Page 1: Service Manual
IMPORTANT: The IMPORTANT notice will give im- specifications or this publication without notice. portant instructions which must be followed to pre- vent damage to systems or components on the machine. E The Toro Company - - 2002, 2003, 2004, 2006, 2007, 2012...
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Page 3 Table Of Contents Chapter 1 − Safety Chapter 5 − Electrical System General Safety Instructions ....1 − 2 Electrical Schematic, Circuit Diagrams, and Jacking Instructions .
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Page 5: Table Of Contents
Chapter 1 Safety Table of Contents GENERAL SAFETY INSTRUCTIONS ... . JACKING INSTRUCTIONS ..... Before Operating .
Page 6: General Safety Instructions
General Safety Instructions The GROUNDSMASTER 4000-D was tested and certi- death. To reduce the potential for injury or death, comply fied by TORO for compliance with the B71.4-1999 speci- with the following safety instructions. fications of the American National Standards Institute.
Page 7: Maintenance And Service
Toro replacement parts and 6. Before disconnecting or performing any work on the accessories. Replacement parts and accessories made...
Page 8: Jacking Instructions
Jacking Instructions CAUTION When changing attachments, tires, or perform- ing 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 machine, remove any attach- ments that may interfere with the safe and prop- er raising of the machine.
Page 9: Safety And Instruction Decals
Safety and Instruction Decals Numerous safety and instruction decals are affixed to the Groundsmaster 4000−D. If any decal becomes illegible or damaged, install a new decal. Part numbers are listed in your Parts Catalog. Groundsmaster 4000−D Safety Page 1 − 5...
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Page 11 Chapter 2 Product Records and Maintenance Table of Contents PRODUCT RECORDS ......Standard Torque for Dry, Zinc Plated, and MAINTENANCE .
Page 12: Product Records
Equivalents and Conversions 0.09375 Product Records and Maintenance Page 2 − 2 Rev. E Groundsmaster 4000−D...
Page 13: Torque Specifications
For critical applications, as determined reduced by 25% for lubricated fasteners to achieve by Toro, either the recommended torque or a torque that the similar stress as a dry fastener. Torque values may is unique to the application is clearly identified and spe- also have to be reduced when the fastener is threaded cified in this Service Manual.
Page 14: Standard Torque For Dry, Zinc Plated, And Steel Fasteners (Inch Series)
Standard Torque for Dry, Zinc Plated, and Steel Fasteners (Inch Series) Grade 1, 5, & SAE Grade 1 Bolts, Screws, Studs, & SAE Grade 5 Bolts, Screws, Studs, & SAE Grade 8 Bolts, Screws, Studs, & Thread Size 8 with Thin Sems with Regular Height Nuts Sems with Regular Height Nuts Sems with Regular Height Nuts...
Page 15: Standard Torque For Dry, Zinc Plated, And
Standard Torque for Dry, Zinc Plated, and Steel Fasteners (Metric Fasteners) Class 8.8 Bolts, Screws, and Studs with Class 10.9 Bolts, Screws, and Studs with Thread Size Thread Size Regular Height Nuts Regular Height Nuts Regular Height Nuts Regular Height Nuts (Class 8 or Stronger Nuts) (Class 10 or Stronger Nuts) M5 X 0.8...
Page 16: Other Torque Specifications
Other Torque Specifications SAE Grade 8 Steel Set Screws Wheel Bolts and Lug Nuts Recommended Torque Thread Size Recommended Torque** Thread Size Thread Size Square Head Hex Socket 7/16 − 20 UNF 65 + 10 ft−lb 88 + 14 N−m Grade 5 1/4 −...
Page 17 Chapter 3 Kubota Diesel Engine Table of Contents GENERAL INFORMATION ..... Radiator ........Stopping the Engine .
Page 18: General Information
Service and repair parts for Kubota engines are sup- that is included at the end of this section. plied through your Authorized Toro Distributor. If no parts list is available, be prepared to provide your distrib- Most repairs and adjustments require tools which are utor with the Toro model and serial number.
Page 19: Specifications
Specifications Item Description Make / Designation Kubota, 4−Cycle, 4 Cylinder, Water Cooled, Turbocharged, Diesel Engine Horse Power 58 HP (43.3 kW) @ 2600 RPM Bore mm (in.) 83.0 (3.27) Stroke mm (in.) 92.4 (3.64) Total Displacement cc (cu. in.) 1999 (122.12) Firing Order 1−3−4−2 Combustion Chamber...
Page 20: Adjustments
Adjustments Run Solenoid 1. When ignition switch is in the RUN position, the run solenoid should energize and position the fuel stop lever to within 1/16” (1.6 mm) of stop on the injection pump. 2. If adjustment is needed, loosen lock nut and rotate the threaded end of the swivel until the lever is properly positioned.
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Page 22: Service And Repairs
Service and Repairs Air Filter System RIGHT FRONT EVACUATOR DIRECTION Figure 3 1. Air cleaner hose 5. Air cleaner strap 9. Hose clamp 2. Hose clamp 6. Lock nut 10. Cap screw 3. Air cleaner assembly 7. Hose clamp 11. Flat washer 4.
Page 23 Removal 1. Remove air cleaner components as needed using Figure 3 as a guide. Installation IMPORTANT: Any leaks in the air filter system will cause serious engine damage. Make sure daily that all air cleaner components are in good condition and are properly secured during reassembly.
Page 24: Exhaust System
Exhaust System 16 to 22 ft−lb (21 to 29 N−m) 16 to 22 ft−lb (21 to 29 N−m) RIGHT FRONT 16 to 22 ft−lb (21 to 29 N−m) Figure 5 1. Muffler 6. Lock nut 11. Flange nut 2. Muffler bracket 7.
Page 25 Removal CAUTION The muffler and exhaust pipe may be hot. To avoid possible burns, allow the engine and ex- haust system to cool before working on the muf- fler. 1. Park machine on a level surface, lower cutting units, stop engine, engage parking brake, and remove key from the ignition switch.
Page 26: Fuel System
Fuel System RIGHT FRONT 27 28 18 17 16 135 to 165 ft−lb 60 to 80 in−lb (183 to 223 N−m) (6.8 to 9 N−m) Figure 7 1. Fuel tank 15. Retaining ring 29. Fuel hose 2. Fuel tank bracket 16.
Page 27: Check Fuel Lines And Connections
Fuel Tank Installation DANGER 1. Install fuel tank using Figure 7 as a guide. A. Torque two locking flange nuts that secure the Because diesel fuel is highly flammable, use cau- fuel tank to the frame from 60 to 80 in−lb (7 to 9 N−m). tion when storing or handling it.
Page 28: Radiator
Radiator RIGHT FRONT Figure 8 1. Radiator cap 17. Bulb seal 33. Flange head screw 18. Radiator support assembly 2. Foam strip 34. Bulb seal 3. Foam strip 19. Retaining ring 35. Grommet 4. Lower radiator hose 20. Oil cooler bracket 36.
Page 29 Removal Installation 1. Park machine on a level surface, lower cutting units, 1. Remove any plugs used during the removal proce- stop engine, engage parking brake, and remove key dure. from the ignition switch. 2. Position radiator to the support frame. Secure radia- 2.
Page 30: Engine
Engine RIGHT FRONT 17 to 21 ft−lb (23 to 28.5 N−m) 10 to 12 ft−lb (13.6 to 16.3 N−m) 35 to 43 ft−lb (47.5 to 58.3 N−m) Figure 9 1. Engine 18. Cap screw 34. Cap screw 2. Engine mount bracket (RH shown) 19.
Page 31: Engine Removal
Engine Removal 1. Park machine on a level surface, lower cutting units, stop engine, engage parking brake, and remove key from the ignition switch. 2. Remove battery cover and strap. Disconnect nega- tive battery cable first and then positive battery cable. Remove battery from machine.
Page 32 8. Disconnect fuel line from injection pump (Fig. 11). 9. Disconnect throttle cable from the speed control le- ver by removing the washer and lock nut. Loosen jam nut and take cable from mounting bracket (Fig. 11). 10.Remove coolant reservoir and bracket from fan shroud.
