Toro Groundsmaster 4000-D Bedienungsanleitung

PRELIMINARY – For Toro Distributor and Toro Company use only.

(Serial No. 290000001 and Above)

PART NO.

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.

REFER TO THE TRACTION UNIT AND CUTTING

UNIT OPERATOR’S MANUALS FOR OPERATING,

MAINTENANCE AND ADJUSTMENT INSTRUC-

TIONS. Space is provided in Chapter 2 of this book to

insert the Operator’s Manuals and Parts Catalogs for

your machine. Replacement Operator’s Manuals and

Parts Catalogs are available on the internet at

www.Toro.com or by sending complete Model and Seri-

al Number to:

The Toro Company

Attn. Technical Publications

8111 Lyndale Avenue South

Bloomington, MN 55420−1196

The Toro Company reserves the right to change product

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: A NOTE will give general information about the

correct operation, maintenance, service, testing or re-

pair of the machine.

IMPORTANT: The IMPORTANT notice will give im-

portant instructions which must be followed to pre-

vent damage to systems or components on the

machine.

The Toro Company −2008

PRELIMINARY – For Toro Distributor and Toro Company use only.

Groundsmaster 4000−D

This page is intentionally blank.

PRELIMINARY – For Toro Distributor and Toro Company use only.

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 −9. . . . . . . . . . . . . . . . . . . .

Special Tools 4 −19. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Troubleshooting 4 −21. . . . . . . . . . . . . . . . . . . . . . . . . . .

Testing 4 −24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Adjustments 4 −49. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Service and Repairs 4 −51. . . . . . . . . . . . . . . . . . . . . . .

Chapter 5 −Electrical System

Electrical Drawings 5 −2. . . . . . . . . . . . . . . . . . . . . . . . .

Special Tools 5 −3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Troubleshooting 5 −5. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Electrical System Quick Checks 5 −8. . . . . . . . . . . . . .

Component Testing 5 −9. . . . . . . . . . . . . . . . . . . . . . . . .

Service and Repairs 5 −30. . . . . . . . . . . . . . . . . . . . . . .

Chapter 6 −Axles, Planetaries and Brakes

Specifications 6 −2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Adjustments 6 −3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Service and Repairs 6 −4. . . . . . . . . . . . . . . . . . . . . . . .

Chapter 7 −Chassis

Service and Repairs 7 −2. . . . . . . . . . . . . . . . . . . . . . . .

Chapter 8 −Cutting Units

Specifications 8 −2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Troubleshooting 8 −3. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Adjustments 8 −4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Service and Repairs 8 −6. . . . . . . . . . . . . . . . . . . . . . . .

Chapter 9 −Foldout Drawings

Hydraulic Schematic 9 −3. . . . . . . . . . . . . . . . . . . . . . . .

Electrical Schematic 9 −4. . . . . . . . . . . . . . . . . . . . . . . .

Wire Harness Drawings 9 −6. . . . . . . . . . . . . . . . . . . . .

SafetyProduct Records

and Maintenance

Kubota

Diesel Engine

Hydraulic

System

Electrical

System

Axles, Planetaries

and Brakes

Cutting Units Chassis

Foldout

Drawings

PRELIMINARY – For Toro Distributor and Toro Company use only.

Groundsmaster 4000−D

This page is intentionally blank.

PRELIMINARY – For Toro Distributor and Toro Company use only.

Groundsmaster 4000−DPage 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

PRELIMINARY – For Toro Distributor and Toro Company use only.

Groundsmaster 4000−D

Page 1 −2

Safety

General Safety Instructions

The GROUNDSMASTER 4000-D was tested and certi-

fied by TORO for compliance with the B71.4-1999 speci-

fications of the American National Standards Institute.

Although hazard control and accident prevention par-

tially are dependent upon the design and configuration

of the machine, these factors are also dependent upon

the awareness, concern, and proper training of the per-

sonnel involved in the operation, transport, mainte-

nance, and storage of the machine. Improper use or

maintenance of the machine can result in injury or

death. To reduce the potential for injury or death, comply

with the following safety instructions.

WARNING

To reduce the potential for injury or death,

comply with the following safety instructions.

