Toro Groundsmaster 4000-D, 4010-D (Model 30448, 30446) Service Repair Manual

Table of Content – Groundsmaster 4000-D, 4010-D (Model 30448, 30446)

Title Page
Revision History
Reader Comments
Preface
1 – Safety
General Safety Instructions
Before Operating
While Operating
Maintenance and Service
Jacking Instructions
Safety and Instruction Decals
2 – Product Records and Maintenance
Product Records
Maintenance
Equivalents and Conversions
Decimal and Millimeter Equivalents
US 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 Series)
Other Torque Specifications
Conversion Factors
3 – Kubota Diesel Engine
Specifications
General Information
Operator’s Manual
Stopping the Engine
Service and Repairs
Air Filter System
Exhaust System
Fuel System
Radiator
Engine
Engine Removal
Engine Installation
Spring Coupler
Kubota Diesel Engine Workshop Manual
4 – Hydraulic System
Specifications
General Information
Operator’s Manual
Check Hydraulic Fluid
Towing Traction Unit
Relieving Hydraulic System Pressure
Traction Circuit Component Failure
Hydraulic Hoses
Hydraulic Hose and Tube Installation
Hydraulic Fitting Installation
Non–Adjustable Fitting
Adjustable Fitting
Hydraulic Schematic
Hydraulic Flow Diagrams
Traction Circuit: Low Speed (4WD)
Traction Circuit: Hi Speed (2WD)
Lower Cutting Deck
Raise Cutting Deck
Mow
Mow Circuit Cutting Deck Blade Braking
Steering Circuit
Engine Cooling Fan Circuit
Special Tools
Troubleshooting
General Hydraulic System Problems
Traction Circuit Problems
Mow Circuit Problems
Lift Circuit Problems
Steering Circuit Problems
Engine Cooling Fan Circuit Problems
Testing
Traction Circuit Charge Pressure
Traction Circuit Relief Pressure
Counterbalance Pressure
Traction Circuit Reducing Valve (PR) Pressure
Rear Traction Circuit (RV) Relief Pressure
Piston (Traction) Pump Flow Test
Cutting Deck Circuit Pressure
PTO Relief Pressure
Cutting Deck Motor Case Drain Leakage
Cutting Deck Gear Pump Flow
Lift, Lower Circuit Relief Pressure
Steering Circuit Relief Pressure
Steering Cylinder Internal Leakage
Steering and Lift, Lower Gear Pump Flow
Engine Cooling Fan Circuit
Engine Cooling Fan Circuit Gear Pump Flow
Adjustments
Traction Linkage Adjustment
Service and Repairs
General Precautions for Removing and Installing Hydraulic System Components
Check Hydraulic Lines and Hoses
Flush Hydraulic System
Filtering Closed-Loop Traction Circuit
Charge Hydraulic System
Hydraulic Reservoir
Hydraulic Oil Cooler
Gear Pump
Gear Pump Service
Traction Circuit
Transport Cylinder
Piston (Traction) Pump
Piston (Traction) Pump Service
Rear Axle Motor
Front Wheel Motor
Rear Axle and Front Wheel Motor Service
4WD Manifold
4WD Manifold Service
Traction (Flow Divider) Manifold
Traction (Flow Divider) Manifold Service
Filter Manifold
Filter Manifold Service
Steering and Engine Cooling Fan Circuits
Steering Control Valve
Steering Control Valve Service
Steering Cylinder
Steering Cylinder Service
Engine Cooling Fan Motor
Engine Cooling Fan Motor Service
Fan Drive Manifold
Fan Drive Manifold Service
PTO Circuit
Cutting Deck Motor
Cutting Deck Motor Service
PTO Manifold
PTO Manifold Service
Cutting Deck Lift, Lower Circuit
Lift, Lower Manifold
Lift, Lower Manifold Service
Side Deck Lift Cylinder
Front Deck Lift Cylinder
Lift Cylinder Service
Eaton Piston Pump Repair Information
