, unplug wire harness connector from headlight switch if equipped. 7 4 11 Figure 16 1. 2. 3. 4. 5. 6. Flat washer Seat belt buckle Coupling nut Spacer Carriage screw (5 used) Cap screw 7. 8. 9. 10. 11. 12. Screw Arm support Hex nut Support bracket Flange nut (5 used) Support channel Assembly (Fig. 15) 1. Install all removed electrical and control arm components using Figure 15 and 16 as guides. 2. Position covers to control arm. As LH cover (item 4) is placed, plug wire harness connector to headlight switch if equipped. 3. Secure each cover to control arm with five (5) washer head screws (item 3). Install screw (item 29) and lock nut (item 5) to secure covers at front of control arm. Chassis 4. Position cover plate and spacers to outside of control arm. Secure with two (2) flange head screws. Groundsmaster 4000--D/4010--D Page 7 -- 17 Chassis Traction Pedal 1 5 6 7 13 to 17 in--lb (1.5 to 1.9 N--m) 10 11 8 37 13 36 14 2 16 24 18 8 22 19 35 38 34 25 9 32 12 15 30 29 17 20 33 21 31 1 23 26 27 3 28 RIGHT 4 FRONT 8 Figure 17 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. Carriage bolt (6 used) Traction pedal Bushing Operator platform Cap screw Rod end bearing Hex nut Flange nut (10 used) Traction pedal shaft Roll pin Cap screw (2 used) Clamp block (2 used) Lock nut Chassis 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. Cap screw Flange nut (2 used) Lock washer Flange mount bearing Cover plate Butterfly plate Butterfly bracket Carriage screw Spacer Threadlock screw (2 used) Cap screw (5 used) Lock nut (6 used) Sensor bracket Page 7 -- 18 27. 28. 29. 30. 31. 32. 33. 34. 35. 36. 37. 38. Bushing hub Position sensor Capture plate Standoff spacer (2 used) Screw (2 used) Spring shaft Flat washer Compression spring Spring retainer Flat washer Lock nut Spring bracket Groundsmaster 4000--D/4010--D F. To install the traction pedal position sensor (item 28 in Fig. 17), press and hold the traction pedal in the reverse direction slightly. Align the slot on the end of the pedal shaft with the slot in the position sensor. Slide position sensor onto screws and release pedal. Hold position sensor in position while installing capture plate (item 29 in Fig. 17) and lock nuts (item 25 in Fig. 17). IMPORTANT: A properly installed and calibrated traction pedal position sensor is critical to accurate traction system response and for reliable sensor life. Use care when removing, installing and calibrating the traction pedal position sensor. Disassembly (Fig. 17) 1. Park machine on a level surface, lower cutting decks, stop engine, apply parking brake and remove key from the ignition switch. G. Torque screws (item 31 in Fig. 17) from 13 to 17 in--lb (1.5 to 1.9 N--m). 2. Remove front steering tower cover (see Steering Tower in this section). H. Leave the hex nut (item 7 in Fig. 17) loose so that the position sensor can be calibrated. 3. Disconnect machine wire harness connector from position sensor (item 28) on traction pedal. 2. After traction pedal assembly, make sure that there is no binding in pedal movement and also that pedal returns to the centered position when released. Correct any sticking or binding before machine operation. 5. Disassemble traction pedal as needed using Figures 17 and 18 as guides. When removing roll pin (item 10 in Fig. 17), make sure to support shaft to prevent component damage. 3. Plug machine wire harness connector into traction pedal position sensor (item 28 in Fig. 17). Assembly (Fig. 17) 4. After assembly of the traction pedal, adjust and calibrate the traction pedal and position sensor using the InfoCenter display (see Traction Pedal Adjustment and Traction Pedal Calibration in the Adjustments section of Chapter 5 -- Electrical System). 1. Assemble traction pedal using Figures 17 and 18 as guides noting the following items: 5. Make sure that hex nut (item 7 in Fig. 17) is tightened after position sensor adjustment. A. Apply grease to both the OD and ID of the spring retainer (item 35 in Fig. 17) before installation. Take care to not get grease on threads of spring shaft (item 32 in Fig. 17) or lock nut (item 37 in Fig. 17). 6. Install front steering tower cover (see Steering Tower in this section). 1 B. If lock nut (item 37 in Fig. 17) was removed, tighten nut until washer (item 36 in Fig. 17) does not rotate. 5 C. If traction pedal shaft (item 9 in Fig. 17) was removed, apply grease to the shaft areas that will be inside the bearings after assembly. 2 D. Use a press to install roll pin (item 10 in Fig. 17). DO NOT damage flange mount bearing (item 17 in Fig. 17) or cover plate (item 18 in Fig. 17) when installing roll pin. Also, take care to not distort roll pin during assembly. E. Make sure that roll pin (item 10 in Fig. 17) is fully inside the butterfly groove of the shim plate (item 20 in Fig. 17). The roll pin should not contact the shim plate throughout the operating range. 3 4 Figure 18 1. Traction pedal 2. Pedal position sensor 3. Traction pedal shaft Groundsmaster 4000--D/4010--D Page 7 -- 19 4. Clamp block (2 used) 5. Spring shaft assembly Chassis Chassis 4. If the traction pedal is to be removed from the traction pedal shaft, use a marker or paint pen on pedal and shaft to identify location of pedal for assembly purposes. Operator Platform 1 2 3 7 3 4 4 95 to 115 ft--lb (129 to 155 N--m) 6 5 5 6 RIGHT FRONT Figure 19 1. Operator platform 2. Cap screw (2 used) 3. Flat washer (4 used) Chassis 4. Center mount (4 used) 5. Plain washer (4 used) Page 7 -- 20 6. Lock nut (4 used) 7. Cap screw (2 used) Groundsmaster 4000--D/4010--D Some service procedures (e.g. removing the hydraulic reservoir) require the operator platform to be raised. The following steps can be used to raise the platform. 5 2 Disassembly (Fig. 19) 1. Park machine on a level surface, lower cutting decks, stop engine, apply parking brake and remove key from the ignition switch. 3 2 2. Disconnect negative battery cable from battery terminal and then disconnect positive cable from battery (see Battery Service in the Service and Repairs section of Chapter 5 -- Electrical System). 4 1 2 3. Remove steering tower covers (see Steering Tower in this section). 4. Disconnect machine wire harness connector from position sensor on traction pedal assembly. Figure 20 1. Operator platform 2. Flange screw (10 used) 3. Front cover 5. Remove fasteners that secure traction pedal assembly to operator platform and then remove traction pedal assembly from platform (Fig. 21). 4. Clip (2 used) 5. Rear cover 1 2 6. Disconnect both brake cables from brake pedals and operator frame (Fig. 22). Access to brake cable jam nuts can obtained by removing adjustment cover on operator platform (Fig. 23). Position brake cables away from operator platform. 7. Disconnect all electrical wire harness connections between operator platform components and main frame locations. As needed, label disconnected electrical connections for proper installation. 4 8. On Groundsmaster 4010 machines: 3 A. Remove operator cab from machine. Figure 21 1. Traction pedal assembly 2. Carriage screw (4 used) 6 NOTE: If desired, operator seat can be removed from operator platform to reduce overall weight of operator platform assembly (see Operator Seat in this section). 2 7 9. Remove four (4) cap screws, flat washers, plain washers and lock nuts that secure operator platform to machine frame. 5 IMPORTANT: Make sure to not damage the electrical wire harness or other components while raising the operator platform. 10.Carefully raise operator platform as needed to access components to be serviced. Support platform to prevent it from moving or shifting. Groundsmaster 4000--D/4010--D 3. Flange nut (4 used) 4. Operator platform Chassis B. Remove cable ties that secure operator cab coolant and air conditioner hoses in engine compartment to allow the operator platform to be raised. Note location of cable ties for assembly purposes. 1 3 4 Figure 22 1. 2. 3. 4. Page 7 -- 21 Brake pedal (RH shown) Cotter pin Clevis pin Brake strap 5. Spring 6. Brake cable (RH shown) 7. Brake cable jam nuts Chassis Assembly (Fig. 19) 2 13 to 17 in--lb (1.5 to 1.9 N--m) 3 1. Make sure that all machine components are installed below operator platform before platform is lowered to frame. 1 IMPORTANT: Make sure to not damage the electrical wire harness or other components while lowering the operator platform. 5 4 6 2. Carefully lower operator platform and position over center mounts (item 4) that are installed in the frame. 7 3. Secure operator platform to machine frame with four (4) cap screws, flat washers, plain washers and lock nuts. Torque lock nuts from 95 to 115 ft--lb (129 to 155 N--m). 4. Connect all electrical wire harness connections between operator platform components and main frame locations. 5. On Groundsmaster 4010 machines: Figure 23 1. 2. 3. 4. Flange screw (3 used) Adjustment cover Switch bracket Brake switch (2 used) 5. Screw (2 per switch) 6. Switch nut (2 used) 7. Clip (3 used) A. Install operator cab to machine. B. Secure operator cab coolant and air conditioner hoses in engine compartment with cable ties in locations noted during disassembly. 