Toro Groundsmaster 4000-D, 4010-D (Model 30603, 30605, 30607, 30609, 30635, 30636) Service Repair Manual

Manuals: Service Repair Manual

Table of Content – Groundsmaster 4000-D, 4010-D (Model 30603, 30605, 30607, 30609, 30635, 30636)

Title Page
Revision History
Reader Comments
NOTES
Preface
Service Procedure Icons

Chapter 1 : Safety

Safety Instructions
Before Operating the Machine
While Operating the Machine
Maintenance and Service
Jacking Instructions
Safety and Instructional Decals

Chapter 2 : Specifications and Maintenance

Specifications
Overall Dimensions
Engine (Models 30603, 30605 and 30635)
Engine (Models 30607, 30609 and 30636)
Hydraulic System
Axles, Planetaries and Brakes
Cutting Decks
Torque Specifications
Calculating the Torque Values When Using a Drive-Adapter Wrench
Identifying the Fastener
Standard Torque for Dry, Zinc Plated, and Steel Fasteners (Inch Series)
Standard Torque for Dry, Zinc Plated, and Steel Fasteners (Metric Fasteners)
Other Torque Specifications
Conversion Factors
Shop Supplies
Special Tools

Chapter 3 : Troubleshooting

GEARS – The Systematic Approach to Defining, Diagnosing and Solving Problems
General Hydraulic System Problems
Traction Circuit Problems
Mow Circuit Problems
Lift Circuit Problems
Steering Circuit Problems
Engine Cooling Fan Circuit Problems
Operator Advisories
Fault Codes
Starting Problems
General Run and Transport Problems
Cutting Deck Operating Problems
Cutting Deck Lift, Lower Problems
Aftercut Appearance

Chapter 4 : Yanmar Diesel Engine

General Information
Operator’s Manual
Yanmar Service and Troubleshooting Manuals
Stopping the Engine
Engine Electronic Control Unit (ECU)
Yanmar Engine: Models 30603, 30605 and 30635
Yanmar Engine: Models 30607, 30609 and 30636
Diesel Particulate Filter
Service and Repairs
Air Cleaner System
Fuel System
Radiator and Oil Cooler Assembly
Engine
Spring Coupler
Exhaust System (Models 30607, 30609 and 30636)
Yanmar TNV (Tier 4i) Series Service Repair Manual
Yanmar TNV (Tier 4i) Series Troubleshooting Manual
Yanmar TNV (Tier 4) Series Service Repair Manual
Yanmar TNV (Tier 4) Series Troubleshooting Manual

Chapter 5 : Hydraulic System

General Information
Operator’s Manual
Check Hydraulic Fluid
Relieving Hydraulic System Pressure
Towing Traction Unit
Traction Circuit Component Failure
Hydraulic Hoses
Installing Hydraulic Hoses and Tubes (O-Ring Face Seal)
Installing the Hydraulic Fittings (SAE Straight Thread O-Ring Fittings)
Hydraulic Schematic
Hydraulic Flow Diagrams
Traction Circuit: LOW Speed (Mow)
Traction Circuit: HI Speed (Transport)
Lower Cutting Deck Circuit
Raise Cutting Deck Circuit
Mow Circuit
Mow Circuit Cutting Deck Blade Braking
Steering Circuit
Engine Cooling Fan Circuit
Testing
Precautions for Hydraulic Testing
Which Hydraulic Tests Are Necessary?
Traction Circuit Charge Pressure (Using Pressure Gauge)
Traction Circuit Relief Pressure (Using Pressure Gauge)
Counterbalance Pressure (Using Pressure Gauge)
Reverse Traction Circuit Reducing Valve (PR) Pressure (Using Pressure Gauge)
Rear Traction Circuit Relief Valve (RV) Pressure (Using Pressure Gauge)
Piston (Traction) Pump Flow Test (Using Tester with Pressure Gauge and Flow Meter)
Cutting Deck Circuit Pressure (Using Pressure Gauge)
PTO Relief Pressure (Using Tester with Pressure Gauge and Flow Meter)
Cutting Deck Motor Case Drain Leakage (Using Tester with Pressure Gauge and Flow Meter)
Lift, Lower Circuit Relief Pressure (Using Pressure Gauge)
Steering Circuit Relief Pressure (Using Pressure Gauge)
Steering Cylinder Internal Leakage
Engine Cooling Fan Circuit (Using Pressure Gauge and Phototac)
Engine Cooling Fan Motor Case Drain Leakage Test
Gear Pump Flow (Using Tester with Pressure Gauge and Flow Meter)
Adjustments
Adjust Control Manifold Relief Valves
Service and Repairs
General Precautions for Removing and Installing Hydraulic System Components
Check Hydraulic Lines and Hoses
Priming Hydraulic Pumps
Flush Hydraulic System
Filtering Closed−Loop Traction Circuit
Charge Hydraulic System
Hydraulic Reservoir
Radiator and Oil Cooler Assembly
Gear Pump
Gear Pump Service
Piston (Traction) Pump
Piston (Traction) Pump Service (For machines serial number below: 400000000)
Piston (Traction) Pump Service (For machines serial number above: 400000000)
Rear Axle Motor
Front Wheel Motors
Rear Axle and Front Wheel Motor Service
Rear Traction Manifold
Rear Traction Manifold Service
Front Traction Manifold
Front Traction Manifold Service
Combination Manifold
Combination Manifold Service
Steering Control Valve (For machines serial number below: 400000000)
Steering Control Valve (For machines serial number above: 400000000)
Steering Control Valve Service (For machines serial number below: 400000000)
Steering Control Valve Service (For machines serial number above: 400000000)
Steering Cylinder
Steering Cylinder Service
Engine Cooling Fan Motor
Engine Cooling Fan Motor Service
Cutting Deck Motors
Cutting Deck Motor Service (Sauer−Danfoss)
Cutting Deck Motor Service (Casappa)
PTO Manifold
PTO Manifold Service
Side Deck Lift Cylinders
Center Deck Lift Cylinders
Lift Cylinder Service
Danfoss H1 Closed Circuit Axial Piston Pumps Service Repair Manual
Danfoss H1 Closed Circuit Axial Pistonpumps Repair Instructions
Danfoss K And L Frame Variable Motors Service Repair Manual
Danfoss Steering Unit Type OSPM Service Repair Manual
Danfoss MP1 Closed Circuit Axial Piston Pumps Service Repair Manual
Eaton Parts And Repair Information: 5 Series Steering Control Units