Page 33: Coupling Disassembly
Coupling Disassembly 1. Remove adapter plate, spring coupling, and cou- pling spacer from engine using Figure 9 as a guide. Coupling Assembly 1. Position coupling spacer to engine and align mount- ing holes. Use two shoulder bolts and lockwashers in the positions shown in Figure 15 to secure the spacer to the half threaded holes in engine flywheel.
Page 34 following electrical components: 17.Check position of wires, fuel lines, hydraulic hoses, and cables for proper clearance with rotating, high tem- A. The temperature sender and alternator (Fig 10). perature, and moving components. B. The engine run solenoid and fuel pump (Fig. 12). 18.Position battery to machine.
Page 35 Chapter 4 Hydraulic System Table of Contents SPECIFICATIONS ......SERVICE AND REPAIRS .
Page 36: Specifications
Specifications Item Description Piston (Traction) Pump Variable displacement piston pump System Relief Pressure: Forward 4000 PSI (274 bar) System Relief Pressure: Reverse 5000 PSI (343 bar) Charge Pressure 250 PSI (17 bar) Gear Pump 3 section, positive displacement gear type pump Steering Relief Pressure 1350 PSI (93 bar) Lift/Lower Relief Pressure...
Page 37: General Information
General Information Hydraulic Hoses Hydraulic hoses are subject to extreme conditions such as pressure differentials during operation and exposure WARNING to weather, sun, chemicals, very warm storage condi- tions, or mishandling during operation or maintenance. Before disconnecting or performing any work These conditions can cause damage or premature dete- on hydraulic system, relieve all pressure in rioration.
Page 38 SAE Straight Thread O- -Ring Port - - Non- -adjustable 1. Make sure both threads and sealing surfaces are free of burrs, nicks, scratches, or any foreign material. 2. Always replace the O--ring seal when this type of fit- ting shows signs of leakage. O- -Ring 3.
Page 39: Towing Traction Unit
Towing Traction Unit IMPORTANT: If towing limits are exceeded, severe damage to the piston pump may occur. If it becomes necessary to tow (or push) the machine, tow (or push) in a forward direction only and at a speed below 3 mph. The piston (traction) pump is equipped with a by--pass valve that needs to be turned for towing.
Page 40: Hydraulic Schematics
Hydraulic Schematics 1500 Hydraulic System (Rev. B) Page 4 - - 6 Groundsmaster 4000--D...
Page 41 Groundsmaster 4000--D Page 4 - - 7 Hydraulic System (Rev. B)
Page 42: Hydraulic Flow Diagrams
Hydraulic Flow Diagrams 1500 Hydraulic System (Rev. B) Page 4 - - 8 Groundsmaster 4000--D...
Page 43: Traction Circuit
Traction Circuit The traction circuit piston pump is a variable displace- Charge pump flow is directed through the oil filter and to ment pump that is directly coupled to the engine fly- the low pressure side of the closed loop traction circuit. wheel.
Page 44 1500 Hydraulic System (Rev. B) Page 4 - - 10 Groundsmaster 4000--D...
Page 45: Lower Cutting Unit
Lower Cutting Unit A three section gear pump is coupled to the piston (trac- To lower the front cutting unit, the center lift lever on the tion) pump. The gear pump section farthest from the pis- lift/lower control valve is pushed to allow valve shift in the ton pump supplies hydraulic flow to both the lift/lower lift/lower control.
Page 46 1500 Hydraulic System (Rev. B) Page 4 - - 12 Groundsmaster 4000--D...
Page 47: Raise Cutting Unit
Raise Cutting Unit A three section gear pump is coupled to the piston (trac- To raise the front cutting unit, the center lift lever on the tion) pump. The gear pump section farthest from the pis- lift/lower control valve is pulled to allow valve shift in the ton pump supplies hydraulic flow to the lift/lower control lift/lower control.
Page 48 1500 Hydraulic System (Rev. B) Page 4 - - 14 Groundsmaster 4000--D...
Page 49: Mow
Hydraulic flow for the mow circuit is supplied by two sec- Return oil from the deck motors is directed to the oil cool- tions of the gear pump. The gear pump section closest er and oil filter. Deck motor case drain leakage returns to the piston (traction) pump supplies hydraulic flow to to the hydraulic reservoir.
Page 50 1500 Hydraulic System (Rev. B) Page 4 - - 16 Groundsmaster 4000--D...
Page 51: Steering Circuit
Steering Circuit A three section gear pump is coupled to the piston (trac- the cylinder is proportional to the amount of the turning tion) pump. The gear pump section farthest from the pis- on the steering wheel. Fluid leaving the cylinder flows ton pump supplies hydraulic flow to the steering control back through the spool valve then through the T port and valve and the lift/lower control valve.
Page 52: Special Tools
Special Tools Order these tools from your Toro Distributor. Hydraulic Pressure Test Kit - - TOR47009 Use to take various pressure readings for diagnostic tests. Quick disconnect fittings provided attach directly to mating fittings on machine test ports without tools. A high pressure hose is provided for remote readings.
Page 53: Hydraulic Test Fitting Kit
Hydraulic Test Fitting Kit - - TOR4079 This kit includes a variety of O--ring Face Seal fittings to TORO TEST FITTING KIT (NO. TOR4079) enable you to connect test gauges into the system. The kit includes: tee’s, unions, reducers, plugs, caps, and male test fittings.
Page 54: Troubleshooting
Troubleshooting The charts that follow contain information to assist in Refer to the Testing section of this Chapter for precau- troubleshooting. There may possibly be more than one tions and specific test procedures. cause for a machine malfunction. Problem Possible Cause Hydraulic system operates hot.
Page 55 Problem Possible Causes Four wheel drive will not engage. Electrical problem exists (see Chapter 5 -- Electrical System). Solenoid valve on 4WD hydraulic manifold is faulty. Cartridge valve in 4WD manifold is damaged or sticking. Rear axle motor is damaged. Four wheel drive will not disengage.
Page 56 Problem Possible Causes Front cutting unit drops too fast or Flow control valve is not adjusted properly. too slow. Cutting units will not lower. Lift arm pivots are binding. Lift cylinder is damaged. Counterbalance pressure is excessive. Lift/lower control valve is worn or damaged. Pilot valve in lift/lower manifold is damaged or sticking.
Page 57: Testing
Testing The most effective method for isolating problems in the hydraulic system is by using hydraulic test equipment WARNING such as pressure gauges and flow meters in the circuits during various operational checks (See the Special Before disconnecting or performing any work Tools section in this Chapter).
Page 58: Test No. 1: Traction Circuit Charge Pressure
TEST NO. 1: Traction Circuit Charge Pressure (Using Pressure Gauge) CHARGE OIL FROM LIFT CIRCUIT CHARGE OIL FROM STEERING CIRCUIT CASE DRAIN FROM PTO (MOW) CIRCUIT TO PTO (MOW) CIRCUIT TO LIFT/LOWER CIRCUIT TO STEERING CIRCUIT RETURN FROM PTO (MOW) CIRCUIT High Pressure Low Pressure Return or Suction...
Page 59 Procedure for Traction Circuit Charge Pressure Test 1. Make sure hydraulic oil is at normal operating tem- perature by operating the machine for approximately 10 minutes. Make sure the hydraulic tank is full. 2. Park machine on a level surface with the cutting units lowered and off.
Page 60: Test No. 2: Traction Circuit Relief Pressure
TEST NO. 2: Traction Circuit Relief Pressure (Forward Shown) (Using Pressure Gauge) CHARGE CIRCUIT CHARGE CIRCUIT CASE DRAIN TO RESERVOIR CHARGE CIRCUIT TO PTO (MOW) CIRCUIT FROM OIL Working Pressure FILTER TO LIFT/LOWER CIRCUIT Low Pressure FROM Return or Suction RESERVOIR Flow TO STEERING CIRCUIT...
Page 61 Procedure for Traction Circuit Relief Pressure Test 1. Make sure hydraulic oil is at normal operating tem- perature by operating the machine for approximately 10 minutes. Make sure the hydraulic tank is full. CAUTION Move machine to an open area, away from people and obstructions.
