Description

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

Type: Groundsmaster
Language: English
Format: PDF Download

• Toro Groundsmaster 4000-D, 4010-D (Model 30603, 30605, 30607, 30609, 30635, 30636) Service Repair Manual – 344 Pages

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

Preface …………………………………………………………………………………………………. 5
Chapter 1: Safety ……………………………………………………………………………….. 1–1
Safety Instructions …………………………………………………………………………… 1–2
Safety and Instructional Decals ………………………………………………………….. 1–9
Chapter 2: Specifications and Maintenance ……………………………………………. 2–1
Specifications ………………………………………………………………………………….. 2–2
Torque Specifications ……………………………………………………………………….. 2–9
Shop Supplies ……………………………………………………………………………….. 2–15
Special Tools …………………………………………………………………………………. 2–17
Chapter 3: Troubleshooting ………………………………………………………………….. 3–1
GEARS – The Systematic Approach to Defining, Diagnosing and Solving
Problems ………………………………………………………………………………………… 3–2
General Hydraulic System Problems …………………………………………………… 3–3
Traction Circuit Problems…………………………………………………………………… 3–4
Mow Circuit Problems ……………………………………………………………………….. 3–5
Lift Circuit Problems………………………………………………………………………….. 3–6
Steering Circuit Problems ………………………………………………………………….. 3–7
Engine Cooling Fan Circuit Problems…………………………………………………… 3–8
Operator Advisories ………………………………………………………………………….. 3–9
Fault Codes …………………………………………………………………………………… 3–10
Starting Problems …………………………………………………………………………… 3–12
General Run and Transport Problems………………………………………………… 3–13
Cutting Deck Operating Problems……………………………………………………… 3–14
Cutting Deck Lift/Lower Problems ……………………………………………………… 3–15
Aftercut Appearance ……………………………………………………………………….. 3–16
Chapter 4: Yanmar Diesel Engine………………………………………………………….. 4–1
General Information …………………………………………………………………………. 4–2
Service and Repairs ……………………………………………………………………….. 4–11
Chapter 5: Hydraulic System………………………………………………………………… 5–1
General Information …………………………………………………………………………. 5–3
Hydraulic Schematic ……………………………………………………………………….. 5–13
Hydraulic Flow Diagrams …………………………………………………………………. 5–14
Testing ………………………………………………………………………………………….. 5–36
Adjustments ………………………………………………………………………………….. 5–82
Service and Repairs ……………………………………………………………………….. 5–83
Chapter 6: Electrical System ………………………………………………………………… 6–1
General Information …………………………………………………………………………. 6–3
Adjustments…………………………………………………………………………………… 6–18
Electrical System Quick Checks………………………………………………………… 6–24
Component Testing…………………………………………………………………………. 6–26
Service and Repairs ……………………………………………………………………….. 6–89
Chapter 7: Axles, Planetaries and Brakes ………………………………………………. 7–1
General Information …………………………………………………………………………. 7–2
Adjustments…………………………………………………………………………………….. 7–3
Service and Repairs …………………………………………………………………………. 7–4
Chapter 8: Chassis……………………………………………………………………………… 8–1
General Information …………………………………………………………………………. 8–2
Service and Repairs …………………………………………………………………………. 8–3
Chapter 9: Cutting Decks …………………………………………………………………….. 9–1
General Information …………………………………………………………………………. 9–2
Service and Repairs …………………………………………………………………………. 9–3
Chapter 10: Operator Cab (For models 30603 and 30607) ……………………………………. 10–1
General Information ……………………………………………………………………….. 10–2
Service and Repairs ……………………………………………………………………….. 10–3
Chapter 11: Operator Cab (For models 30635 and 30636) ……………………………………. 11–1
General Information ……………………………………………………………………….. 11–2
Platform Wire Harness Diagram (For machines serial numbers above
408000000) ……………………………………………………………………………………A–33
Platform Wire Harness Diagram (For machines serial numbers above
408000000) ……………………………………………………………………………………A–34
Rear Wire Harness Diagram (For machines serial number below
400000000) ……………………………………………………………………………………A–35
Rear Wire Harness Diagram (For machines serial number below
400000000) ……………………………………………………………………………………A–36
Rear Wire Harness Diagram (For machines serial number 400000000 to
408000000) ……………………………………………………………………………………A–37
Rear Wire Harness Diagram (For machines serial number 400000000 to
408000000) ……………………………………………………………………………………A–38
Rear Wire Harness Diagram (For machines serial number above
408000000) ……………………………………………………………………………………A–39
Rear Wire Harness Diagram (For machines serial number above
408000000) ……………………………………………………………………………………A–40
Engine Wire Harness Drawing for Models 30607, 30609, 30636 (For
machines serial number below 400000000)…………………………………………A–41
Engine Wire Harness Diagram for Models 30607, 30609, 30636 (For
machines serial number below 400000000)…………………………………………A–42
Engine Wire Harness Diagram for Models 30607, 30609, 30636 (For
machines serial numbers 400000001 to 403450000)…………………………….A–43
Engine Wire Harness Diagram for Models 30607, 30609, 30636 (For
machines serial numbers 400000001 to 403450000)…………………………….A–44
Engine Wire Harness Diagram for Models 30607, 30609, 30636 (For
machines serial 403450001 to 408000000) …………………………………………A–45
Engine Wire Harness Diagram for Models 30607, 30609, 30636 (For
machines serial 403450001 to 408000000) …………………………………………A–46
Engine Wire Harness Diagram for Models 30607, 30609, 30636 (For
machines serial above 408000000) ……………………………………………………A–47
Engine Wire Harness Diagram for Models 30607, 30609, 30636 (For
machines serial above 408000000) ……………………………………………………A–48
Engine DPF Wire Harness Diagram for Models 30607, 30609, 30636 (For
machines serial above 408000000) ……………………………………………………A–49
……………………………………………………………………………………………………..A–50
Engine Wire Harness Drawing for Models 30603, 30605,
30635…………………………………………………………………………………………….A–51
Engine Wire Harness Diagram for Models 30603, 30605,
30635…………………………………………………………………………………………….A–52
Operator Cab Wire Harness Diagram (For machines serial number below
400000000) ……………………………………………………………………………………A–53
Operator Cab Wire Harness Diagram (For machines serial number below
400000000) ……………………………………………………………………………………A–54
Operator Cab Wire Harness Diagram (For machines serial number above
400000000) ……………………………………………………………………………………A–55
Operator Cab Wire Harness Diagram (For machines serial number above
400000000) ……………………………………………………………………………………A–56
Operator Cab Interconnect Wire Harness ……………………………………………A–57
Wire Harness Diagram − Two−Post ROPS Extension (Models 30605 and
30609) …………………………………………………………………………………………..A–58
Wire Harness Diagram − Two−Post ROPS Extension (Models 30605 and
30609) …………………………………………………………………………………………..A–59
Light Kit Wire Harness ……………………………………………………………………..A–60
RH Rear Lights Wire Harness ……………………………………………………………A–61
LH Rear Lights Wire Harness…………………………………………………………….A–62

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