6. Connect both brake cables to brake pedals and operator frame. Adjust brakes so that both pedals have 1/2 to 1 inch (13 to 25 mm) of free travel. 7. Position traction pedal assembly to operator platform and secure with removed fasteners (Fig. 21). Connect machine wire harness connector to position sensor on traction pedal assembly. 8. Secure steering tower covers to machine (see Steering Tower in this section). 9. Connect positive battery cable from battery terminal and then connect negative cable to battery (see Battery Service in the Service and Repairs section of Chapter 5 -- Electrical System). Chassis Page 7 -- 22 Groundsmaster 4000--D/4010--D Chassis This page is intentionally blank. Groundsmaster 4000--D/4010--D Page 7 -- 23 Chassis Operator Seat 8 7 38 9 37 25 31 21 5 6 1 2 12 4 10 3 6 13 32 28 11 15 35 16 33 27 14 17 34 19 36 23 20 22 27 30 18 4 26 28 RIGHT 27 FRONT 29 24 Figure 24 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. Carriage screw (5 used) Support channel Support bracket Flange nut (6 used) Cap screw Flat washer (4 used) Arm support Screw Coupler nut Spacer Flange nut (4 used) Seat belt Cap screw Chassis 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. Seat latch Locking cotter pin Latch rod Locking cotter pin (2 used) Clevis pin (2 used) Flat washer (4 used) Cap screw (4 used) Seat belt latch Lock washer Cap screw Operator platform Hex nut Prop rod Page 7 -- 24 27. 28. 29. 30. 31. 32. 33. 34. 35. 36. 37. 38. Flat washer (3 used) Cotter pin (2 used) Clevis pin (2 used) Locking cotter pin (2 used) Manual tube Seat and suspension assembly Flat washer Bushing Compression spring Seat plate R--clamp (2 used) Flange head screw (2 used) Groundsmaster 4000--D/4010--D B. Secure control arm support (item 7) to coupler nut (item 9) with screw (item 8). Removal (Fig. 24) 1. Park machine on a level surface, lower cutting decks, stop engine, apply parking brake and remove key from the ignition switch. C. Place flat washer (item 6), seat belt latch (item 21) and spacer (item 10) between seat and control arm support (item 7). Secure with cap screw (item 5) and second flat washer (item 6). 2. Disconnect seat electrical connector from machine wire harness (Fig. 25). 3. Support control arm assembly to prevent it from shifting. 4. Remove flange nut (item 4) and carriage screw (item 1) that secure support bracket (item 3) to support channel (item 2). D. Fully tighten all fasteners to secure control arm assembly to seat. 4. Connect seat electrical connector to machine wire harness (Fig. 25). 5. Remove screw (item 8) that secures control arm support (item 7) to coupler nut (item 9). 1 2 6. Remove cap screw (item 5), flat washers (item 6), spacer (item 10) and seat belt latch (item 21) from seat and control arm support (item 7). IMPORTANT: Make sure to not damage the electrical harness, control cable or other parts while moving the control arm assembly. 3 7. Carefully move control arm assembly away from seat. 8. Remove four (4) torx head screws that secure seat to seat suspension (Fig. 26). Note that the screw near the seat adjustment handle is longer than the other three (3) screws. Figure 25 1. Operator seat 2. Seat switch connector 3. Suspension connector 9. Lift seat from seat suspension and remove from machine. NOTE: Refer to Operator Seat Suspension in this section if seat suspension service is necessary. 1 Installation (Fig. 24) 1. Carefully position seat to seat suspension. 2. Secure seat to seat suspension with four (4) torx head screws (Fig. 26). Make sure that longer screw is positioned near the seat adjustment handle. Torque screws 18 ft--lb (25 N--m). IMPORTANT: Make sure to not damage the electrical harness, control cable or other parts while moving the control arm assembly. 4 3. Position and secure control arm assembly to seat. Install all fasteners before fully tightening them. A. Secure support bracket (item 3) and support channel (item 2) with flange nut (item 4) and carriage screw (item 1). Groundsmaster 4000--D/4010--D Chassis 3 18 ft--lb (25 N--m) 2 Figure 26 1. Seat 2. Suspension assembly Page 7 -- 25 3. Screw (M8x12) (3 used) 4. Screw (M8x16) Chassis Operator Seat Service 7 6 21 1 2 13 5 28 12 21 22 26 25 30 29 16 18 19 20 11 4 24 14 17 3 23 9 8 27 10 15 Figure 27 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. Backrest cushion Seat cushion Armrest cover LH armrest Bushing (2 used) Backrest Plug (2 used) Cable tie (3 used) LH adjustment rail Bumper (2 used) Chassis 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. Washer Cap screw (2 used) Seat Nut Spring (2 used) Magnet Seat switch Rivet (4 used) Mounting plate Return spring Page 7 -- 26 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. Torx screw (5 used) RH adjustment rail Rail stop Torx screw Torx screw (3 used) Washer (3 used) Handle Nut Support bracket Cap screw Groundsmaster 4000--D/4010--D Disassembly (Fig. 27) 2 1. Disassemble operator seat as necessary using Figures 27 and 28 as guides. 3 Assembly (Fig. 27) 1. Assemble operator seat using Figures 27 and 28 as guides. 1 4 6 7 5 Figure 28 Operator seat R--clamp (2 used) Screw (2 used) Manual tube 5. Flat washer 6. Seat belt 7. Cap screw Chassis 1. 2. 3. 4. Groundsmaster 4000--D/4010--D Page 7 -- 27 Chassis Operator Seat Suspension RIGHT 16 17 FRONT 24 22 25 23 5 18 2 19 21 33 1 20 3 39 14 12 7 13 35 28 30 6 15 38 27 31 4 36 8 29 9 10 26 33 11 34 37 32 Figure 29 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. Cover Cover Level control Air control valve Shock absorber Air spring Air tube assembly Wire harness Compressor Bellows Stop Bumper set (2 used) Roller (4 used) Chassis 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. Washer (2 used) Tether Rivet (2 used) Washer (4 used) C--clip (4 used) Pin (2 used) Rivet (2 used) Washer (3 used) Screw (2 used) Washer Housing support (4 used) Spacer (4 used) Hose nipple Page 7 -- 28 27. 28. 29. 30. 31. 32. 33. 34. 35. 36. 37. 38. 39. Clamp (2 used) Hose nipple Screw Handle Bumper Nut Plastic plug (23 used) Screw (2 used) Roller (2 used) Screw (4 used) Base plate Suspension frame Upper plate Groundsmaster 4000--D/4010--D NOTE: Most of the seat suspension components can be serviced with the seat suspension base mounted to the frame platform. If the air spring assembly (item 6) requires removal, the seat suspension base will have to be removed from the seat platform. 1 2 Disassembly (Fig. 29) 1. Remove operator seat from seat suspension (see Operator Seat Removal in this section). 3 2. Disconnect seat suspension connector from machine wire harness (Fig. 30). 3. If the air spring assembly (item 6) or base plate (item 37) requires removal, remove seat suspension from seat plate (Fig. 31): A. Raise and support seat plate assembly. Support seat suspension to prevent it from falling. Figure 30 1. Operator seat 2. Seat switch connector B. Remove four (4) cap screws, flat washers and flange nuts that secure seat suspension to seat plate. 3. Suspension connector 1 C. Remove seat suspension from machine. 4. Remove seat suspension components as needed using Figure 29 as a guide. 4 Assembly (Fig. 29) 1. Install all removed seat suspension components using Figure 29 as a guide. 5 2. If seat suspension was removed from seat plate, secure suspension to seat plate (Fig. 31): A. Position seat suspension onto seat plate. B. Secure seat suspension to seat plate with four (4) cap screws, flat washers and flange nuts. 2 C. Lower and secure seat plate assembly. 3 3. Install operator seat to seat suspension (see Operator Seat Installation in this section). 1. Seat suspension 2. Flat washer (4 used) 3. Cap screw (4 used) 4. Flange nut (4 used) 5. Seat plate Chassis 4. Make sure that seat electrical connectors are connected to machine wire harness (Fig. 30). Figure 31 Groundsmaster 4000--D/4010--D Page 7 -- 29 Chassis Hood 21 4 1 20 24 29 18 26 28 25 31 7 23 30 27 12 9 22 6 8 5 15 RIGHT 11 10 FRONT 14 2 3 17 16 19 13 Figure 32 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. Hood Screen assembly Bulb seal Flange nut (2 used) Screen pivot (2 used) Hair pin (2 used) Hood support Plastite screw (4 used) Door handle (2 used) Bulb seal Hood pivot (2 used) Chassis 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. Flexible draw latch (2 used) Corner screen seal (2 used) Screw (8 used) LH hood support Hood rod (2 used) Clevis pin (2 used) R--clamp (2 used) Hair pin (2 used) Rear screen Top screen Page 7 -- 30 22. 23. 24. 25. 26. 27. 28. 29. 30. 31. Carriage bolt (24 used) Carriage bolt (2 used) Plastic plug (43 used) Foam seal (2 used) Flange nut (2 used) Screw (2 used) Cap screw (2 used) Flange nut (24 used) RH hood support Pop rivet (8 used) Groundsmaster 4000--D/4010--D Removal 1. Park machine on a level surface, lower cutting decks, stop engine, apply parking brake and remove key from the ignition switch. 1 3 2. Remove hood assembly from machine: A. Remove hair pins (item 6) that retain screen pivots to hood pivots. 