Page 62: Test No. 3: Cutting Deck Circuit Pressure
TEST NO. 3: Cutting Deck Circuit Pressure (Front Deck Shown) (Using Pressure Gauge) TRACTION CIRCUIT TO LIFT/LOWER CIRCUIT TO STEERING CIRCUIT FROM RESERVOIR Working Pressure Low Pressure Return or Suction Flow Hydraulic System (Rev. B) Page 4 - - 28 Groundsmaster 4000--D...
Page 63 Procedure for Cutting Deck Circuit Pressure Test 1. Make sure hydraulic oil is at normal operating tem- perature by operating the machine for approximately 10 minutes. Make sure the hydraulic tank is full. 2. Park machine on a level surface with the cutting units lowered and off.
Page 64: Test No. 4: Cutting Deck Gear Pump Flow
TEST NO. 4: Cutting Deck Gear Pump Flow (Front Deck Shown) (Using Tester with Pressure Gauges and Flow Meter) TRACTION CIRCUIT TO LIFT/LOWER CIRCUIT TO STEERING CIRCUIT FROM RESERVOIR Working Pressure Low Pressure Return or Suction Flow Hydraulic System (Rev. B) Page 4 - - 30 Groundsmaster 4000--D...
Page 65 Procedure for Cutting Deck Gear Pump Flow Test 8. Flow indication should be approximately 14 GPM. NOTE: Over a period of time, the gears and wear plates 9. Shut off engine. in the pump can wear. A worn pump will by pass oil and 10.Disconnect flow tester from hydraulic hose and man- make the pump less efficient.
Page 66: Test No. 5: Cutting Deck Manifold Relief Pressure
TEST NO. 5: Cutting Deck Manifold Relief Pressure (Front Deck Shown) (Using Tester with Pressure Gauges and Flow Meter) TRACTION CIRCUIT TO LIFT/LOWER CIRCUIT TO STEERING CIRCUIT FROM RESERVOIR Working Pressure Low Pressure Return or Suction Flow Hydraulic System (Rev. B) Page 4 - - 32 Groundsmaster 4000--D...
Page 67 Procedure for Cutting Deck Manifold Relief 10.Disengage cutting units. Shut off engine. If specifica- Pressure Test tion is not met, adjust or clean relief valve in deck man- ifold port (R1BY). Adjust relief valve as follows: 1. Make sure hydraulic oil is at normal operating tem- perature by operating the machine for approximately 10 NOTE: Do not remove valve from the hydraulic man- minutes.
Page 68: Test No. 6: Cutting Deck Motor Case Drain Leakage
TEST NO. 6: Cutting Deck Motor Case Drain Leakage (Using Tester with Pressure Gauges and Flow Meter) TRACTION CIRCUIT TO LIFT/LOWER CIRCUIT TO STEERING CIRCUIT FROM RESERVOIR MEASURING CONTAINER Working Pressure Low Pressure Return or Suction Flow Hydraulic System (Rev. B) Page 4 - - 34 Groundsmaster 4000--D...
Page 69 Procedure for Cutting Deck Motor Case Drain 5. Sit on seat and start the engine. Move throttle to full Leakage Test speed (2730 + 30 RPM). Move PTO switch to ON. NOTE: Over a period of time, a deck motor can wear in- 6.
Page 70: Test No. 7: Steering Circuit Relief Pressure
TEST NO. 7: Steering Circuit Relief Pressure (Using Pressure Gauge) STEERING CYL NOTE: LEFT TURN SHOWN 1350 STEERING CONTROL T TO LIFT/LOWER CIRCUIT CHARGE CIRCUIT TO PTO (MOW) CIRCUIT RESERVOIR TRACTION 2.48 CIRCUIT FROM RESERVOIR FROM OIL FILTER High Pressure Low Pressure Return or Suction Flow...
Page 71 Procedure for Steering Circuit Relief Pressure Test 1. Make sure hydraulic oil is at normal operating tem- perature by operating the machine for approximately 10 minutes. Make sure the hydraulic tank is full. 2. Park machine on a level surface with the cutting units lowered and off.
Page 72: Test No. 8: Lift/Lower Circuit Relief Pressure
TEST NO. 8: Lift/Lower Circuit Relief Pressure (Using Pressure Gauge) NOTE: LH DECK RAISE SHOWN LIFT/LOWER CONTROL VALVE LH WING DECK LIFT CYL3 CYL1 FRONT DECK LIFT CYL2 CYL4 RH WING DECK LIFT CHARGE RESERVOIR CIRCUIT TRACTION 2.48 CIRCUIT FROM RESERVOIR FROM OIL FILTER...
Page 73 Procedure for Lift/Lower Circuit Relief Pressure Test NOTE: Before attempting to check or adjust lift pres- sure, make sure that counterbalance pressure is cor- rectly adjusted. 1. Make sure hydraulic oil is at normal operating tem- perature by operating the machine for approximately 10 minutes.
Page 74: Test No. 9: Steering And Lift/Lower Gear Pump Flow
TEST NO. 9: Steering and Lift/Lower Gear Pump Flow (Using Tester with Pressure Gauges and Flow Meter) NOTE: LIFT/LOWER GEAR PUMP FLOW TEST SHOWN TO STEERING CIRCUIT TO LIFT/LOWER CIRCUIT TRACTION 2.48 CIRCUIT FROM RESERVOIR FROM OIL FILTER High Pressure Low Pressure Return or Suction Flow...
Page 75 Procedure for Steering and Lift/Lower Gear Pump 7. If the total of the two flows is lower than 7 GPM or a Flow Test pressure of 1000 PSI could not be obtained, check for restriction in pump intake line. If intake line is not re- Output from the steering and lift/lower gear pump sec- stricted, remove gear pump and repair or replace as tion is equally divided by a proportional valve to provide...
Page 76: Test No. 10: Counterbalance Pressure
TEST NO. 10: Counterbalance Pressure (Using Pressure Gauge) LIFT/LOWER CONTROL VALVE LH WING DECK LIFT CYL3 CYL1 FRONT DECK LIFT CYL2 CYL4 RH WING DECK LIFT CHARGE RESERVOIR CIRCUIT TRACTION 2.48 CIRCUIT FROM RESERVOIR FROM OIL FILTER High Pressure Low Pressure Return or Suction Flow Hydraulic System (Rev.
Page 77 Procedure for Counterbalance Pressure Test 1. Make sure hydraulic oil is at normal operating tem- perature by operating the machine for approximately 10 minutes. Make sure the hydraulic tank is full. 2. Park machine on a level surface with the cutting units lowered and off.
Page 78: Test No. 11: Rear Traction Circuit (Rv5) Relief Pressure
TEST NO. 11: Rear Traction Circuit (RV5) Relief Pressure (Using Pressure Gauge) CHARGE CIRCUIT CHARGE CIRCUIT CASE DRAIN TO RESERVOIR CHARGE CIRCUIT TO PTO (MOW) CIRCUIT FROM OIL Working Pressure FILTER TO LIFT/LOWER CIRCUIT Low Pressure FROM Return or Suction RESERVOIR Flow TO STEERING CIRCUIT...
Page 79 Procedure for Rear Traction Circuit (RV5) Relief Pressure Test 1. Make sure hydraulic oil is at normal operating tem- perature by operating the machine for approximately 10 minutes. Make sure the hydraulic tank is full. 2. Park machine on a level surface with the cutting units lowered and off.
Page 80: Test No. 12: Traction Circuit Reducing Valve (Pr) Pressure
TEST NO. 12: Traction Circuit Reducing Valve (PR) Pressure (Using Pressure Gauge) CHARGE CIRCUIT CHARGE CIRCUIT CASE DRAIN TO RESERVOIR CHARGE CIRCUIT TO PTO (MOW) CIRCUIT FROM OIL Working Pressure FILTER TO LIFT/LOWER CIRCUIT Low Pressure FROM Return or Suction RESERVOIR Flow TO STEERING CIRCUIT...
