Toro Groundsmaster 4000-D Bedienungsanleitung

(Model 30412)

Part No. 08161SL (Rev. A)

Service Manual

GroundsmasterR4000--D

Preface

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

Groundsmaster 4000--D (Model 30412).

REFER TO THE OPERATOR’S MANUAL FOR OPER-

ATING, MAINTENANCE AND ADJUSTMENT

INSTRUCTIONS. For reference, insert a copy of the

Operator’s Manual and Parts Catalog for your machine

into Chapter 2 of this service manual. Additional copies

of the Operator’s Manual and Parts Catalog are avail-

able on the internet at www.Toro.com.

TheToroCompanyreservestherighttochangeproduct

specifications or this publication without notice.

This safety symbol means DANGER, WARNING,

or CAUTION, PERSONAL SAFETY INSTRUC-

TION. When you see this symbol, carefully read

the instructions that follow. Failure to obey the

instructions may result in personal injury.

NOTE: ANOTE will give general information about the

correct operation, maintenance, service, testing or re-

pair of the machine.

IMPORTANT: The IMPORTANT notice will give im-

portantinstructionswhich mustbefollowedtopre-

vent damage to systems or components on the

machine.

EThe Toro Company -- 2008, 2012

Groundsmaster 4000--D

This page is intentionally blank.

Groundsmaster 4000--D

Table Of Contents

Chapter 1 -- Safety

General Safety Instructions 1 -- 2..................

Jacking Instructions 1 -- 4.........................

Safety and Instruction Decals 1 -- 5................

Chapter 2 -- Product Records and Maintenance

Product Records 2 -- 1...........................

Maintenance 2 -- 1...............................

Equivalents and Conversions 2 -- 2................

Torque Specifications 2 -- 3.......................

Chapter 3 -- Kubota Diesel Engine

General Information 3 -- 2........................

Specifications 3 -- 3..............................

Service and Repairs 3 -- 4........................

KUBOTA WORKSHOP MANUAL, DIESEL ENGINE,

V2403--M--T--E3B SERIES

Chapter 4 -- Hydraulic System

Specifications 4 -- 2..............................

General Information 4 -- 3........................

Hydraulic Schematic 4 -- 8........................

Hydraulic Flow Diagrams 4 -- 10...................

Special Tools 4 -- 26.............................

Troubleshooting 4 -- 28...........................

Testing 4 -- 31...................................

Adjustments 4 -- 60..............................

Service and Repairs 4 -- 61.......................

EATON MODEL 72400 SERVO CONTROLLED PIS-

TON PUMP REPAIR INFORMATION

EATON MODEL 74318 and 74348 PISTON MOTORS:

FIXED DISPLACEMENT, VALVE PLATE DESIGN

REPAIR INFORMATION

Chapter 5 -- Electrical System

General Information 5 -- 2........................

Special Tools 5 -- 3..............................

Troubleshooting 5 -- 5............................

Electrical System Quick Checks 5 -- 8..............

Component Testing 5 -- 9.........................

General Information 5 -- 34.......................

Chapter 6 -- Axles, Planetaries and Brakes

Specifications 6 -- 2..............................

General Information 6 -- 3........................

Service and Repairs 6 -- 4........................

Chapter 7 -- Chassis

General Information 7 -- 1........................

Service and Repairs 7 -- 2........................

Chapter 8 -- Cutting Decks

Specifications 8 -- 2..............................

General Information 8 -- 3........................

Troubleshooting 8 -- 4............................

Service and Repairs 8 -- 6........................

Chapter 9 -- Foldout Drawings

Hydraulic Schematic 9 -- 3........................

Electrical Schematics 9 -- 4.......................

Circuit Diagrams 9 -- 6...........................

Wire Harness Drawings 9 -- 12....................

SafetyProduct Records

and Maintenance

Kubota

Diesel Engine

Hydraulic

System

Electrical

System

Axles, Planetaries

and Brakes

Cutting Decks Chassis

Foldout

Drawings

Groundsmaster 4000--D

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Groundsmaster 4000--D Page 1 -- 1 Safety

Chapter 1

Safety

Table of Contents

GENERAL SAFETY INSTRUCTIONS 2............