2 B. Slide hood assembly to disengage screen pivots from hood pivots and lift hood from machine. 3. Disassemble hood as needed using Figure 32 as a guide. Figure 33 Installation 1. LH shim location 2. LH hood pivot 1. Assemble hood using Figure 32 as a guide. 3. LH screen pivot 2. Install hood to machine: A. Position hood to machine and engage screen pivots to hood pivots. 3 B. Install hair pins (item 6) to secure screen pivots to hood pivots. 3. Align hood to machine to allow correct operation of hood latch and dust seals: A. Place shim that is from 3/8” to 7/16“ (9.5 to 11.1 mm) thick on top of frame (both RH and LH sides) near the sides of radiator/oil cooler (Figs. 33 and 34). 2 B. Close hood so that it rests on shims and fasten the hood latches. C. Loosen hood pivots at frame to adjust vertical placement of pivots. Re--tighten hood pivot fasteners. 1 Figure 34 1. RH shim location 2. RH hood pivot 3. RH screen pivot D. Loosen screen pivots to allow hood latches to pull hood against radiator support. Re--tighten screen pivot fasteners. 4. After hood is assembled to machine, check for the following: Chassis A. Check that bulb and foam seals are equally compressed at all contact points with hood. Bulb and foam seals should compress from 0.125” to 0.375” (3.2 to 9.5 mm) when hood assembly is correct. B. Hood should open and close without contacting oil cooler hardware. C. Hood should fit to fuel tank with no open gaps. Groundsmaster 4000--D/4010--D Page 7 -- 31 Chassis This page is intentionally blank. Chassis Page 7 -- 32 Groundsmaster 4000--D/4010--D Chapter 8 Cutting Decks Table of Contents Cutting Decks SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . 3 Operator’s Manual . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Castor Wheel Tire Pressure . . . . . . . . . . . . . . . . . . 3 Blade Stopping Time . . . . . . . . . . . . . . . . . . . . . . . . 3 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . 4 Factors That Can Affect Quality of Cut . . . . . . . . . 4 SERVICE AND REPAIRS . . . . . . . . . . . . . . . . . . . . . . 6 Center Cutting Deck . . . . . . . . . . . . . . . . . . . . . . . . . 6 Side Cutting Decks . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Idler Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Blade Spindle Assemblies . . . . . . . . . . . . . . . . . . . 12 Blade Spindle Service . . . . . . . . . . . . . . . . . . . . . . 14 Castor Forks and Wheels . . . . . . . . . . . . . . . . . . . 16 Groundsmaster 4000--D/4010--D Page 8 -- 1 Cutting Decks Specifications MOUNTING: Cutting decks are supported by lift arms controlled with individual lift switches. CONSTRUCTION: Deck chamber is welded steel construction reinforced with channels and plates. HEIGHT--OF--CUT RANGE: 1” to 5” (25.4 mm to 127 mm) in 1/2” (12.7 mm) increments. Center deck height-of--cut adjustment is achieved by changing spacers on castor wheels and adjusting length of deck support chains. Side deck adjustment requires adding or removing spacers from the castor forks, re--positioning the castor wheel axles in the castor forks and securing the pivot arms to the correct height--of--cut bracket holes. DECK DRIVE: Closed loop hydraulic system operates hydraulic motor on each cutting deck. The motor drives one spindle directly with remaining deck spindle(s) driven by B section kevlar v--belt(s). Blade spindles are 1.250” (31.7 mm) shafts supported by greaseable, tapered roller bearings. WIDTH OF CUT: Center deck provides 62” (1575 mm) width of cut. Each side deck has 42” (1067 mm) width of cut. Total width of cut is 132” (3353 mm) with 7” (128 mm) overlap. DISCHARGE: Clippings are discharged from the rear of the cutting decks. Provided mounting holes allow attachment of optional Guardian Recycler Kit. SUSPENSION SYSTEM: A fully floating suspension with hydraulic counterbalance. Center deck suspended at rear from lift arms and has two (2) castor wheels, two (2) adjustable skids and two (2) anti--scalp rollers. Each side deck supported by three (3) castor wheels and a spring damper system which connects the fourth deck corner to the traction unit. There is a main lift arm that provides counterbalance to the side decks along with a rear anti--rotation link which also provides bi--directional impact protection. Optional Guardian Recycler Kit includes one anti--scalp roller on each cutting deck. CUTTING BLADE: Cutting blade dimensions are 21.750” (552 mm) long, 2.500” (64 mm) wide and 0.250” (6.4 mm) thick. Anti--scalp cup installed on each cutting blade. Three (3) blades on front deck and two (2) blades on each side deck. Cutting Decks Page 8 -- 2 Groundsmaster 4000--D/4010--D General Information CAUTION Never install or work on the cutting decks or lift arms with the engine running. Always stop engine and remove key first. Operator’s Manual The Operator’s Manual provides information regarding the operation, general maintenance and maintenance intervals for your Groundsmaster machine. Refer to that publication for additional information when servicing and adjusting the cutting decks on your Groundsmaster. Castor Wheel Tire Pressure Castor tires on the front and side decks should be inflated to 50 PSI (345 kPa). Blade Stopping Time The blades of the cutting deck are to come to a complete stop in approximately five (5) seconds after the cutting deck engagement switch is shut down. NOTE: Make sure the decks are lowered onto a clean section of turf or hard surface to avoid dust and debris. the blades on one of the cutting decks. Have the operator shut the cutting decks down and record the time it takes for the blades to come to a complete stop. If this time is greater than seven (7) seconds, the braking valve on the hydraulic manifold may need adjustment. Cutting Decks To verify this stopping time, have a second person stand back from the deck at least twenty (20) feet and watch Groundsmaster 4000--D/4010--D Page 8 -- 3 Cutting Decks Troubleshooting There are a number of factors that can contribute to unsatisfactory quality of cut, some of which may be turf conditions. Turf conditions such as excessive thatch, uneven ground conditions, “sponginess” or attempting to cut off too much grass height may not always be overcome by adjusting the machine. Remember that the “effective” or actual height--of--cut depends on cutting deck weight, tire pressures, hydraulic counterbalance settings and turf conditions. Effective height--of--cut will be different than the bench set height-of--cut. Factors That Can Affect Quality of Cut Factor Possible Problem/Correction 1. Maximum governed engine speed. Check maximum governed engine speed. Adjust speed to specifications if necessary. 2. Blade speed. All deck blades should rotate at the same speed. See items in Troubleshooting Section of Chapter 4 -Hydraulic System. 3. Tire pressure. Check air pressure of each tire including castor tires. Adjust to pressures specified in Operator’s Manual. 4. Blade condition. Sharpen blades if their cutting edges are dull or nicked. Inspect blade sail for wear or damage. Replace blade if needed. 5. Mower housing condition. Make sure that cutting chambers are in good condition. Keep underside of deck clean. Debris buildup will reduce cutting performance. 6. Height--of--cut. Make sure all cutting decks are set at the same height--of--cut. Set decks as specified in the Operator’s Manual. 7. Cutting deck alignment and ground following. Check lift arms and cutting deck pivot linkages for wear, damage or binding. Also, inspect for bent or damaged pivot shafts. 8. Roller and castor wheel condition. All rollers and caster wheels should rotate freely. Replace bearings if worn or damaged. 9. Grass conditions. Mow when grass is dry for best cutting results. Also, remove only 1” (25 mm) or 1/3 of the grass blade when cutting. Cutting Decks Page 8 -- 4 Groundsmaster 4000--D/4010--D Cutting Decks This page is intentionally blank. Groundsmaster 4000--D/4010--D Page 8 -- 5 Cutting Decks Service and Repairs CAUTION Never install or work on the cutting decks or lift arms with the engine running. Always stop engine and remove key from ignition switch first. Center Cutting Deck RIGHT FRONT 90 to 100 ft--lb (123 to 135 N--m) 38 17 19 8 18 37 20 6 5 4 2 12 11 10 3 15 14 9 34 5 30 31 29 37 33 25 23 28 7 23 24 21 22 14 13 36 36 32 11 15 12 27 26 150 to 175 ft--lb (203 to 237 N--m) 35 1 16 16 35 Figure 1 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. Center deck assembly Grease fitting Ball joint seal Hydraulic deck motor Flange head screw RH lift arm LH lift arm Lift cylinder (2 used) Pin (2 used) Flange nut (2 used) Jam nut (LH threads) (2 used) Ball joint (LH threads) (2 used) Cotter pin (2 used) Cutting Decks 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. Ball joint mount (2 used) Flange nut (2 per mount) Cap screw (2 per mount) Sensor plate Carriage screw Flat washer Flange nut U--bolt (2 used) Height--of--cut chain (2 used) Flat washer (4 per u--bolt) Hex nut (2 per u--bolt) Lock nut (2 per u--bolt) Clevis pin (2 used) Page 8 -- 6 27. 