Chapter 6 : Electrical System

General Information
Operator’s Manual
Toro Electronic Controllers (TEC)
Yanmar Engine Electronic Control Unit (ECU)
Yanmar Engine Electrical Components
CAN−bus Communications
Electrical Drawings
InfoCenter Display
Adjustments
Cutting Deck Position Switch Adjustment
Traction Pedal Adjustment
Traction Pedal Position Sensor Calibration
Electrical System Quick Checks
Battery Test (Open Circuit)
Charging System Test
Check Operation of Interlock Switches
Component Testing
Ignition Switch
Fuses
Operator Cab Fuses (Groundsmaster 4010−D)
Fusible Link Harness
PTO Switch
HI, LOW Speed, Engine Speed and Cutting Deck Lift Switches
Cruise Control Switch
Seat Switch
Parking Brake Switch
Service Brake Switches
Headlight Switch (Groundsmaster 4010−D)
Windshield Wiper, Washer Switch (Groundsmaster 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, 30605 and 30635)
Fuel Pump (Models 30607, 30609 and 30636)
Cutting Deck Position Switches
Hydraulic Oil Temperature Sender
Fan Speed Switch (Machines with Two−Post ROPS Extension Operator Fan Kit)
Resistor Module (Machines with Two−Post ROPS Extension Operator Fan Kit)
Audio Alarm
Service and Repairs
Battery Care
Battery Storage
Battery Service

Chapter 7 : Axles, Planetaries and Brakes

General Information
Operator’s Manual
Adjustments
Planetary Drive Assembly Endplay (OPH−2 series planetary drives)
Service and Repairs
Brake Assembly
Brake Inspection and Repair
Planetary Drive Assembly
OPH−2 Series Planetary Drive Service
VA02 Series Planetary 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
Gear Pattern Movement Summary

Chapter 8 : Chassis

General Information
Operator’s Manual
Service and Repairs
Steering Tower (For machines serial number below: 400000000)
Steering Tower (For machines serial number above: 400000000)
Center Deck Lift Arms
Side Deck Lift Arms
Side Deck Rear Arm Assembly
Lift Arm Joint Yoke
Control Arm
Traction Pedal
Operator Platform
Operator Seat
Operator Seat Service
Operator Seat Suspension
Hood

Chapter 9 : Cutting Decks

General Information
Operator’s Manual
Castor Wheel Tire Pressure
Blade Stopping Time
Service and Repairs
Center Cutting Deck
Side Cutting Decks
Idler Assembly
Blade Spindle Assemblies
Blade Spindle Service
Castor Forks and Wheels

Chapter 10 : Operator Cab (For models 30603 and 30607)

General Information
Operator’s Manual
Electrical Components and Schematic
Air Conditioning System
Cab Heater System
Service and Repairs
General Precautions for Removing and Installing the Air Conditioning System Components
Air Conditioning Compressor
Roof Assembly
Air Conditioning Condenser Assembly
Heater, Evaporator Assembly
Windshield Wiper
Sanden SD Compressor Service Guide

Chapter 11 : Operator Cab (For models 30635 and 30636)