Before Operating 2............................

While Operating 2.............................

Maintenance and Service 3....................

JACKING INSTRUCTIONS 4.....................

SAFETY AND INSTRUCTION DECALS 5..........

Safety

Groundsmaster 4000--D

Page 1 -- 2

Safety

General Safety Instructions

TheGROUNDSMASTER4000-Distestedandcertified

by Toro for compliance with existing safety standards

and specifications. Although hazard control and acci-

dentpreventionpartiallyaredependentuponthedesign

andconfigurationofthemachine,thesefactors arealso

dependent upon the awareness, concern and proper

trainingofthepersonnelinvolvedintheoperation,trans-

port, maintenance and storage of the machine. Improp-

eruseormaintenanceofthemachinecanresultininjury

ordeath.Toreducethepotentialforinjuryordeath,com-

ply with the following safety instructions.

WARNING

To reduce the potential for injury or death,

comply with the following safety instructions.

Before Operating

1. Review and understand the contents of the Opera-

tor’s Manual and Operator’s DVD before starting and

operatingthevehicle. Become familiar with the controls

and know how to stop the vehicle and engine quickly.

AdditionalcopiesoftheOperator’sManualareavailable

on the internet at www.Toro.com.

2. Keep all shields,safety devices and decals in place.

Ifashield,safetydeviceordecalisdefective,illegibleor

damaged, repair or replace it before operating the ma-

chine.Alsotightenanyloosenuts,boltsorscrewstoen-

sure machine is in safe operating condition.

3. Assure interlock switches are adjusted correctly so

engine cannot be started unless traction pedal is in

NEUTRAL and cutting decks are DISENGAGED.

4. Since diesel fuel is highly flammable, handle it care-

fully:

A. Use an approved fuel container.

B. Donotremovefueltankcapwhileengineishotor

running.

C. Do not smoke while handling fuel.

D. Fillfueltankoutdoorsandonlytowithinaninchof

the top of the tank, not the filler neck. Do not overfill.

E. Wipe up any spilled fuel.

While Operating

1. Sit on the seat when starting and operating the ma-

chine.

2. Before starting the engine:

A. Apply the parking brake.

B. Make sure traction pedal is in neutral and the

PTO switch is OFF (disengaged).

C. Afterengineisstarted,releaseparkingbrakeand

keepfootofftractionpedal.Machinemustnotmove.

If movement is evident, the traction pedal linkage is

adjusted incorrectly; therefore, shut engine off and

adjust until machine does not move when traction

pedal is released.

3. Do not run engine in a confined area without ade-

quate ventilation. Exhaust fumes are hazardous and

could possibly be deadly.

4. Do not touch engine, muffler or exhaust pipe while

engineisrunningorsoonafteritisstopped.Theseareas

could be hot enough to cause burns.

5. Before getting off the seat:

A. Ensure that traction pedal is in neutral.

B. Apply the parking brake.

C. Disengage cutting decks and wait for blades to

stop.

D. Stop engine and remove key from switch.

E. Toro recommends that anytime the machine is

parked(short orlongterm), thecuttingdecks should

be lowered to the ground. This relieves pressure

from the lift circuit and eliminates the risk of cutting

decks accidentally lowering to the ground.

F. Donotparkonslopesunlesswheelsarechocked

or blocked.

Groundsmaster 4000--D Page 1 -- 3 Safety

Maintenance and Service

1. Before servicing or making adjustments, lower

decks, stop engine, apply parking brake and remove

key from the switch.

2. Make sure machine is in safeoperating condition by

keeping all nuts, bolts and screws tight.

3. Never store the machine or fuel container inside

wherethereisanopenflame,suchasnearawaterheat-

er or furnace.

4. Makesureall hydraulic line connectors are tight and

all hydraulic hoses and lines are in good condition be-

fore applying pressure to the system.