28. 29. 30. 31. 32. 33. 34. 35. 36. 37. 38. Hair pin (2 used) Cap screw Spherical rod end Damper Clevis rod end Spring pin Grease fitting (2 used) Spacer Flat washer (2 used) Slotted hex nut Grease fitting Front frame Groundsmaster 4000--D/4010--D Removal (Fig. 1) 1. Position machine on a clean, level surface. Lower cutting decks, stop engine, apply parking brake and remove key from the ignition switch. 2. Remove spring pin (item 32) that secures damper (item 30) to cutting deck. Position damper away from cutting deck. 2 NOTE: Removal of clevis pin from deck and height--of-cut chain is easier if deck is lifted slightly. 1 3. Remove hairpin and clevis pin that secure the height--of--cut chain to the rear of the cutting deck (Fig. 2). 4. Remove hydraulic motor from cutting deck (see Cutting Deck Motor Removal in the Service and Repairs Section of Chapter 4 -- Hydraulic System). Figure 2 1. Hairpin and clevis pin 2. Height--of--cut chain 5. Remove cap screws, washers and lock nuts securing ball joint mounts (item 14) to center deck castor arms (Fig. 4). 6. Slide the center cutting deck away from the traction unit. 1 1 Installation (Fig. 1) 1. Position machine on a clean, level surface. Lower lift arms, stop engine, apply parking brake and remove key from the ignition switch. 2 2. Position the center deck to the lift arms. Figure 3 3. Align ball joint mounts (item 14) to center deck castor arms and secure with cap screws, washers and lock nuts (Fig. 4). 1. Flange head screw 2. Hydraulic motor 2 NOTE: Installation of clevis pin to deck and height--of-cut chain is easier if deck is lifted slightly. 4. Install clevis pin and hairpin that secure the height-of--cut chain to the rear of the cutting deck (Fig. 2). 1 5. Install hydraulic motor to cutting deck (see Cutting Deck Motor Installation in the Service and Repairs Section of Chapter 4 -- Hydraulic System). 6. Position damper (item 30) to cutting deck bracket and secure with spring pin (item 32). 3 7. Lubricate grease fittings on cutting deck and lift arm assemblies. Figure 4 3. Castor arm Cutting Decks 1. Ball joint mount 2. Lift arm Groundsmaster 4000--D/4010--D Page 8 -- 7 Cutting Decks Side Cutting Decks RIGHT FRONT 11 2 4 3 7 5 6 1 10 9 8 Figure 5 1. 2. 3. 4. Cutting deck (LH shown) Flange head screw (2 used) Hydraulic deck motor Spider Cutting Decks 5. 6. 7. 8. Clevis pin Hair pin Deck mount (LH shown) Cap screw (8 used per mount) Page 8 -- 8 9. Lock washer (8 used per mount) 10. Flat washer (8 used per mount) 11. Lift arm (LH shown) Groundsmaster 4000--D/4010--D Removal (Fig. 5) 1. Position machine on a clean, level surface. Lower cutting decks, stop engine, apply parking brake and remove key from the ignition switch. 3 2. Remove hydraulic motor from cutting deck (see Cutting Deck Motor Removal in the Service and Repairs Section of Chapter 4 -- Hydraulic System). 2 IMPORTANT: Do not change the length of the damper link (Fig. 8). 1 3. Remove hairpin and clevis pin that secure the damper link to the rear of the cutting deck (Fig. 8). 4. Remove eight (8) cap screws, lock washers and flat washers that secure deck mount to cutting deck (Fig. 6). Figure 6 1. Flange head screw 2. Hydraulic motor 3. Deck mount screw 5. Raise lift arm enough to separate deck mount from cutting deck (Fig. 7). 1 6. Slide the cutting deck away from the traction unit. Installation (Fig. 5) 2 3 1. Position machine on a clean, level surface. Stop engine, apply parking brake and remove key from the ignition switch. 2. Position the side cutting deck to the lift arm and deck mount. 3. Lower lift arm while aligning deck mount to cutting deck. 4. Install deck mount to cutting deck with (8) cap screws, lock washers and flat washers (Fig. 6). Tighten fasteners. Figure 7 1. Lift arm (RH shown) 2. Rear arm assembly 3. Deck mount IMPORTANT: The length of the damper link should be from 5.295” to 5.445” (134 to 138 mm) measured between rod end centers. 5. Install clevis pin and hairpin that secure the damper link to the rear of the cutting deck (Fig. 8). 1 6. Install hydraulic motor to cutting deck (see Cutting Deck Motor Installation in the Service and Repairs Section of Chapter 4 -- Hydraulic System). 5.295” to 5.445” (134 to 138mm) 7. Lubricate grease fittings on cutting deck and lift arm assembly. Figure 8 1. Damper link Groundsmaster 4000--D/4010--D Page 8 -- 9 2. Clevis pin Cutting Decks Cutting Decks 2 Idler Assembly 18 17 16 22 RIGHT 15 FRONT 14 20 5 21 7 20 19 8 11 1 10 24 6 19 13 23 18 12 9 8 7 5 4 2 19 3 22 2 4 10 Figure 9 1. 2. 3. 4. 5. 6. 7. 8. Cutting deck (front shown) Flange nut Flange nut Adjusting screw Idler pulley Driven spindle (double pulley shown) Flat washer Lock washer 9. 10. 11. 12. 13. 14. 15. 16. Socket head screw Idler stop bolt Flange nut Cap screw Spacer Shoulder bolt Idler spring Lock nut 17. 18. 19. 20. 21. 22. 23. 24. Idler arm Retaining ring Thrust washer Bushing (2 used per idler) Grease fitting Washer Driven spindle (single pulley) Drive belt NOTE: The front deck is shown in Figure 9. The idler assemblies used on the side decks use the same idler components. Cutting Decks Page 8 -- 10 Groundsmaster 4000--D/4010--D Removal (Fig. 9) 1. Park machine on a level surface, lower cutting deck, stop engine, engage parking brake and remove key from the ignition switch. 2. Remove deck covers from top of cutting deck. CAUTION Be careful when removing idler spring. The spring is under heavy load and may cause personal injury. 3. Use spring hook tool to unhook the idler spring (item 15) from the adjusting screw (item 4). 4. Remove drive belt(s) from deck pulleys. 5. Loosen flange nuts (item 11) that secure idler stop bolt (item 10) to cutting deck to allow clearance between idler arm and stop bolt. 6. Remove idler components as needed using Figure 9 as a guide. Note location of washers, idler spacer and screw as idler assemblies are being removed. CAUTION Be careful when installing the idler spring. The spring is under heavy load and may cause personal injury. 3. Use spring hook tool to attach the idler spring (item 15) onto the adjusting screw (item 4) and shoulder bolt on idler arm. 4. With the idler arm tensioning the drive belt, the idler spring hook to hook length should be from 3.250” to 3.750” (82.6 to 95.2 mm) (Fig. 10). If necessary, disconnect spring and change position of adjusting screw. When idler spring is the correct length, tighten second flange nut to secure idler adjustment. 5. Adjust location of idler stop bolt so that the clearance between idler arm and idler stop bolt head is from 0.125” to 0.185” (3.2 to 4.6 mm) (Fig. 10). 6. Lubricate idler arm grease fitting. 7. Install deck covers to cutting deck. Installation (Fig. 9) 3 1 2 1. Install removed idler components using Figure 9 as a guide. A. Make sure that one (1) thrust washer (item 19) is placed above and below the idler arm. Location of additional washer (item 22) depends on whether the idler pulley mounts on the bottom side of the idler arm or on the top of the idler arm. B. Secure idler arm assembly to cutting deck with retaining ring. Figure 10 1. Idler stop bolt 2. Idler spring 3. Adjusting screw Cutting Decks 2. Install drive belt to pulleys. 0.125” to 0.185” (3.2 to 4.6 mm) 3.250” to 3.750” (82.6 to 95.2 mm) C. If idler stop bolt (item 10) was removed from deck, make sure that it is installed in the hole that allows the stop bolt head to align with the idler arm. Groundsmaster 4000--D/4010--D Page 8 -- 11 Cutting Decks Blade Spindle Assemblies 6 6 2 3 5 4 4 5 5 6 4 6 1 RIGHT FRONT 6 6 Figure 11 1. Center cutting deck 2. RH cutting deck Cutting Decks 3. LH cutting deck 4. Drive spindle assembly Page 8 -- 12 5. Driven spindle assembly 6. Grease fitting location Groundsmaster 4000--D/4010--D Removal (Figs. 11 and 12) 1. Park machine on a level surface, lower cutting decks, stop engine, apply parking brake and remove key from the ignition switch. 2. Remove covers from cutting deck to allow access to spindle assemblies. 3. If drive spindle assembly is to be serviced, remove hydraulic motor from cutting deck (see Cutting Deck Motor Removal in the Service and Repairs Section of Chapter 4 -- Hydraulic Systems). Position motor away from spindle. 4. Loosen idler assembly to release drive belt tension (see Idler Assembly Removal in this section). Remove drive belt from spindle assembly that is to be serviced. 5. Start the engine and raise the cutting deck. Stop engine and remove key from the ignition switch. Latch or block up the cutting deck so it cannot fall accidentally. 4. Slowly rotate cutting blades to verify that blades do not contact any deck components. 5. Install drive belt to spindle pulleys and idler pulley. Adjust drive belt tension (see Idler Assembly Installation in this section). 6. If drive spindle assembly was removed, install hydraulic motor to cutting deck (see Cutting Deck Motor Installation in the Service and Repairs Section of Chapter 4 -- Hydraulic Systems). IMPORTANT: Pneumatic grease guns can produce air pockets when filling large cavities and therefore, are not recommended to be used for proper greasing of spindle housings. 