General Information
Traction Unit Operator’s Manual
Electrical Components and Schematic
Air Conditioning System
Cab Heater System
Air Conditioning System Performance
Service and Repairs
General Precautions for Removing and Installing the Air Conditioning System Components
Air Conditioning Compressor
Roof Assembly
Heating and Air Conditioning Components
Air Conditioning Condenser Fan Assembly
Air Conditioning Condenser Assembly
Mixing Box Assembly
Heater and Air Conditioning Evaporator Cores
Blower Fan
Windshield Wiper Assembly
Badger Compressor Service Repair Manual
Appendix A: Foldout Drawings
Electrical Drawing Designations
Hydraulic Schematic
Electrical Schematic for Models 30605 and 30603, 30635 (For machines serial number below 400000000)
Electrical Schematic for Models 30605 and 30603, 30635 (For machines serial number 400000001 to 403450000)
Electrical Schematic for Models 30605 and 30603, 30635 (For machines serial number 400000001 to 403450000)
Electrical Schematic for Models 30605 and 30603, 30635 (For machines serial number 403450001 to 408900000)
Electrical Schematic for Models 30605 and 30603, 30635 (For machines serial number 403450001 to 408900000)
Electrical Schematic for Models 30605 and 30603, 30635 (For machines serial number above 408900000)
Electrical Schematic for Models 30605 and 30603, 30635 (For machines serial number above 408900000)
Electrical Schematic for Models 30609 and 30607, 30636 (For machines serial number below 400000000)
Electrical Schematic for Models 30609 and 30607, 30636 (For machines serial numbers 400000001 to 403450000)
Electrical Schematic for Models 30609 and 30607, 30636 (For machines serial numbers 400000001 to 403450000)
Electrical Schematic for Models 30609 and 30607, 30636 (For machines serial numbers 403450001 to 408000000)
Electrical Schematic for Models 30609 and 30607, 30636 (For machines serial numbers 403450001 to 408000000)
Electrical Schematic for Models 30609 and 30607, 30636 (For machines serial numbers above 408000000)
Electrical Schematic for Models 30609 and 30607, 30636 (For machines serial numbers above 408000000)
Electrical Schematic – Operator Cab (shown with lights for models 30603 and 30607)
Electrical Schematic – Operator Cab (shown with lights for models 30635 and 30636)
Electrical Schematic – International Light Kits
Platform Wire Harness Diagram (For machines serial number below 400000000)
Platform Wire Harness Diagram (For machines serial number below 400000000)
Platform Wire Harness Diagram (For machines serial number below 400000000)
Platform Wire Harness Diagram (For machines serial numbers 400000000 to 403450000)
Platform Wire Harness Diagram (For machines serial numbers 400000000 to 403450000)
Platform Wire Harness Diagram (For machines serial numbers 400000000 to 403450000)
Platform Wire Harness Diagram (For machines serial numbers 403450001 to 408000000)
Platform Wire Harness Diagram (For machines serial numbers 403450001 to 408000000)
Platform Wire Harness Diagram (For machines serial numbers 403450001 to 408000000)
Platform Wire Harness Diagram (For machines serial numbers above 408000000)
Platform Wire Harness Diagram (For machines serial numbers above 408000000)
Platform Wire Harness Diagram (For machines serial numbers above 408000000)
Rear Wire Harness Diagram (For machines serial number below 400000000)
Rear Wire Harness Diagram (For machines serial number below 400000000)
Rear Wire Harness Diagram (For machines serial number 400000000 to 408000000)
Rear Wire Harness Diagram (For machines serial number 400000000 to 408000000)
Rear Wire Harness Diagram (For machines serial number above 408000000)
Rear Wire Harness Diagram (For machines serial number above 408000000)
Engine Wire Harness Drawing for Models 30607, 30609, 30636 (For machines serial number below 400000000)
Engine Wire Harness Diagram for Models 30607, 30609, 30636 (For machines serial number below 400000000)
Engine Wire Harness Diagram for Models 30607, 30609, 30636 (For machines serial numbers 400000001 to 403450000)
Engine Wire Harness Diagram for Models 30607, 30609, 30636 (For machines serial numbers 400000001 to 403450000)
Engine Wire Harness Diagram for Models 30607, 30609, 30636 (For machines serial 403450001 to 408000000)
Engine Wire Harness Diagram for Models 30607, 30609, 30636 (For machines serial 403450001 to 408000000)
Engine Wire Harness Diagram for Models 30607, 30609, 30636 (For machines serial above 408000000)
Engine Wire Harness Diagram for Models 30607, 30609, 30636 (For machines serial above 408000000)
Engine DPF Wire Harness Diagram for Models 30607, 30609, 30636 (For machines serial above 408000000)
NO TITLE
Engine Wire Harness Drawing for Models 30603, 30605, 30635
Engine Wire Harness Diagram for Models 30603, 30605, 30635
Operator Cab Wire Harness Diagram (For machines serial number below 400000000)
Operator Cab Wire Harness Diagram (For machines serial number below 400000000)
Operator Cab Wire Harness Diagram (For machines serial number above 400000000)
Operator Cab Wire Harness Diagram (For machines serial number above 400000000)
Operator Cab Interconnect Wire Harness
Wire Harness Diagram − Two−Post ROPS Extension (Models 30605 and 30609)
Wire Harness Diagram − Two−Post ROPS Extension (Models 30605 and 30609)
Light Kit Wire Harness
RH Rear Lights Wire Harness
LH Rear Lights Wire Harness