5. Keepbodyandhandsawayfrompinholeleaksinhy-

drauliclinesthatejecthighpressurehydraulicfluid.Use

cardboard or paper to find hydraulic leaks. Hydraulic

fluid escaping under pressure can penetrate skin and

cause injury. Fluid accidentally injected into the skin

mustbesurgicallyremovedwithinafewhoursbyadoc-

tor familiar with this form of injury or gangrene may re-

sult.

6. Before disconnecting or performing any work onthe

hydraulic system, all pressure in system must be re-

lieved by stopping engine and lowering cutting decks to

the ground.

7. Ifmajorrepairsareeverneededorassistance isde-

sired, contact an Authorized Toro Distributor.

8. To reduce potential fire hazard, keep engine area

free of excessive grease, grass, leaves and dirt. Clean

protective screen on machine frequently.

9. Ifenginemustberunningtoperformmaintenanceor

an adjustment, keep hands, feet, clothing and other

parts of the body away from cutting decks and other

moving parts. Keep bystanders away.

10.Do not overspeed the engine by changing governor

setting.Toassuresafetyandaccuracy,checkmaximum

engine speed.

11.Shut engine off before checking or adding oil to the

crankcase.

12.Disconnect battery before servicing the machine.

Disconnect negative cable first and positive cable last.

If battery voltage is required for troubleshooting or test

procedures,temporarilyconnectthebattery.Reconnect

positive cable first and negative cable last.

13.Battery acid is poisonous and can cause burns.

Avoid contact with skin, eyes and clothing. Protect your

face, eyes and clothing when working with a battery.

14.Battery gases can explode. Keep cigarettes, sparks

and flames away from the battery.

15.At the time of manufacture, the machine conformed

tothe safetystandardsfor ridingmowers.Toassure op-

timumperformanceandcontinuedsafetycertificationof

the machine, use genuine Toro replacement parts and

accessories.Replacementpartsandaccessoriesmade

by other manufacturers may result in non-conformance

with the safety standards and the warranty may be

voided.

16.When changing attachments, tires or performing

other service, use correct blocks, hoists and jacks.

Make sure machine is parked on a solid level surface

suchasaconcretefloor.Priortoraisingthemachine,re-

move any attachments that may interfere with the safe

and proper raising of the machine. Always chock or

block wheels. Use appropriate jack stands to support

the raised machine. If the machine is not properly sup-

ported by jack stands, the machine may move or fall,

whichmayresultinpersonalinjury(seeJackingInstruc-

tions in this chapter).

Safety

Groundsmaster 4000--D

Page 1 -- 4

Safety

Jacking Instructions

CAUTION

When changing attachments, tires or perform-

ing other service, use correct jacks and sup-

ports. Make sure machine is parked on a solid,

level surface such as a concrete floor. Prior to

raising machine, remove any attachments that

may interfere with the safe and proper raising of

themachine.Alwayschockorblockwheels.Use

jack stands to support the raised machine. If the

machine is not properly supported by jack

stands, the machine may move or fall, which

may result in personal injury.

Jacking the Front End (Fig. 1)

1. Set parking brake and chock both rear tires to pre-

vent the machine from moving.

2. Positionjack securely undertheframe,justtothein-

side of the front tire. Jack front wheel off the ground.

3. Once the machine is raised, position jack stand un-

der the frame as close to the wheel as possible to sup-

port the machine.

Jacking the Rear End (Fig. 2)

1. Place jack securely under the center of rear axle.

2. Chock both front tires. Jack rear of machine off the

ground.

3. Once the machine is raised, use jack stands under

the axle to support the machine.

1. Frame jacking point 2. Front tire

Figure 1

1. Rear axle jacking point 2. Rear tire

Figure 2

Groundsmaster 4000--D Page 1 -- 5 Safety

Safety and Instruction Decals

Numerous safety and instruction decals are affixed to

theGroundsmaster4000--D.Ifanydecalbecomesilleg-

ible or damaged, install a new decal. Decal part num-

bers are listed in your Parts Catalog.

Safety

Groundsmaster 4000--D

Page 1 -- 6

Safety

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