Eaton Piston Motor Repair Information
5 – Electrical System
General Information
Operator’s Manual
Toro Electronic Controllers (TEC)
CAN–bus Communications
Electrical Drawings
Special Tools
Troubleshooting
Diagnostic Display
Verify Diagnostic Display Input Functions
Verify Diagnostic Display Output Functions
Starting Problems
General Run and Transport Problems
Cutting Deck Operating Problems
Cutting Deck Lift, Lower Problems
Adjustments
Cutting Deck Position Switches
Electrical System Quick Checks
Battery Test (Open Circuit Test)
Charging System Test
Glow Plug System Test
Check Operation of Interlock Switches
Component Testing
Ignition Switch
Fuses
Operator Cab Fuses (Groundsmaster 4010–D)
Warning Lights
PTO Switch
Cutting Deck Lift Switches
Hi, Low Speed and Headlight (Groundsmaster 4010–D) Switches
Flow Divider and Engine Cooling Fan Switches
Seat Switch
Parking Brake Switch
Windshield Wiper, Washer Switch (Groundsmaster 4010–D)
Air Conditioning Switch (Groundsmaster 4010–D)
Hour Meter
Audio Alarm
Main Power, Glow and Operator Cab Power (Groundsmaster 4010–D) Relays
Start and Air Conditioning (Groundsmaster 4010–D) Relays
Toro Electronic Controllers (TEC)
Hydraulic Valve Solenoids
Traction Neutral Switch
Diode Assembly
Fuel Sender
Fuel Gauge
Fuel Pump
Temperature Sender
Temperature Gauge
Cutting Deck Position Switches
Engine Coolant and Hydraulic Oil Temperature Senders
Service and Repairs
Battery Storage
Battery Care
Battery Service
Battery Removal and Installation
Battery Inspection and Maintenance
Battery Testing
Battery Charging
6 – Axles, Planetaries and Brakes
Specifications
General Information
Operator’s Manual
Service and Repairs
Brake Assembly
Brake Inspection and Repair
Planetary Wheel Drive Assembly
Planetary Wheel Drive Service
Rear Axle Assembly
Rear Axle Service
Bevel Gear Case and Axle Case
Differential Shafts
Axle Shafts
Input Shaft, Pinion Gear
Differential Gear
Pinion Gear to Ring Gear Engagement
7 – Chassis
General Information
Operator’s Manual
Service and Repairs
Steering Tower
Front Deck Lift Arm
Side Deck Lift Arm
Side Deck Rear Arm Assembly
Lift Arm Joint Yoke
Console Arm
Operator Seat
Operator Seat Service
Operator Seat Suspension
Hood
8 – Cutting Decks
Specifications
General Information
Operator’s Manual
Castor Wheel Tire Pressure
Blade Stopping Time
Troubleshooting
Factors That Can Affect Quality of Cut
Service and Repairs
Front Cutting Deck
Side Cutting Deck
Idler Assembly
Blade Spindles
Blade Spindle Service
Castor Forks and Wheels
9 – Operator Cab
General Information
Operator’s Manual
Electrical Components and Schematic
Air Conditioning System
Cab Heater System
Service and Repairs
General Precautions for Removing and Installing Air Conditioning System Components
Air Conditioning Compressor
Roof Assembly
Air Conditioning Condenser Assembly
Heater, Evaporator Assembly
Sanden Compressor Service Guide
10 – Foldout Drawings
Hydraulic Schematic
Electrical Schematic Sheet 1 of 3
Electrical Schematic Sheet 2 of 3
Electrical Schematic Sheet 3 of 3
Electrical Schematic Operator Cab
Platform Wire Harness Drawing
Platform Wire Harness Diagram Sheet 1 of 2
Platform Wire Harness Diagram Sheet 2 of 2
Rear Wire Harness Drawing
Rear Wire Harness Diagram
Cab Wire Harness Drawing
Cab Wire Harness Diagram
Cab Interconnect Wire Harness