Toro Groundsmaster 4000-D, 4010-D (Model 30603, 30605, 30607, 30609, 30635, 30636) 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
• Table of Contents
• 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