7. Attach a hand pump grease gun to grease fitting on spindle housing and fill housing cavity with grease until grease starts to come out of lower seal. 8. Install covers to cutting deck. 6. Remove cutting blade, anti--scalp cup and blade bolt from spindle assembly that is to be serviced. 5 3 7. Remove spindle assembly from deck. A. For driven spindle assemblies, remove eight (8) flange nuts that secure spindle assembly to deck. B. For drive spindle assemblies, remove four (4) cap screws with washers that secure spindle assembly and hydraulic motor mount to deck. Remove motor mount. Then, remove four (4) flange nuts that secure spindle assembly to deck. 1 2 C. Lift spindle assembly from deck. 6 8. If necessary, press screws from spindle housing. 4 7 Installation (Figs. 11 and 12) 1. If screws were removed from spindle housing, press new screws into housing. Make sure that screw head is squarely seated against housing after installation. 2. Position spindle assembly on cutting deck noting orientation of grease fitting (Fig. 11). Secure spindle assembly to deck with removed fasteners. 88 to 108 ft--lb (120 to 146 N--m) 10 Figure 12 1. 2. 3. 4. 5. Deck (RH shown) Driven spindle assembly Drive spindle assembly Flange nut Drive belt 6. 7. 8. 9. 10. Washer Cap screw Blade Anti--scalp cup Blade bolt Cutting Decks 3. Install cutting blade, anti--scalp cup and blade bolt to spindle. Tighten blade bolt from 88 to 108 ft--lb (120 to 146 N--m). 9 8 Groundsmaster 4000--D/4010--D Page 8 -- 13 Cutting Decks Blade Spindle Service 2 1 130 to 150 ft--lb (176 to 203 N--m) 3 130 to 150 ft--lb (176 to 203 N--m) 7 1 8 9 2 6 10 5 11 12 9 8 13 DRIVE SPINDLE 4 Figure 13 1. 2. 3. 4. 5. Lock nut Hardened washer Driven pulley (single shown) Spindle shaft Drive pulley 6. 7. 8. 9. Hydraulic motor mount O--ring Oil seal Bearing cup and cone 10. 11. 12. 13. Spacer set Spindle housing Grease fitting Spindle shaft spacer Disassembly (Fig. 13) Assembly (Fig. 13) 1. Loosen and remove lock nut from top of spindle shaft. Remove hardened washer and pulley from spindle. For drive spindle, remove hydraulic motor mount. NOTE: A replacement spindle bearing set contains two (2) bearings, a spacer ring and a large snap ring (items 1, 2 and 3 in Fig. 14). These parts cannot be purchased separately. Also, do not mix bearing set components from one deck spindle to another. 2. Remove the spindle shaft from the spindle housing which may require the use of an arbor press. The spindle shaft spacer should remain on the spindle shaft as the shaft is being removed. 3. Carefully remove oil seals from spindle housing taking care to not damage seal bore in housing. 4. Allow the bearing cones, inner bearing spacer and spacer ring to drop out of the spindle housing (Fig. 14). 5. Using an arbor press, remove both of the bearing cups and the outer bearing spacer from the housing. 6. The large snap ring can remain inside the spindle housing. Removal of this snap ring is very difficult. Cutting Decks NOTE: A replacement bearing spacer set includes the inner spacer and outer spacer (items 4 and 5 in Fig. 14). Do not mix bearing spacers from one deck spindle to another. IMPORTANT: If new bearings are installed into a used spindle housing, it may not be necessary to replace the original large snap ring. If the original snap ring is in good condition with no evidence of damage (e.g. spun bearing), leave the snap ring in the housing and discard the snap ring that comes with the new bearings. If the large snap ring is found to be damaged, replace the snap ring. 1. If large snap ring was removed from spindle housing, install snap ring into housing groove. Make sure snap ring is fully seated in housing groove. Page 8 -- 14 Groundsmaster 4000--D/4010--D 2. Install outer bearing spacer into top of spindle housing. The spacer should fit against the snap ring. 1 3. Using an arbor press, push the bearing cups into the top and bottom of the spindle housing. The top bearing cup must contact the outer bearing spacer previously installed, and the bottom bearing cup must contact the snap ring. Make sure that the assembly is correct by supporting the first bearing cup and pressing the second cup against it (Fig 15). 2 1 Figure 14 1. Bearing 2. Spacer ring 3. Large snap ring 4 6. Slide spacer ring and inner bearing spacer into spindle housing, then install upper bearing cone and oil seal into top of housing. Note: The upper seal must have the lip facing in (down) (Fig. 16). Also, upper seal should be flush or up to 0.060” (1.5 mm) recessed into housing. 8. Install spindle shaft spacer onto shaft. Place thin sleeve or tape on spindle shaft splines to prevent seal damage during shaft installation. 4. Inner bearing spacer 5. Outer bearing spacer PRESS IMPORTANT: If bearings are being replaced, make sure to use the spacer ring that is included with new bearing set (Fig. 14). 7. Inspect the spindle shaft and shaft spacer to make sure there are no burrs or nicks that could possibly damage the oil seals. Lubricate the shaft and spacer with grease. 5 3 4. Pack the bearing cones with grease. Apply a film of grease on lips of oil seals and O--ring. 5. Install lower bearing cone and oil seal into bottom of spindle housing. Note: The bottom seal must have the lip facing out (down) (Fig. 16). This seal installation allows grease to purge from the spindle during the lubrication process. 4 3 1 6 2 5 Figure 15 1. Bearing cups 2. Large snap ring 3. Outer bearing spacer 4. Arbor press 5. Support 6. Arbor press base 2 9. Carefully slide spindle shaft with spacer up through spindle housing. The bottom oil seal and spindle spacer fit together when the spindle is fully installed. 10.Install O--ring to top of spindle shaft. For drive spindle, position hydraulic motor mount to top of spindle. 11. Install pulley (hub down), hardened washer and lock nut to spindle shaft. Tighten lock nut from 130 to 150 ft-lb (176 to 203 N--m). 1 12.Attach a hand pump grease gun to grease fitting on housing and fill housing cavity with grease. 13.Rotate spindle shaft to make sure that it turns freely. Groundsmaster 4000--D/4010--D Figure 16 1. Bottom seal installation Page 8 -- 15 2. Upper seal installation Cutting Decks Cutting Decks IMPORTANT: Pneumatic grease guns can produce air pockets when filling large cavities and therefore, are not recommended to be used for proper greasing of spindle housings. Castor Forks and Wheels CASTOR FORK SIDE CUTTING DECK 34 14 13 12 16 1 11 20 6 7 19 10 9 8 31 5 15 2 10 32 17 21 22 33 7 60 to 80 ft--lb (81 to 108 N--m) 6 5 18 3 4 CASTOR WHEEL 4 28 23 60 to 80 ft--lb (81 to 108 N--m) 24 29 30 23 25 26 27 Figure 17 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. Castor arm (center deck shown) Cap screw (5 used) Castor fork Cap screw Lock nut Castor spacer Thrust washer Flange nut (5 used) Grease fitting Flange bushing Retaining ring Cap washer 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. Compression spring Cap Flat washer Lock nut (3 used per bracket) Carriage screw (3 used per bracket) Castor fork bracket Shim Castor bracket Hairpin Cutting deck (RH shown) Bearing 24. 25. 26. 27. 28. 29. 30. 31. 32. 33. 34. Inner bearing spacer Wheel hub Wheel rim half Castor tire Wheel rim half Plate Flange nut Flat washer Tension rod Flange nut Clevis pin Disassembly Assembly 1. Disassemble castor wheel as needed using Figure 17 as a guide. 1. Assemble castor wheel using Figure 17 as a guide. 2. If castor fork was removed, lubricate grease fitting. 3. Torque castor wheel lock nut (item 5) from 60 to 80 ft--lb (81 to 108 N--m). Cutting Decks Page 8 -- 16 Groundsmaster 4000--D/4010--D Chapter 9 Operator Cab Operator Cab Table of Contents GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . 2 Operator’s Manual . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Electrical Components and Schematic . . . . . . . . . 2 Air Conditioning System . . . . . . . . . . . . . . . . . . . . . 2 Cab Heater System . . . . . . . . . . . . . . . . . . . . . . . . . 2 SERVICE AND REPAIRS . . . . . . . . . . . . . . . . . . . . . . 3 General Precautions for Removing and Installing Air Conditioning System Components . . . . . . . . 3 Air Conditioning Compressor . . . . . . . . . . . . . . . . . 4 Roof Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Air Conditioning Condenser Assembly . . . . . . . . . 8 Heater/Evaporator Assembly . . . . . . . . . . . . . . . . 10 Windshield Wiper . . . . . . . . . . . . . . . . . . . . . . . . . . 12 SANDEN SD COMPRESSOR SERVICE GUIDE Groundsmaster 4010--D Page 9 -- 1 Operator Cab General Information The information in this chapter pertains to the operator cab on the Groundsmaster 4010--D. Operator’s Manual The Operator’s Manual provides information regarding the operation, general maintenance and maintenance intervals for your Groundsmaster. Refer to the Operator’s Manual for additional information when servicing the machine. Electrical Components and Schematic Information regarding Groundsmaster 4010--D electrical cab components (switches and relay) is included in Chapter 5 -- Electrical System. The electrical schematic and wire harness drawings for the operator cab are included in Chapter 10 -- Foldout Drawings. Air Conditioning System The air conditioning system used on the Groundsmaster 4010--D consists of the following components: 4. The necessary hoses and tubes that connect the system components. 