Page 81 Procedure for Traction Circuit Reducing Valve (PR) Pressure Test 1. Make sure hydraulic oil is at normal operating tem- perature by operating the machine for approximately 10 minutes. Make sure the hydraulic tank is full. 2. Park machine on a level surface with the cutting units lowered and off.
Page 82: Adjustments
Adjustments Adjust Front Cutting Unit Lift Flow Control The front cutting unit lift circuit is equipped with an ad- justable flow control valve used to adjust the rate at which the front deck lowers. Adjust flow control valve as follows: 1.
Page 83: Service And Repairs
Service and Repairs General Precautions for Removing and Installing Hydraulic System Components Before Repair or Replacement of Components After Repair or Replacement of Components 1. Before removing any parts from the hydraulic sys- 1. Check oil level in the hydraulic reservoir and add cor- tem, park machine on a level surface, engage parking rect oil if necessary.
Page 84: Flush Hydraulic System
Flush Hydraulic System IMPORTANT: Flush the hydraulic system any time 6. Reconnect all hydraulic hoses, lines, and compo- there is a severe component failure or the system is nents that were disconnected while draining system. contaminated (oil appears milky, black, or contains NOTE: Use only hydraulic fluids specified in the Opera- metal particles).
Page 85: Charge Hydraulic System
Charge Hydraulic System NOTE: When initially starting the hydraulic system with 11. After the hydraulic system starts to show signs of fill, new or rebuilt components such as motors, pumps, or actuate lift control lever until the lift cylinder rod moves lift cylinders, it is important that the hydraulic system be in and out several times.
Page 86: Gear Pump
Gear Pump RIGHT FRONT Figure 39 1. 90 hydraulic fitting 10. O- -ring 19. Flat washer 2. O- -ring 11. Clamp 20. Engine 3. O- -ring 12. Hydraulic T fitting 21. Piston pump 4. 90 hydraulic fitting 13. O- -ring 22.
Page 87 Removal Installation 1. Park machine on a level surface, lower cutting units, 1. Lubricate new o--rings with clean hydraulic oil and stop engine, engage parking brake, and remove key position on pump. from the ignition switch. 2. Slide coupler onto the piston pump output shaft. 2.
Page 88: Gear Pump Service
Gear Pump Service 25 to 28 ft- -lb (34 to 38 N- -m) 20 21 21 to 24 ft- -lb (29 to 33 N- -m) 21 to 24 ft- -lb (29 to 33 N- -m) Figure 40 1. Shaft seal 11.
Page 89 3. Remove pump from vise, hold pump in hands and Inspection bump shaft against wooden block to separate front 1. Clean and dry all pump components. Remove nicks pump sections. Front body (10) will remain with either and burrs from all parts with emery cloth. front plate (15) or front adapter plate (23).
Page 90 Reassembly 11. Dip idler gear (21) in clean hydraulic oil and install in gear pocket of middle body. It is important that the relationship of the backplate, adapter plates, bodies, wear plates and front plate is 12.Install rear adapter plate (24) in place on middle body correct.
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Page 92: Piston (Traction) Pump
Piston (Traction) Pump 85 to 95 ft- -lb (115 to 128 N- -m) RIGHT FRONT Figure 41 1. Hydraulic T fitting 11. O- -ring 21. Clamp 2. O- -ring 12. Hose connector 22. Roll pin 3. O- -ring 13. 90 hydraulic fitting 23.
Page 93 Removal Installation 1. Park machine on a level surface, lower cutting units, 1. Carefully lower piston pump into the machine and stop engine, engage parking brake, and remove key position it to the engine adapter plate. Support pump to from the ignition switch. prevent it from falling while installing two (2) cap screws and washers securing piston pump to engine adapter 2.
Page 94: Piston (Traction) Pump Service
Piston (Traction) Pump Service 100 to 110 ft- -lb 27 to 31 ft- -lb (136 to 149 N- -m) (37 to 42 N- -m) 100 to 110 ft- -lb (136 to 149 N- -m) 150 to 160 in- -lb (17 to 18 N- -m) 4 to 6 ft- -lb (5 to 8 N- -m) 40 to 48 in- -lb...
Page 95 Disassembly 12.Remove the two cap screws (42) that secure cradle sub--assembly inside housing. Move the cradle sub--as- 1. Position the pump into a protected jaw vise, clamp- sembly back--and--forth to release dowel bushings (40) ing onto the outer portion of the flange, with the cap and remove cradle sub--assembly from housing.
Page 96 3. Inspect camplate assembly: A. The finish on the piston shoe surfaces of the cam- plate (11) should show no signs of scoring. B. Inspect camplate (11) bushing surface for wear. Also inspect surface for coating transfer from bush- ing. 4.
Page 97 8. Place exterior retaining ring (3), thrust race (12), 20.Secure control assembly with six socket head thrust bearing (13), second thrust race (12), and second screws (17). Torque screws from 40 to 48 in--lb (4.5 to retaining ring (3) onto drive shaft (21). Position washer 5.4 N--m).
Page 98: Piston Pump Control Assembly
Piston Pump Control Assembly 44 to 52 ft- -lb (60 to 70 N- -m) 17 to 26 in- -lb (2 to 3 N- -m) 28 to 34 in- -lb (3.2 to 3.8 N- -m) Figure 47 1. Plug 9. O- -ring 17.
Page 99 5. Apply Loctite #242 or equivalent to set screw (18) 5. Test the switch by moving the control arm to the det- and install into control housing. Adjust set screw until it ent position, the light should be on. Move the control arm bottoms out on input shaft and back out one--quarter out of detent, the light should go off.
Page 100: Hydraulic Control Manifold: 4 Wheel Drive
Hydraulic Control Manifold: 4 Wheel Drive RIGHT FRONT Figure 49 1. Frame assembly 8. Fitting cap 14. Hydraulic fitting 2. Manifold 9. Hydraulic fitting 15. Adapter 3. 90 hydraulic fitting 10. O- -ring 16. Hydraulic fitting 4. O- -ring 11. O- -ring 17.
Page 101 Removal Installation NOTE: The ports on the manifold are marked for easy 1. Install hydraulic manifold to the frame using Figure identification of components. Example: P1 is a piston 49 as guide. pump connection port and 2 is the location for the sole- 2.
Page 102: Hydraulic Control Manifold Service: 4 Wheel Drive
Hydraulic Control Manifold Service: 4 Wheel Drive 80 to 90 ft- -lb EATON/VICKERS MANIFOLD (108 to 122 N- -m) 80 to 90 ft- -lb (108 to 122 N- -m) 60 to 70 ft- -lb (81 to 95 N- -m) 25 to 30 ft- -lb (34 to 41 N- -m) 35 to 40 ft- -lb (47 to 54 N- -m)
Page 103 5. Visually inspect cartridge valve for damaged sealing 7. Reinstall the cartridge valve: surfaces and contamination. A. Lubricate new seal kit components with clean hy- A. Contamination may cause valves to stick or hang draulic oil and install on valve. The o--rings, sealing up.
Page 104: Hydraulic Control Manifold: Deck Drive
Hydraulic Control Manifold: Deck Drive RIGHT FRONT Figure 52 1. Hydraulic manifold (front deck) 10. O- -ring 19. Elbow (90 2. Quick fitting 11. Cap screw 20. Hydraulic fitting 3. Flange nut 12. Fitting cap 21. O- -ring 4. O- -ring 13.
Page 105: Hydraulic Control Manifold Service: Deck Drive
Hydraulic Control Manifold Service: Deck Drive 30 to 35 ft- -lb 30 to 35 ft- -lb (41 to 47 N- -m) (41 to 47 N- -m) 12 to 15 ft- -lb (16 to 20 N- -m) 2 to 5 ft- -lb (3 to 7 N- -m) 80 ft- -lb (108 N- -m)
Page 106: Hydraulic Control Manifold: Cutting Deck Lift/Lower
Hydraulic Control Manifold: Cutting Deck Lift/Lower RIGHT FRONT Figure 54 1. Lift/lower hydraulic manifold 7. Lock nut 12. Cap screw 2. Valve plate 8. Hydraulic fitting 13. 90 hydraulic fitting 3. Flat washer 9. O- -ring 14. O- -ring 4. Cap screw 10.