Before Operating

1. Read and understand the contents of the Operator’s

Manual before starting and operating the machine. Be-

come familiar with the controls and know how to stop the

machine and engine quickly. A replacement Operator’s

Manual is available on the Internet at www.Toro.com or

by sending the complete model and serial number to:

The Toro Company

Attn. Technical Publications

8111 Lyndale Avenue South

Bloomington, Minnesota 55420−1196

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

If a shield, safety device, or decal is defective, illegible

or damaged, repair or replace it before operating the

machine. Also tighten any loose nuts, bolts or screws to

ensure 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 units are DISENGAGED.

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

fully:

A. Use an approved fuel container.

B. Do not remove fuel tank cap while engine is hot or

running.

C. Do not smoke while handling fuel.

D. Fill fuel tank outdoors and only to within an inch of

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. Engage the parking brake.

B. Make sure traction pedal is in neutral and the

PTO switch is OFF (disengaged).

C. After engine is started, release parking brake and

keep foot off traction pedal. Machine must not move.

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

engine is running or soon after it is stopped. These areas

could be hot enough to cause burns.

5. Before getting off the seat:

A. Ensure that traction pedal is in neutral.

B. Set parking brake.

C. Disengage cutting units and wait for blades to

stop.

D. Stop engine and remove key from switch.

E. Toro recommends that anytime the machine is

parked (short or long term), the cutting units should

be lowered to the ground. This relieves pressure

from the lift circuit and eliminates the risk of cutting

units accidentally lowering to the ground.

F. Do not park on slopes unless wheels are chocked

or blocked.

PRELIMINARY – For Toro Distributor and Toro Company use only.

Groundsmaster 4000−DPage 1 −3 Safety

Maintenance and Service

1. Before servicing or making adjustments, lower

decks, stop engine, set parking brake, and remove key

from the switch.

2. Make sure machine is in safe operating condition by

keeping all nuts, bolts and screws tight.

3. Never store the machine or fuel container inside

where there is an open flame, such as near a water heat-

er or furnace.

4. Make sure all hydraulic line connectors are tight, and

all hydraulic hoses and lines are in good condition be-

fore applying pressure to the system.

5. Keep body and hands away from pin hole leaks in hy-

draulic lines that eject high pressure hydraulic fluid. 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

must be surgically removed within a few hours by a doc-

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

sult.

6. Before disconnecting or performing any work on the

hydraulic system, all pressure in system must be re-

lieved by stopping engine and lowering cutting units to

the ground.

7. If major repairs are ever needed or assistance is de-

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. If engine must be running to perform maintenance or

an adjustment, keep hands, feet, clothing and other

parts of the body away from cutting units and other mov-

ing parts. Keep bystanders away.

10.Do not overspeed the engine by changing governor

setting. To assure safety and accuracy, check maximum

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, temporarily connect the battery. 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

to the safety standards for riding mowers. To assure op-

timum performance and continued safety certification of

the machine, use genuine Toro replacement parts and

accessories. Replacement parts and accessories made

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

such as a concrete floor. Prior to raising the machine, re-

move any attachments that may interfere with the safe

and proper raising of the machine. Always chock or

block wheels. Use jack stands or solid wood blocks to

support the raised machine. If the machine is not proper-

ly supported by blocks or jack stands, the machine may

move or fall, which may result in personal injury (see

Jacking Instructions).

Safety

PRELIMINARY – For Toro Distributor and Toro Company use only.

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

the machine. Always chock or block wheels. 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. Position jack securely under the frame, just to the in-

side of the front tire.

3. Position jack stands or hardwood blocks under the

frame as close to the wheels as possible to support 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. Use jack stands or blocks 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

PRELIMINARY – For Toro Distributor and Toro Company use only.

Groundsmaster 4000−DPage 1 −5 Safety

Safety and Instruction Decals

Numerous safety and instruction decals are affixed to

the Groundsmaster 4000−D. If any decal becomes illeg-

ible or damaged, install a new decal. Part numbers are

listed in your Parts Catalog.

Safety

PRELIMINARY – For Toro Distributor and Toro Company use only.

Groundsmaster 4000−D

Page 1 −6

Safety

This page is intentionally blank.

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