1. A compressor mounted on the engine and driven by a v--belt. 5. A fan motor that provides air movement through the evaporator and into the cab. The fan motor is located in the cab headliner and is also used for the cab heater system. 2. A condenser and condenser fan located on the top of the cab. 3. A drier--receiver, an expansion valve and an evaporator (combined with the heater core) mounted in the headliner of the cab. 6. Operator controls to turn the air conditioning on, to adjust the fan speed and to control the cab air temperature. Cab Heater System The cab heater system used on the Groundsmaster 4010--D consists of the following components: 1. A heater core (combined with the A/C evaporator) located in the cab headliner. 2. Hoses to allow a circuit for engine coolant to circulate through the heater core. The heater core (combined with the A/C evaporator) is located in the headliner of the cab. Operator Cab 3. A fan motor that provides air movement through the heater core and into the cab. The fan motor is located in the cab headliner and is also used for the air conditioning system. 4. Operator controls to adjust the fan speed and to control the cab air temperature. Page 9 -- 2 Groundsmaster 4010--D Service and Repairs 5. Put labels on disconnected lines and hoses for proper installation after repairs are completed. CAUTION The air conditioning system is under high pressure. Do not loosen any system fitting or component until after the system has been completely discharged by a certified A/C service technician. WARNING Always wear safety goggles or a face shield when working with air conditioning system components. Also, do not allow refrigerant contact with your skin or eyes as there would be the possibility of serious injury. CAUTION Never use compressed air to leak test or pressure test the air conditioning system. Under certain conditions, pressurized mixtures of refrigerant and air can be combustible. 1. Before servicing any air conditioning system components, park machine on a level surface, apply parking brake, lower cutting decks or attachments and stop engine. Remove key from the ignition switch. 2. Clean machine before disconnecting, removing or disassembling any air conditioning system components. Thorough cleaning will prevent system contamination while performing service procedures. 3. Put caps or plugs on any lines, fittings or components left open or exposed to prevent system contamination. 4. Before loosening or removing any air conditioning system hose or other component, have a certified air conditioning service technician recover the system refrigerant and then evacuate the air conditioning system completely. It is illegal to vent refrigerant to the atmosphere. Groundsmaster 4010--D 6. If compressor is removed from machine, keep compressor in the same orientation as the installed position. This will prevent compressor oil from filling the compressor cylinders. 7. Note the position of fittings (especially elbow fittings) before removal. Mark parts if necessary to make sure they will be aligned properly when reinstalling hoses and tubes. 8. Always use a DOT approved tank for storing used and recycled refrigerants. 9. The Groundsmaster 4010--D air conditioning system uses R134a refrigerant. DO NOT use other refrigerants in the system. A/C system capacity is 1.35 pounds of R134a refrigerant. 10.Refrigerant containers (either full or empty) are under pressure that will increase if the containers are heated. DO NOT expose refrigerant containers to high heat sources or flame. 11. Be sure the work area is properly ventilated to prevent any accumulation of refrigerant or other fumes. 12.Make sure that caps are always placed on the pressure hose ports. These caps prevent refrigerant leakage from the system. 13.The drier--receiver component is used to collect moisture that will reduce air conditioning performance. If the air conditioning system is opened for component repair or replacement, drier--receiver replacement is recommended. 14.After installing air conditioning components, have a certified air conditioning service technician evacuate the air conditioning system completely, properly recharge the system with R134a refrigerant and then leak test the system. Page 9 -- 3 Operator Cab Operator Cab General Precautions for Removing and Installing Air Conditioning System Components Air Conditioning Compressor 21 7 8 1 2 15 5 6 13 14 16 4 3 9 2 18 10 19 20 3 17 11 12 RIGHT FRONT Figure 1 1. 2. 3. 4. 5. 6. 7. Cap screw (2 used) Flat washer (4 used) Lock washer (6 used) Hex nut (2 used) Conduit O--ring (2 used) 90o fitting 8. 9. 10. 11. 12. 13. 14. O--ring A/C compressor Cap screw (4 used) Cap screw (2 used) A/C compressor mount Flange head screw (2 used) Exhaust bracket Removal (Fig. 1) 1. Park machine on a level surface, lower cutting decks, stop engine, engage parking brake and remove key from the ignition switch. 2. Raise hood to allow access to engine. 3. Remove exhaust pipe (item 15). Operator Cab 15. 16. 17. 18. 19. 20. 21. Exhaust pipe Flange nut Carriage screw Idler pulley Compressor drive belt Engine (model 30603 shown) Clamp assembly 4. Loosen flange nut that secures idler pulley. Move pulley to loosen A/C compressor drive belt. Remove drive belt from A/C compressor pulley. 5. Inspect compressor drive belt for glazing or damage. Replace belt if necessary. 6. Disconnect compressor electrical connector from machine wire harness. Page 9 -- 4 Groundsmaster 4010--D CAUTION The air conditioning system is under high pressure. Do not loosen any system fitting or component until after the system has been completely discharged by a certified A/C service technician. 8. Have refrigerant evacuated from air conditioning system by a certified A/C service technician. 9. Label and remove hoses from compressor. Immediately cap hoses and fittings to prevent moisture and contaminants from entering the system. 10.Support compressor to prevent it from shifting or falling. NOTE: There may be shims mounted between compressor and compressor mount. When removing compressor, note shim location and quantity for assembly purposes. 11. Remove fasteners and washers that secure compressor to compressor mount. IMPORTANT: To prevent compressor oil from filling the compressor cylinders, keep compressor in the same orientation as the installed position. 2. Secure compressor to compressor mount with removed fasteners and spacers. Do not fully tighten fasteners. IMPORTANT: After the compressor has been installed, make sure to rotate the compressor drive shaft several times to properly distribute oil in the compressor. Compressor damage due to oil slugging can occur if this procedure is not performed. 3. Manually rotate the compressor drive shaft at least ten (10) revolutions to make sure that no compressor oil is in the compressor cylinders. 4. Place drive belt onto compressor pulley. 5. Tension compressor drive belt with idler pulley. Make sure to tighten flange nut to secure belt adjustment. 6. Install exhaust pipe (item 15). 7. Remove caps that were placed on hoses and fittings during the removal process. Using labels placed during removal, properly secure hoses to compressor. 8. Connect compressor electrical connector to machine wire harness. 9. Have a certified air conditioning service technician evacuate the air conditioning system completely, properly recharge the system with R134a refrigerant and then leak test the system. A/C system capacity is 1.35 pounds of R134a refrigerant. 10.Lower and secure hood. 2 12.Carefully remove compressor from engine and machine. NOTE: The replacement of the drier--receiver is recommended whenever A/C compressor is removed from the system (see Heater and Evaporator Assembly in this section). 3 NOTE: The air conditioning compressor used on the Groundsmaster 4010--D is a Sanden model SD5H09. For air conditioning compressor repair procedures, see the Sanden SD Compressor Service Guide at the end of this chapter. 1 Installation (Fig. 1) 1. Position compressor to compressor mount on engine. Figure 2 1. A/C compressor 2. Alternator 3. A/C compressor mount NOTE: The clearance between the compressor mounting flanges and compressor mount must be less than 0.004” (0.10 mm). If necessary, install shims between compressor flanges and mount to adjust clearance. See Compressor Parts Catalog for shim kit. Groundsmaster 4010--D Page 9 -- 5 Operator Cab Operator Cab 7. Read the General Precautions for Removing and Installing Air Conditioning System Components at the beginning of the Service and Repairs section of this chapter. Roof Assembly 16 3 4 1 15 14 2 3 FRONT 7 13 4 5 8 6 4 12 2 9 3 4 11 10 10 9 Figure 3 1. 