Page 107: Hydraulic Control Manifold Service: Cutting Deck Lift/Lower
Hydraulic Control Manifold Service: Cutting Deck Lift/Lower 35 to 40 ft- -lb 35 to 40 ft- -lb (47 to 54 N- -m) (47 to 54 N- -m) 35 to 40 ft- -lb (47 to 54 N- -m) Figure 55 1. Manifold body 4.
Page 108: Hydraulic Control Manifold: Filter Manifold
Hydraulic Manifold: Filter Manifold RIGHT FRONT Figure 56 1. Filter manifold 9. Flat washer 17. 90 hydraulic elbow 2. 45 hydraulic elbow 10. Hydraulic fitting 18. Hydraulic hose 3. Test nipple 11. O- -ring 19. Hydraulic fitting 4. Fitting cap 12.
Page 109 Hydraulic Manifold Service: Filter Manifold 35 to 40 ft- -lb (47 to 54 N- -m) 60 to 70 ft- -lb (81 to 95 N- -m) 13 12 Figure 57 1. Filter manifold assembly 7. Seal kit 12. Plug (SAE #5) 2.
Page 110: Flow Divider
Hydraulic Manifold: Flow Divider RIGHT FRONT Figure 58 1. Hydraulic manifold 8. O- -ring 14. O- -ring 2. O- -ring 9. 90 hydraulic elbow 15. 90 hydraulic elbow 3. Hydraulic fitting 10. O- -ring 16. O- -ring 4. Bracket 11. Hydraulic hose 17.
Page 111 Hydraulic Manifold Service: Flow Divider 50 ft- -lb (67.8 N- -m) 20 ft- -lb (27.1 N- -m) 20 ft- -lb (27.1 N- -m) 20 ft- -lb (27.1 N- -m) 4 to 5 ft- -lb (5.4 to 6.8 N- -m) 20 ft- -lb (27.1 N- -m) Figure 59 1.
Page 112: Rear Axle Motor
Rear Axle Motor Arrow on side of motor case points up 59 to 73 ft- -lb (80 to 99 N- -m) RIGHT FRONT Figure 60 1. Wheel motor 7. External snap ring 12. O- -ring 2. 90 hydraulic fitting 8. Pinion gear 13.
Page 113 Removal Installation 1. Park machine on a level surface, lower cutting units, 1. If removed, install pinion gear to axle motor. stop engine, engage parking brake, and remove key 2. Install o--ring onto motor. Position motor to rear axle from the ignition switch. assembly making sure that arrows on the side of motor 2.
Page 114: Front Wheel Motors
Front Wheel Motors Arrow on side of motor case points up RIGHT 75 to 85 ft- -lb (101 to 115 N- -m) FRONT Figure 61 1. Front wheel motor 9. Flange head screw 16. O- -ring 2. Internal retaining ring 10.
Page 115 Removal Installation 1. Park machine on a level surface, lower cutting units, 1. Position wheel motor to brake assembly making sure stop engine, engage parking brake, and remove key that arrows on the side of motor case point upward. from the ignition switch. 2.
Page 116: Rear Axle/Front Wheel Motor Service
Rear Axle/Front Wheel Motor Service 15 to 18 ft- -lb (20 to 24 N- -m) Figure 62 1. Drive shaft 7. Cap screw 13. Thrust bearing 2. Backplate (front motor shown) 8. Shaft seal 14. Roll pin 3. Housing assembly 9.
Page 117 4. Remove motor from vise and remove rotating as- 2. If necessary, install new needle bearing (17) in hous- sembly (4) from motor housing. ing (3) with numbered end of the bearing outward. 5. Remove the camplate insert (5) from housing. Use 3.
Page 118 This page is intentionally blank. Hydraulic System (Rev. B) Page 4 - - 84 Groundsmaster 4000--D...
Page 119: Cutting Deck Motor
Cutting Deck Motor Removal 1. Park machine on a level surface, lower cutting units, stop engine, engage parking brake, and remove key from the ignition switch. 2. Read the General Precautions for Removing and Installing Hydraulic System Components at the begin- ning of the Service and Repairs section of this chapter.
Page 120: Cutting Deck Motor Service
Cutting Deck Motor Service 33 to 40 ft- -lb (45 to 55 N- -m) Figure 66 1. Rear cover 7. Spider hub 12. Idler gear 2. Drive gear 8. Pressure seal 13. Cap screw 3. Seal 9. Back- -up ring 14.
Page 121 IMPORTANT: Mark the relative positions of the gear teeth and the bearing blocks so they can be re- assembled in the same position. Do not touch the gear surfaces as residue on hands may be corrosive to gear finish. 7. Place the motor on its side and push on the rear bear- ing block to remove the bearing block and gear set (Fig.
Page 122 Reassembly 8. Install dowel pins in body. NOTE: When reassembling the motor, check the identi- IMPORTANT: Do not dislodge o- -rings, pressure fication marks made during disassembly to make sure seals, or back- -up rings during final assembly. the parts are properly aligned during reassembly. 9.
Page 123 This page is intentionally blank. Groundsmaster 4000--D Page 4 - - 89 Hydraulic System (Rev. B)
Page 124: Lift/Lower Control Valve
Lift/Lower Control Valve RIGHT FRONT Figure 71 1. Control valve assembly 10. Cotter pin 18. O- -ring 2. Valve bracket 11. RH lever assembly 19. Cap screw 3. Grommet 12. Spacer 20. Hydraulic fitting 4. Cap screw 13. Cap screw 21.
Page 125 Removal Installation 1. Park machine on a level surface, lower cutting units, 1. Install control valve using Figure 71 as a guide. stop engine, engage parking brake, and remove key 2. Make sure hydraulic tank is full. Add correct oil if nec- from the ignition switch.
Page 126: Lift/Lower Control Valve Service
Lift/Lower Control Valve Service 20 to 25 ft- -lb (27 to 33 N- -m) Figure 72 1. Poppet 13. Washer 25. O- -ring 2. Spacer 14. Washer 26. Backup washer 3. Wiper 15. Washer 27. Disc 4. Seat 16. Washer 28.
Page 127 Disassembly Assembly 1. Plug all ports and clean outside of valve thoroughly. 1. Thoroughly clean and dry all parts. Apply a light coat- ing of clean hydraulic oil to parts prior to assembly. 2. Remove caps (9). Do not remove retaining rings (12) from spools unless spring (19) is broken.
Page 128: Steering Valve
Steering Valve 18 to 22 ft- -lb (25 to 29 N- -m) RIGHT FRONT Figure 73 1. Hex nut 11. O- -ring 21. Steering column assembly 2. Flat washer 12. Flange head screw 22. Flange bushing 3. Steering wheel 13. Hydraulic adapter 23.
Page 129 Removal Installation 1. Park machine on a level surface, lower cutting units, 1. Install steering valve using Figure 73 as a guide. stop engine, engage parking brake, and remove key 2. Make sure hydraulic tank is full. Add correct oil if nec- from the ignition switch.
Page 130: Steering Valve Service
Steering Valve Service 150 in- -lb (17 N- -m) 140 to 160 in- -lb (16 to 18 N- -m) Figure 74 1. Steering valve housing 9. Cap screw 17. Geroter drive 2. Dust seal 10. End cap 18. Wear plate 3.
Page 131 8. Put the thrust bearing and races into the housing. CAUTION The thrust bearing goes between the two races (Fig. 75). IMPORTANT: Do not damage the dust or quad seals The centering springs are under tension. Re- when installing the spool and sleeve assembly. move the retaining ring carefully.
Page 132 Side Deck Lift Cylinder RIGHT FRONT Figure 76 1. Lift arm assembly (LH shown) 5. Flange locking nut 9. Cylinder pin 2. Shoulder screw 6. 90 hydraulic fitting 10. Spring pin 3. Pin assembly 7. O- -ring 11. Lock nut 4.
Page 133 Removal Installation 1. Park machine on a level surface, lower cutting units, 1. Position cylinder barrel clevis to frame and insert cyl- stop engine, engage parking brake, and remove key inder pin through the frame and cylinder clevis. Secure from the ignition switch. pin with flat washer and lock nut.
