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
• Table Of Contents
• 1 – Safety
• Table of Contents
• General Safety Instructions
• Before Operating
• While Operating
• Maintenance and Service
• Jacking Instructions
• Safety and Instruction Decals
• 2 – Product Records and Maintenance
• Table of Contents
• 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
• Table of Contents
• 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
• Table of Contents
• Specifications
• General Information
• Operator’s Manual
• Check Hydraulic Fluid
• Towing Traction Unit
• Relieving Hydraulic System Pressure
• Traction Circuit Component Failure
• Hydraulic Hoses
• Hydraulic 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
• Table of Contents
• 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
• Table of Contents
• 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
• Table of Contents
• 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
• Table of Contents
• 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
• Table of Contents
• 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
• Table of Contents
• 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