2. 3. 4. 5. 6. Roof Screw (2 used) Flat washer (6 used) Bushing (10 used) Rear fastener (2 used) Rear spacer (2 used) Operator Cab 7. 8. 9. 10. 11. Panel nut Roof mount Flange nut (2 used) Flange nut (4 used) Headliner Page 9 -- 6 12. 13. 14. 15. 16. Front spacer (2 used) Front fastener (2 used) Rubber washer Cap screw Hex nut (4 used) Groundsmaster 4010--D To gain access to the heater core and air conditioning components that are located under the cab roof, the roof panel can be loosened, raised and supported. 5 3 6 Removal (Fig. 3) 1 8 2. Remove screw (item 2), flat washer (item 3) and bushing (item 4) that secure the rear of the roof to the roof mount. 3. Remove the cap screw (item 15) and rubber washer (item 14) that secure the front of the roof. 4. Remove four (4) hex nuts (item 16), flat washers (item 3) and bushings (item 4) that secure roof to front and rear fasteners. 5. Carefully lift front of roof while leaving rear of roof against headliner. Support front of roof in the raised position to allow access to heater and air conditioning components. Installation (Fig. 3) 1. Make sure that all components in headliner and roof are installed and secure. 7 2 1 4 FRONT Figure 4 1. 2. 3. 4. 5. 6. 7. 8. Condensation drain hose (2 used) Heater valve A/C hose: evaporator to compressor Heater hose: heater valve to heater core A/C hose: compressor to condenser A/C hose: condenser to drier Heater hose: thermostat to heater valve Heater hose: heater core to water pump 2. Remove support and carefully lower roof into position. 3. Secure roof to headliner with all removed fasteners. Groundsmaster 4010--D Page 9 -- 7 Operator Cab Operator Cab 1. Park machine on a level surface, lower cutting decks, stop engine, engage parking brake and remove key from the ignition switch. Air Conditioning Condenser Assembly 10 1 2 6 8 3 6 4 2 6 8 7 6 FRONT 9 5 Figure 5 1. 2. 3. 4. Condenser cover Lock nut (4 used) Condenser fan Condenser coil assembly 5. Carriage screw (2 used) 6. Flat washer (8 used) 7. Roof Removal (Fig. 5) 1. Park machine on a level surface, lower cutting decks, stop engine, engage parking brake and remove key from the ignition switch. 6. Read the General Precautions for Removing and Installing Air Conditioning System Components at the beginning of the Service and Repairs section of this chapter. 2. Remove fasteners that secure roof in place. Raise and support roof to allow access to condenser assembly (see Roof Assembly in this section). 3. Disconnect wire harness connector from condenser fan motor. 4. Remove button head screws (item 10) that secure condenser fan and cover to condenser coil. 5. Remove fasteners (items 2, 6 and 8) that secure front of condenser cover to roof. Lift condenser fan and cover from roof. Operator Cab 8. Bushing (4 used) 9. Mounting strap 10. Button head screw (4 used) CAUTION The air conditioning system is under high pressure. Do not loosen any system fitting or component until after the system has been completely discharged by a certified A/C service technician. 7. Have refrigerant evacuated from air conditioning system by a certified A/C service technician. Page 9 -- 8 Groundsmaster 4010--D 8. Label and remove hoses from condenser coil. Immediately cap hoses and fittings to prevent moisture and contaminants from entering the system. 7 3 11 NOTE: The replacement of the drier--receiver is recommended whenever the air conditioning system is opened (see Heater/Evaporator in this section). 21 Installation (Fig. 5) 20 19 2 17 1. Install condenser coil to roof using Figure 6 as a guide. 18 9 2. Remove caps that were placed on hoses and fittings during the removal process. Using labels placed during removal, properly secure hoses to condenser coil. 6 16 3. Position condenser cover and condenser fan to roof. Secure cover and fan with removed fasteners (items 2, 6 and 8). 14 13 4. Secure condenser fan to condenser coil with button head screws (item 10). 15 5 5. Connect wire harness connector to condenser fan motor. 12 8. Lower and secure roof assembly (see Roof Assembly in this section). Groundsmaster 4010--D 1 10 8 6. Make sure that all machine air conditioning components are installed and secure. 7. Have a certified air conditioning service technician evacuate the air conditioning system completely, properly recharge the system with R134a refrigerant and then leak test the system. A/C system capacity is 1.35 pounds of R134a refrigerant. Operator Cab 9. Remove condenser coil from roof using Figure 6 as a guide. 4 Figure 6 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. Page 9 -- 9 Bushing (4 used) Condenser coil Fan shroud Condenser fan Isolator mount (4 used) Coupler nut (4 used) Screw (4 used) Screw (4 used) Screw (4 used) Flat washer (4 used) Clip (4 used) 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. Tray foam Screen frame End foam (2 used) Screen Side foam (2 used) Lock nut Latch plate Friction washer (2 used) Latch spacer Carriage screw Operator Cab Heater/Evaporator Assembly 2 16 12 10 1 9 15 13 14 13 11 7 6 4 8 12 3 5 Figure 7 1. 2. 3. 4. 5. 6. Heater/evaporator assembly Top cover Flange head screw (2 used) Drier--receiver mount Bottom cover Hose clamp (2 used) 7. 8. 9. 10. 11. Speed nut (8 used) Panel nut (4 used) Drier--receiver assembly Screw (8 used) Screw (4 used) Removal (Fig. 7) 1. Park machine on a level surface, lower cutting decks, stop engine, engage parking brake and remove key from the ignition switch. 2. Remove fasteners that secure roof in place. Raise and support roof to allow access to heater/evaporator assembly (see Roof Assembly in this section). 12. 13. 14. 15. 16. Blower fan assembly Expansion valve Freeze switch Screw (2 used) Screw (12 used) CAUTION The air conditioning system is under high pressure. Do not loosen any system fitting or component until after the system has been completely discharged by a certified A/C service technician. 3. Disconnect wire harness connectors from fan motor and binary switch on drier--receiver. 5. Have refrigerant evacuated from air conditioning system by a certified A/C service technician. 4. Read the General Precautions for Removing and Installing Air Conditioning System Components at the beginning of the Service and Repairs section of this chapter. 6. Label and remove hoses from heater core, evaporator and drier--receiver. Immediately cap hoses and fittings to prevent moisture and contaminants from entering the system. Operator Cab Page 9 -- 10 Groundsmaster 4010--D 7. Loosen hose clamp that secures air duct hose to heater/evaporator assembly covers. Slide hose from covers. 5 3 8. Remove screws that secure top cover to bottom cover. Remove top cover to access heater/evaporator assembly. 6 9. Disassemble heater/evaporator assembly using Fig. 7 as a guide. 8 10.If necessary, remove fan resistor from blower fan assembly (Fig. 9). 7 NOTE: The replacement of the drier--receiver is recommended whenever the air conditioning system is opened. 2 4 1 FRONT Installation (Fig. 7) 1. Assemble heater/evaporator assembly using Fig. 7 as a guide. Make sure that expansion valve is covered with insulating tape to prevent condensation issues. Figure 8 1. 2. 3. 4. 5. 6. 7. 8. 2. If removed, secure fan resistor to blower fan assembly (Fig. 9). 3. Position heater/evaporator assembly into bottom cover in headliner. Secure top cover to bottom cover with removed screws. Condensation drain hose (2 used) Heater valve A/C hose: evaporator to compressor Heater hose: heater valve to heater core A/C hose: compressor to condenser A/C hose: condenser to drier Heater hose: thermostat to heater valve Heater hose: heater core to water pump 1 4. Slide air duct hose onto heater/evaporator assembly covers and secure with hose clamp. 4 5. Remove caps that were placed on hoses and fittings during the removal process. Using labels placed during removal, properly secure hoses to heater core, evaporator and drier--receiver. 2 6. Make sure that condensation hoses are secured to bottom housing of heater/evaporator assembly and are routed to cab frame for proper draining of condensate. 3 7. Connect wire harness connectors to fan motor and binary switch on drier--receiver. 8. Make sure that all machine air conditioning components are installed and secure. Figure 9 1. Fan resistor 2. Blower fan assembly 3. Clamp 4. Screw (2 used) 9. Have a certified air conditioning service technician evacuate the air conditioning system completely, properly recharge the system with R134a refrigerant and then leak test the system. A/C system capacity is 1.35 pounds of R134a refrigerant. 10.Operate the heater system to make sure that no engine coolant leaks exist. 11. Lower and secure roof assembly (see Roof Assembly in this section). Groundsmaster 4010--D Page 9 -- 11 Operator Cab Operator Cab 1 Windshield Wiper 8 1 7 9 2 3 4 10 6 5 11 12 13 Figure 10 1. 2. 3. 4. 5. Wiper motor Gasket Linkage bracket Lock washer Cap screw Operator Cab 6. 7. 8. 9. Cap (2 used) Washer Nut Flange nut (2 used) Page 9 -- 12 10. 