Page 134 Front Deck Lift Cylinder RIGHT FRONT Figure 77 1. Lift cylinder 5. Cap screw 9. O- -ring 2. Upper lift pin 6. Flat washer 10. Straight hydraulic fitting 3. Cotter pin 7. Lock nut 11. O- -ring 4. Pin assembly 8.
Page 135 Removal Installation 1. Park machine on a level surface, lower cutting units, 1. Position cylinder barrel clevis to frame and insert up- stop engine, engage parking brake, and remove key per lift pin into frame and clevis. Secure lift pin with cotter from the ignition switch.
Page 136: Side Deck Lift Cylinder
Lift Cylinder Service 10 7 SIDE DECK LIFT CYLINDER Figure 78 1. Barrel with clevis 6. O- -ring 11. Piston 2. Collar 7. Back- -up ring 12. Lock nut 3. Shaft with clevis 8. Head 13. Grease fitting 4. Dust seal 9.
Page 137 Disassembly 2. Coat new O--rings, Uni--ring, rod seal, back--up ring, and dust seal with clean hydraulic oil. 1. Remove oil from lift cylinder into a drain pan by slowly pumping the cylinder shaft. Plug both ports and clean A. Install Uni--ring and O--ring to the piston. the outside of the cylinder.
Page 138: Steering Cylinder
Steering Cylinder 100 to 125 ft- -lb (135 to 169 N- -m) RIGHT 100 to 125 ft- -lb (135 to 169 N- -m) FRONT Figure 81 1. Steering cylinder 6. Grease fitting 11. Ball joint spacer 2. Ball joint 7. 90 hydraulic fitting 12.
Page 139 Removal Installation 1. Park machine on a level surface, lower cutting units, 1. Place a washer onto each ball joint. Slide ram end stop engine, engage parking brake, and remove key ball joint through hole on steering arm. Secure with axle from the ignition switch.
Page 140: Steering Cylinder Service
Steering Cylinder Service Figure 82 1. Butt and tube assembly 5. Lock nut 9. O- -ring 2. Shaft 6. O- -ring 10. U- -cup 3. Piston rod assembly 7. PTFE seal 11. Wiper 4. Gland (head) 8. O- -ring Rev. E Hydraulic System (Rev.
Page 141 Disassembly 2. Install new O--rings and PTFE seal to the piston rod and new O--ring, U--cup, and wiper to gland. 1. Pump oil out of cylinder into a drain pan by SLOWLY moving rod and piston in and out of cylinder bore. Plug 3.
Page 142: Hydraulic Reservoir
Hydraulic Reservoir RIGHT FRONT Figure 84 1. Hydraulic reservoir 9. Stand pipe 17. Hose clamp 2. Petcock 10. Hose clamp 18. Hose 3. O- -ring 11. Screen filter 19. Hose clamp 4. Strap 12. Dipstick 20. Cap screw 5. Felt strap 13.
Page 143 Removal Inspection 1. Park machine on a level surface, lower cutting units, 1. Clean hydraulic reservoir and suction strainer with stop engine, engage parking brake, and remove key solvent. from the ignition switch. 2. Inspect for leaks, cracks, or other damage. 2.
Page 144: Hydraulic Oil Cooler
Hydraulic Oil Cooler Removal CAUTION The radiator and oil cooler may be hot. To avoid possible burns, allow the engine and cooling systems to cool before working on the oil cooler. 1. Park machine on a level surface, lower cutting units, stop engine, engage parking brake, and remove key from the ignition switch.
Page 145 Chapter 5 Electrical System Table of Contents ELECTRICAL SCHEMATIC, CIRCUIT DIAGRAMS, Glow Relay ....... . AND WIRE HARNESS DRAWINGS .
Page 146: Electrical Schematic, Circuit Diagrams, And Wire Harness Drawings
Electrical Schematic, Circuit Diagrams, and Wire Harness Drawings The electrical schematic, circuit diagrams, and wire har- ness drawings for the Groundsmaster 4000−D are lo- cated in Chapter 9 − Electrical Diagrams. Electrical System Page 5 − 2 Groundsmaster 4000−D...
Page 147: Special Tools
Multimeter The meter can test electrical components and circuits for current, resistance, or voltage. NOTE: Toro recommends the use of a DIGITAL Volt− Ohm−Amp multimeter when testing electrical circuits. The high impedance (internal resistance) of a digital me- ter in the voltage mode will make sure that excess cur- rent is not allowed through the meter.
Page 148: Troubleshooting
Troubleshooting For effective troubleshooting and repairs, you must have a good understanding of the electrical circuits and CAUTION components used on this machine (see Chapter 9 − Electrical Diagrams). Remove all jewelry, especially rings and If the machine has any interlock switches by−passed, watches, before doing any electrical trouble- shooting or testing.
Page 149: General Run & Transport Problems
Problem Possible Causes Engine cranks, but does not start. Engine is not cranking fast enough. Engine fuel stop solenoid, circuit wiring, or fuel pump is faulty. The problem is not electrical (see Chapter 3 − Kubota Engine). Starter cranks, but should not when the traction pedal The traction neutral switch is out of adjustment.
Page 150: Cutting Unit Operating Problems
Cutting Unit Operating Problems The cutting units remain engaged, but should not, with The seat switch or circuit wiring is faulty. no operator in the seat. Cutting units run, but should not, when raised. Units The deck position switch or circuit wiring is faulty. shut off with PTO switch.
Page 151: Electrical System Quick Checks
Electrical System Quick Checks Battery Test (Open Circuit Test) Use a multimeter to measure the voltage between the Voltage Measured Battery Charge Level battery terminals. 12.68 V (or higher) Fully charged (100%) Set multimeter to the DC volts setting. The battery 12.45 V 75% charged should be at a temperature of 60 to 100...
Page 152: Component Testing
Component Testing For accurate resistance and/or continuity checks, elec- trically disconnect the component being tested from the CAUTION circuit (e.g. unplug the ignition switch connector before doing a continuity check). When testing electrical components for continu- NOTE: For engine component testing information, see ity with a multimeter (ohms setting), make sure the Kubota Workshop Manual, Diesel Engine, V2003−T that power to the circuit has been disconnected.
Page 153: Fuses
Fuses The fuse blocks are located under the operator’s control panel. Identification, Function, and Wiring The fuses are held in two fuse blocks. Use Figure 7 to identify each individual fuse and its correct amperage. Each fuse holder has the following functions and wire connected to it.
Page 154: Warning Lights
Warning Lights Testing Warning Lights 1. Apply 12 VDC to terminals 1A and 2A. 2. Ground terminals 1B and 2B. 3. Both indicator lights should light. Engine Oil Pressure Light The oil pressure light should come on when the ignition switch is in the ON position with the engine not running.
Page 155: Pto Switch
PTO Switch The PTO switch is attached to the control console next to the operator seat (Fig. 11). The switch terminals are marked as shown in Figure 12. The circuitry of the PTO switch is shown in the chart be- low.
Page 156: Transport, Alarm Silence, And Temperature Override Switches
Transport, Alarm Silence, and Temperature Override Switches The transport, alarm silence, and temperature override rocker switches are located on the control console (Fig. 13). These switches have common switching logic. The switch terminals are marked as shown in Figure 14 and Figure 15.
Page 157: Seat Switch
Seat Switch The seat switch is normally open and closes when the operator is on the seat. If the traction system or PTO switch is engaged when the operator raises out of the seat, the engine will stop. The seat switch and its electri- cal connector are located directly under the seat.
Page 158: Hour Meter
Hour Meter The hour meter is located on the control console next to the operator seat. 1. Connect the positive (+) terminal of a 12 VDC source to the positive (+) terminal of the hour meter. 2. Connect the negative (−) terminal of the voltage source to the other terminal of the hour meter.
Page 159: Start, Engine Shutdown, Seat, Pto, Alarm, And Over Temperature Relays
Start, Engine Shutdown, Seat, PTO, Alarm, and Over Temperature Relays These six relays are located under the console housing cover. The wiring harness is tagged to identify each relay. NOTE: The relays may be manufactured by one of two different manufacturers. Verify manufacturer name and part number before performing the resistance check on the relay coil.