11. 12. 13. Cover (2 used) Wiper arm assembly Wiper blade Screw (2 used) Groundsmaster 4010--D Disassembly (Fig. 10) Assembly (Fig. 10) 1. Park machine on a level surface, lower cutting decks, stop engine, engage parking brake and remove key from the ignition switch. 1. Assemble windshield wiper components using Figure 10 as a guide. 2. If roof was raised, lower and secure roof assembly (see Roof Assembly in this section). Operator Cab 2. If access to wiper motor is necessary, remove fasteners that secure roof in place. Raise and support roof to allow access to condenser assembly (see Roof Assembly in this section). 3. Remove windshield wiper components as needed using Figure 10 as a guide. Groundsmaster 4010--D Page 9 -- 13 Operator Cab This page is intentionally blank. Operator Cab Page 9 -- 14 Groundsmaster 4010--D Chapter 10 Foldout Drawings Table of Contents Groundsmaster 4000--D/4010--D Page 10 -- 1 Foldout Drawings ELECTRICAL DRAWING DESIGNATIONS . . . . . . . 2 HYDRAULIC SCHEMATIC . . . . . . . . . . . . . . . . . . . . . 3 ELECTRICAL SCHEMATICS Models 30605 and 30603 . . . . . . . . . . . . . . . . . . . . 4 Models 30609 and 30607 . . . . . . . . . . . . . . . . . . . . 5 Operator Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 International Light Kits . . . . . . . . . . . . . . . . . . . . . . . 7 WIRE HARNESS DRAWINGS Platform Wire Harness Drawing . . . . . . . . . . . . . . . 9 Rear Wire Harness Drawing . . . . . . . . . . . . . . . . . 12 Engine Wire Harness Drawing (Models 30609 and 30607) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Engine Wire Harness Drawing (Models 30605 and 30603) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Operator Cab Wire Harness Drawing . . . . . . . . . 18 Operator Cab Interconnect Wire Harness Drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Foldout Drawings Electrical Drawing Designations The following abbreviations are used for wire harness colors on the electrical schematics and wire harness drawings in this chapter. ABBREVIATION COLOR BK BLACK BR or BN BROWN BU BLUE GN GREEN GY GRAY OR ORANGE PK PINK R or RD RED T TAN VIO VIOLET W or WH WHITE Y or YE YELLOW Numerous harness wires used on Groundsmaster 4000 and 4010 machines include a line with an alternate color. These wires are identified with the wire color and line color with either a / or _ separating the color abbreviations listed above (e.g. R/BK is a red wire with a black line, OR_BK is an orange wire with a black line). NOTE: The electrical harness drawings in this chapter identify both the wire color and the wire gauge. For example, 16 BK on a harness diagram identifies a 16 gauge wire that has a black insulator. NOTE: A splice used in a wire harness will be identified on the wire harness diagram by SP. The manufacturing number of the splice is also identified on the wire harness diagram (e.g. SP01 is splice number 1). Foldout Drawings Page 10 -- 2 Groundsmaster 4000--D/4010--D 2.00” BORE 4.20” STROKE 0.625” ROD M1 STEERING CYLINDER G R STEERING CONTROL VALVE COOLING FAN MOTOR 0.51 CID G M1 L LEFT DECK 2.50” BORE 6.50” STROKE 1.125” ROD M2 C3 C4 C2 C5 OR5 .070 OR3 .070 S10 RIGHT DECK 2.50” BORE 6.50” STROKE 1.125” ROD CENTER DECK RAM CYLINDERS 1.50” BORE 3.08” STROKE C6 OR7 .070 P1 CH4 .025 1.17 CID 3250 PSI PRV G 3000 PSI S4 S9 6.1 CID P E S5 T S2 PD PRV CV1 4 PSI LC1 S3 PR P2 600 PSI CD CV2 4 PSI CENTER DECK S8 G1 RV M2 S7 S6 310 PSI OR4 .040 OR2 .063 S11 RV2 1600 PSI OR6 .063 G2 M1 LS P1 S1 CF PD PRV EC LC1 80 PSI 1350 PSI 3300 PSI RV1 RV S12 CV4 4 PSI P2 600 PSI CD P4 LEFT DECK P1 M1 .025 RV3 CV3 60 PSI G4 M2 1.17 CID OR1 .030 G 3000 PSI .025 1.17 CID CH1 P3 G3 CH3 T 2SP COMBINATION MANIFOLD 3.3 GPM 1.2 CID / 0.64 CID 4.4 GPM G 2000 PSI CH2 OR9 .030 13.7 GPM M1 CH1 CV1 PD PRV LC1 30.5 GPM RV M2 HFD Split 55--45 P1 14.3 GPM 600 PSI P2 CD 1.2 CID / 0.64 CID 14.3 GPM OR .063 G RIGHT DECK FRONT TRACTION MANIFOLD CV2 G CH2 G .0315 .0315 50 PSI 0.3 CID 0.4 CID M3 4350 PSI 1.29 CID 1.29 CID 16.8 GPM 2.75 CID CH ENGINE IDLE 200 PSI 2.14 CID / 1.16 CID T4 -- 2700 / 1200 RPM EU -- 2600 / 1200 RPM 250 PSI 650 PSI CV 5000 PSI RV 1. FLOWS SHOWN ARE CALCULATED AT HIGH IDLE AND 95% PUMP EFFICIENCY UNLESS OTHERWISE NOTED 380 PSI P2 G REAR TRACTION MANIFOLD OR1 .050 T PR M8 Groundsmaster 4000--D/4010--D Hydraulic Schematic Page 10 -- 3 Groundsmaster 4000--D/4010--D Models 30605 and 30603 Electrical Schematic NOTE: WHEN A WIRE FROM THIS SCHEMATIC CONTINUES TO THE OPERATOR CAB, A REFERENCE NUMBER WILL BE LISTED. THE CAB SCHEMATIC WILL ALSO INCLUDE THE REFERENCE NUMBER. All relays and solenoids are shown as de-- energized. All ground wires are black. TRACTION PEDAL POSITION SENSOR TRACTION PEDAL POSITION SENSOR 1 5 2 4 3 NOTE: REFER TO ELECTRICAL DRAWING DESIGNATIONS IN THIS CHAPTER FOR WIRE COLOR ABBREVIATIONS. Page 10 -- 4 Groundsmaster 4000--D/4010--D Models 30609 and 30607 Electrical Schematic NOTE: WHEN A WIRE FROM THIS SCHEMATIC CONTINUES TO THE OPERATOR CAB, A REFERENCE NUMBER WILL BE LISTED. THE CAB SCHEMATIC WILL ALSO INCLUDE THE REFERENCE NUMBER. All relays and solenoids are shown as de-- energized. All ground wires are black. TRACTION PEDAL POSITION SENSOR 1 5 TRACTION PEDAL POSITION SENSOR 2 4 3 NOTE: REFER TO ELECTRICAL DRAWING DESIGNATIONS IN THIS CHAPTER FOR WIRE COLOR ABBREVIATIONS. Page 10 -- 5 NOTE: REFER TO ELECTRICAL DRAWING DESIGNATIONS IN THIS CHAPTER FOR WIRE COLOR ABBREVIATIONS. 1 2 TO GROUND BLOCK 4 FROM OPERATOR PLATFORM WIRE HARNESS 3 Groundsmaster 4010--D Operator Cab (shown with lights for US model) Electrical Schematic All relays and solenoids are shown as de-- energized. All ground wires are black. NOTE: THE OPERATOR CAB SCHEMATIC SHOULD BE USED WITH THE ELECTRICAL SCHEMATIC FOR THE APPROPRIATE MODEL NUMBER WHICH IS ON A SEPARATE PAGE. WHEN A WIRE FROM THIS CAB SCHEMATIC CONTINUES TO THE MACHINE SCHEMATIC, A REFERENCE NUMBER WILL BE LISTED. Page 10 -- 6 TO CAB WIRE HARNESS TO OPERATOR PLATFORM WIRE HARNESS NOTE: REFER TO ELECTRICAL DRAWING DESIGNATIONS IN THIS CHAPTER FOR WIRE COLOR ABBREVIATIONS. 4 2 FROM OPERATOR PLATFORM WIRE HARNESS 3 5 TO OPERATOR PLATFORM WIRE HARNESS TO OPERATOR PLATFORM WIRE HARNESS TO CAB WIRE HARNESS Groundsmaster 4010--D International Light Kits Electrical Schematic All relays and solenoids are shown as de-- energized. All ground wires are black. NOTE: THE OPERATOR CAB SCHEMATIC SHOULD BE USED WITH THE ELECTRICAL SCHEMATIC FOR THE APPROPRIATE MODEL NUMBER WHICH IS ON A SEPARATE PAGE. WHEN A WIRE FROM THIS CAB SCHEMATIC CONTINUES TO THE MACHINE SCHEMATIC, A REFERENCE NUMBER WILL BE LISTED. Page 10 -- 7 This page is intentionally blank. Page 10 -- 8 A B C D 1 2 3 4 5 Groundsmaster 4000--D/4010--D Platform Wire Harness Drawing Page 10 -- 9 NOTE: THIS DRAWING IDENTIFIES WIRE GAUGE SIZE AND WIRE COLOR. REFER TO ELECTRICAL DRAWING DESIGNATIONS IN THIS CHAPTER FOR ADDITIONAL INFORMATION. Groundsmaster 4000--D/4010--D Platform Wire Harness Diagram Sheet 1 of 2 NOTE: THE PLATFORM WIRE HARNESS DIAGRAM IS SHOWN ON TWO (2) SHEETS. WHEN A CONDUCTOR CONTINUES ON ANOTHER SHEET, A REFERENCE NUMBER WILL BE IDENTIFIED. Page 10 -- 10 NOTE: THIS DRAWING IDENTIFIES WIRE GAUGE SIZE AND WIRE COLOR. REFER TO ELECTRICAL DRAWING DESIGNATIONS IN THIS CHAPTER FOR ADDITIONAL INFORMATION. Groundsmaster 4000--D/4010--D Platform Wire Harness Diagram Sheet 2 of 2 NOTE: THE PLATFORM WIRE HARNESS DIAGRAM IS SHOWN ON TWO (2) SHEETS. WHEN A CONDUCTOR CONTINUES ON ANOTHER SHEET, A REFERENCE NUMBER WILL BE IDENTIFIED. Page 10 -- 11 Groundsmaster 4000--D/4010--D Rear Wire Harness Drawing Page 10 -- 12 NOTE: THIS DRAWING IDENTIFIES WIRE GAUGE SIZE AND WIRE COLOR. REFER TO ELECTRICAL DRAWING DESIGNATIONS IN THIS CHAPTER FOR ADDITIONAL INFORMATION. Groundsmaster 4000--D/4010--D Rear Wire Harness Diagram Page 10 -- 13 Groundsmaster 4000--D/4010--D Models 30609 and 30607 Engine Wire Harness Drawing Page 10 -- 14 NOTE: THIS DRAWING IDENTIFIES WIRE GAUGE SIZE AND WIRE COLOR. REFER TO ELECTRICAL DRAWING DESIGNATIONS IN THIS CHAPTER FOR ADDITIONAL INFORMATION. Groundsmaster 4000--D/4010--D Models 30609 and 30607 Engine Wire Harness Diagram Page 10 -- 15 Groundsmaster 4000--D/4010--D Models 30605 and 30603 Engine Wire Harness Drawing Page 10 -- 16 NOTE: THIS DRAWING IDENTIFIES WIRE GAUGE SIZE AND WIRE COLOR. REFER TO ELECTRICAL DRAWING DESIGNATIONS IN THIS CHAPTER FOR ADDITIONAL INFORMATION. Groundsmaster 4000--D/4010--D Models 30605 and 30603 Engine Wire Harness Diagram Page 10 -- 17 Groundsmaster 4010--D Operator Cab Wire Harness Drawing Page 10 -- 18 NOTE: THIS DRAWING IDENTIFIES WIRE GAUGE SIZE AND WIRE COLOR. REFER TO ELECTRICAL DRAWING DESIGNATIONS IN THIS CHAPTER FOR ADDITIONAL INFORMATION. Groundsmaster 4010--D Operator Cab Wire Harness Diagram Page 10 -- 19 NOTE: THIS DRAWING IDENTIFIES WIRE GAUGE SIZE AND WIRE COLOR. REFER TO ELECTRICAL DRAWING DESIGNATIONS IN THIS CHAPTER FOR ADDITIONAL INFORMATION. Groundsmaster 4010--D Operator Cab Interconnect Wire Harness Page 10 -- 20
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