Page 160: Hydraulic Valve Solenoids
Hydraulic Valve Solenoids There are four hydraulic valve solenoids on the Ground- 5. Install new solenoid if necessary. smaster 4000−D (Fig. 23). Testing of these solenoids A. Apply “Loctite 242” or equivalent to threads on can be done with the solenoid on the hydraulic valve. end of valve stem before installing nut.
Page 161: Engine Run Solenoid
Engine Run Solenoid The engine run solenoid must be energized for the en- gine to run. It is mounted on the engine block near the injection pump. In Place Testing NOTE: Prior to taking small resistance readings with a digital multimeter, short the meter test leads together. The meter will display a small resistance value (usually 0.5 ohms or less).
Page 162: Fuel Sender
Fuel Sender The fuel sender is located on top of the fuel tank. 1. Remove white wire and black ground wire from the sender. FULL POSITION 2. Remove screws and lock washers that secure the sender to the fuel tank. 3.
Page 163: Fuel Gauge
Fuel Gauge The fuel gauge can be tested using a new gauge as a substitute or with the use of a DC voltage source and a variable resistance box. CAUTION Make sure the voltage source is turned OFF be- fore connecting it to the electrical circuit to avoid VARIABLE electrical shock and prevent damaging the RESISTANCE...
Page 164: Fuel Pump
Fuel Pump The fuel pump is attached to the frame above the fuel water separator. Operational Test 1. Park machine on a level surface, lower cutting units, stop engine, and engage parking brake. 2. Disconnect electrical connector from the fuel stop solenoid to prevent the engine from firing.
Page 165: Glow Controller
Glow Controller The glow controller is located under the console cover. NOTE: Refer to Chapter 9 − Electrical Schematics and Diagrams when troubleshooting the controller. Controller Operation 1. When the ignition switch is placed in the ON position, the controller energizes the glow plugs and lights up the glow lamp for 10 seconds.
Page 166: Temperature Sender
Apply thread sealant to the threads of the sender. B. Screw sender into the water flange and tighten. C. Reconnect gray wire to sender. Apply skin−over grease (Toro Part No. 505−165) to sender terminal. 5. Fill engine cooling system (see Operator’s Manual). Rev. E Electrical System Page 5 −...
Page 167: High Temperature Shutdown Switch
High Temperature Shutdown Switch The high temperature shutdown switch is located near the glow plug connection on the engine cylinder head (Fig. 33). There is a blue wire attached to the switch. CAUTION Make sure engine is cool before removing the temperature switch.
Page 168: Temperature Gauge
Temperature Gauge The temperature gauge can be tested using a new gauge as a substitute or by the use of a DC voltage source and a variable resistance box. CAUTION Make sure the voltage source is turned OFF be- fore connecting variable resistance to the elec- VARIABLE trical circuit to avoid electrical shock and to pre- RESISTANCE...
Page 169: Traction Neutral Switch
Traction Neutral Switch The traction neutral switch is closed when the traction pedal is in the neutral position and opens when the pedal is depressed in either direction. The switch is located on the right side of the piston (traction) pump. Test the switch by disconnecting the wires from the switch terminals and connecting a continuity tester across the two switch terminals.
Page 170: Diode Circuit Board
Diode Circuit Board The circuit board contains four diodes (Fig. 39) and is lo- cated under the console housing. The diodes are used for circuit protection from inductive voltage spikes that occur when a hydraulic valve solenoid is de−energized. Diode D1 is in the left cutting deck circuit, D2 is in the Transport/Mow circuit, D3 is in the front cutting deck cir- cuit, and D4 is in the right cutting deck circuit.
Page 171: Cutting Deck Position Switch
Cutting Deck Position Switch The cutting deck position switches on the Groundsmas- ter 4000−D are located on the traction unit frame (Fig. 40 and 41) and are normally open. The position switch is a powered proximity switch that incorporates an inter- nal reed switch and relay (see schematic in Figure 42).
Page 172: Service And Repairs
A. Clean battery by washing entire case with a solu- tion of baking soda and water. Rinse with clear water. B. Coat battery posts and cable connectors with skin−over grease (Toro Part No. 505−165) or petro- leum jelly to prevent corrosion. Rev. E Electrical System Page 5 −...
Page 173: Battery Service
Battery Service The battery is the heart of the electrical system. With regular and proper service, battery life can be extended. Additionally, battery and electrical component failure can be prevented. CAUTION When working with batteries, use extreme cau- tion to avoid splashing or spilling electrolyte. Electrolyte can destroy clothing and burn skin or eyes.
Page 174 C. If the difference between the highest and lowest H. Using the table below, determine the minimum cell specific gravity is 0.050 or greater or the lowest voltage for the cell temperature reading: cell specific gravity is less than 1.225, charge the bat- tery.
Page 175 Charging CAUTION To minimize possible damage to the battery and allow the battery to be fully charged, the slow charging meth- od is presented here. This charging method can be ac- Do not charge a frozen battery because it can ex- complished with a constant current battery charger plode and cause injury.
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Page 177 Chapter 6 Axles, Planetaries, and Brakes Table of Contents SPECIFICATIONS ......Rear Axle Assembly .
Page 178: Specifications
Specifications Item Specification Wheel lug nut torque 85 to 100 ft−lb (115 to 135 N−m), front and rear Steering cylinder bolt torque 100 to 125 ft−lb (139 to 169 N−m) Rear wheel toe−in .125 in (3.18 mm) Tire pressure 25 to 30 psi (1.7 to 2.1 bar), front and rear Planetary brake housing and wheel motor 75 to 85 ft−lb (101 to 115 N−m) mounting screw torque...
Page 179: Adjustments
Adjustments See Operator’s Manual for adjustment procedures for Groundsmaster 4000−D axles, planetaries, and brakes. Groundsmaster 4000−D Page 6 − 3 Axles, Planetaries, and Brakes (Rev. B)
Page 180: Service And Repairs
Service and Repairs Brake Assembly 85 to 100 ft−lb (115 to 135 N−m) RIGHT FRONT 75 to 85 ft−lb (101 to 115 N−m) Figure 1 1. Planetary assembly 7. Flat washer 13. Brake cable 2. Retaining ring 8. Cap screw 14.
Page 181 CAUTION WARNING When changing attachments, tires, or perform- Failure to maintain proper torque could result ing other service, use correct blocks, hoists, in failure or loss of wheel and may result in and jacks. Make sure machine is parked on a personal injury.
Page 182: Brake Inspection And Repair
Brake Inspection and Repair Figure 4 1. Brake housing (LH shown) 6. Hitch pin 11. Rotating actuator 2. Seal 7. Stationary disc 12. Extension spring 3. Pull rod 8. Rotating disc 13. Ball 4. Clevis pin 9. Retaining ring 14. Plug 5.
Page 183 This page is intentionally blank. Groundsmaster 4000−D Page 6 − 7 Axles, Planetaries, and Brakes (Rev. B)
Page 184: Planetary Wheel Drive Assembly
Planetary Wheel Drive Assembly 85 to 100 ft−lb (115 to 135 N−m) 75 to 85 ft−lb (101 to 115 N−m) RIGHT FRONT 75 to 85 ft−lb (101 to 115 N−m) Figure 5 1. Planetary assembly 6. Hydraulic wheel motor 11. Gasket 2.
Page 185 Planetary Wheel Drive Removal WARNING 1. Park machine on a level surface, lower cutting units, stop engine, engage parking brake, and remove key Failure to maintain proper wheel lug nut from the ignition switch. torque could result in failure or loss of wheel and may result in personal injury.
Page 186: Planetary Wheel Drive Service
Planetary Wheel Drive Service 9 ft−lb (12 N−m) Figure 7 1. Spindle 9. Thrust washer 17. Input shaft 2. Seal 10. Retaining ring (external) 18. Carrier assembly 3. Bearing cone 11. Ring gear 19. Cap screw 4. Bearing cup 12. Retaining ring (internal) 20.
Page 187 Planetary Wheel Drive Disassembly (Figure 7) Planetary Wheel Drive Assembly (Figure 7) 1. Remove retaining ring (12). NOTE: Use new seal kit when assembling planetary wheel drive. 2. Remove cover plate (14). 1. Clean parts in solvent. Inspect parts for damage or 3.
Page 188: Rear Axle Assembly
Rear Axle Assembly RIGHT FRONT 70 ft−lb maximum (94 N−m) Figure 8 1. Frame assembly 8. Rear axle assembly 14. Lock nut 2. Cap screw 9. Thrust washer (thin) 15. Flange nut 3. Lock washer 10. Washer head screw 16. Rear bumper 4.
Page 189 8. Remove cap screw and flange nut that secures front corner of 4WD hydraulic manifold to rear frame mount. 9. If required, remove tie rod ends from steering arms on rear axle (Fig. 10). Remove the cotter pins and castle nuts from the tie rod ball joints.
Page 190 9. Install steering cylinder to axle assembly (see Steer- ing Cylinder in Service and Repairs section of Chapter 4 − Hydraulic System). 10.Install hydraulic motor to axle assembly (see Rear Axle Motor in Service and Repairs section of Chapter 4 −...
Page 191: Bevel Gear Case And Axle Case
Bevel Gear Case and Axle Case The following procedures assume the rear axle assem- 35 to 41 ft−lb bly has been removed from the machine. (47 to 56 N−m) Removal 1. Remove the mounting screws, nuts, and lock wash- ers. Remove the bevel gear case/axle case assembly and O-ring from the axle support (Fig.
Page 192 5. Remove the knuckle pin mounting screws and the knuckle pin. Remove the gasket and any remaining gas- ket material from either mating surface (Fig. 16). 17 to 20 ft−lb 6. While holding the bevel gear case, tap the upper end (23 to 27 N−m) of the bevel gear shaft out of the upper bearing and up- per bevel gear.
Page 193 Installation 1. Coat new shaft seal with grease and install in axle case as shown (Fig. 18). Figure 18 1. Axle case 3. Shaft seal 2. Bevel gear case 2. Install the lower bevel gear, and bevel gear shaft in the axle case cover.
Page 194 5. Determine necessary quantity of support shims. 57 to 67 ft−lb A. Lubricate the axle case support bushing with a (77 to 91 N−m) thin coat of grease and slide axle case support onto knuckle pin. B. Position support shims that were removed during VERTICAL disassembly between axle case support and axle ENDPLAY...
Page 195 9. Remove the bevel gear case/axle case assembly NOTE: Axle bearing shims are available in 0.008 in. from the axle support. Coat a new O-ring with grease (0.2 mm), 0.012 in. (0.3 mm), and 0.020 in. (0.5 mm) and temporarily install the axle cover assembly. Position thickness.
Page 196: Differential Shafts
Differential Shafts The following procedures assume the rear axle assem- 35 to 41 ft−lb bly has been removed from the machine. (47 to 56 N−m) Removal IMPORTANT: Do not interchange right and left dif- ferential shaft assemblies. 1. Remove the mounting screws, nuts, and lock wash- ers.
Page 197: Axle Shafts
Axle Shafts The following procedures assume the rear axle assem- 17 to 20 ft−lb bly has been removed from the machine. (23 to 27 N−m) Removal 1. Remove the axle cover mounting screws. Remove the axle cover from the axle case as an assembly (Fig.
Page 198: Input Shaft/Pinion Gear
Input Shaft/Pinion Gear 35 to 41 ft−lb (47 to 56 N−m) 35 to 41 ft−lb (47 to 56 N−m) Figure 28 1. Nut 7. O-ring 13. Shim 2. Lockwasher 8. Seal collar 14. Screw 3. Stud 9. Bearing 15. Gear case 4.
Page 199 6. Set the bearing preload by securing the bearing case in a vise. Thread a M12 x 1.5 hex head cap screw into the splined end of the input shaft/pinion gear and slowly tighten the locknut until 4 to 6 in-lb (0.4 to 0.7 N−m) of force is required to rotate the input shaft/pinion gear in the bearing case.
Page 200: Differential Gear
Differential Gear The following procedures assume the rear axle assem- 35 to 41 ft−lb bly has been removed from the machine. (47 to 56 N−m) Removal 1. Remove bevel gear case/axle case assemblies (see Bevel Gear Case/Axle Case Assembly in this section of this manual).
Page 201 Inspection 1. Measure the differential side gear O.D. and the dif- ferential case I.D. to determine the side gear to case clearance (Fig. 35). Replace components as necessary. SIDE GEAR TO CASE CLEARANCE: 0.002 to 0.012 in. (0.05 to 0.30 mm) SIDE GEAR O.D.
Page 202 Installation 1. If the ring gear was removed from the differential case, use medium strength Loctite thread locker and tighten the mounting screws from 22 to 25 ft-lb (30 to 34 N−m). 2. Apply molybdenum disulfide lubricant (Three Bond 1901 or equivalent) to the splines and bearing surfaces of the differential pinion gears, pinion washers and side gears.
Page 203: Pinion Gear To Ring Gear Engagement
Pinion Gear to Ring Gear Engagement (4 Wheel Drive Axle) The final position of the pinion gear is verified by using PROFILE the gear contact pattern method as described in the fol- TOP LAND lowing procedure. GEAR TOOTH DEFINITIONS (Fig. 39): Toe −...
Page 204 Gear Pattern Movement Summary Heel Contact Base Contact Every gear has a characteristic pattern. The illustrations show typical patterns only and explain how patterns shift as gear location is changed. 1. If contact is toward the heel or base of the gear (Fig. 42): A.
Page 205 Chapter 7 Chassis Table of Contents SERVICE AND REPAIRS ..... . Steering Tower ......Front Deck Lift Arm .
Page 206: Service And Repairs
Service and Repairs Steering Tower 18 to 22 ft−lb (25 to 29 N−m) RIGHT FRONT Figure 1 Hex nut 15. Lock nut 29. Cap screw Flat washer 16. Parking brake switch 30. Pivot hub 31. Flange head screw Steering wheel 17.
Page 207 Disassembly Assembly 1. Park machine on a level surface, lower cutting units, 1. Assemble steering tower using Figure 1 as a guide. stop engine, engage parking brake, and remove key Note: Thrust washer(s) (24) on steering column are from the ignition switch. used as needed to remove end play of steering shaft.
Page 208: Front Deck Lift Arm
Front Deck Lift Arm 60 to 70 ft−lb (81 to 94 N−m) 150 to 175 ft−lb (203 to 237 N−m) RIGHT FRONT Figure 2 Flange bushing 14. Lift arm pin 27. Cotter pin Ball joint 15. Cotter pin 28. Washer Lock nut 16.
Page 209 7. Install ball joint mount to ball joint with slotted hex nut. Torque nut from 150 to 175 ft−lb (203 to 237 N−m) while CAUTION aligning cotter pin holes. Install cotter pin. When changing attachments, tires, or perform- 8. Install front cutting deck (see Front Cutting Unit in ing other service, use correct blocks, hoists, Chapter 8 −...
Page 210: Side Deck Lift Arm
Side Deck Lift Arm 16 17 19 18 Thread locking Compound 9 10 Anti−seize Lubricant RIGHT 30 33 FRONT Figure 5 Lift arm (LH shown) 14. Rubber bumper 27. Lock nut Shoulder screw 15. Slotted roll pin 28. Flat washer Lift cylinder pin 16.
Page 211 Removal 9/16” hole 3” x 12” (3/8” to 1/2” thick) plate steel 1. Park machine on a level surface, lower cutting units, stop engine, engage parking brake, and remove key from the ignition switch. 2. Remove side deck from lift arm (see Side Cutting 1/2”...
Page 212: Side Deck Rear Arm Assembly
Side Deck Rear Arm Assembly Thread locking Compound 24 25 35 36 22 to 27 ft−lb (30 to 37 N−m) 114 ft−lb (155 N−m) RIGHT FRONT Figure 7 Cutting deck (LH shown) 16. Lock nut 31. Damper rod end Deck mount (LH shown) 17.
Page 213 Disassembly 1. Disassemble rear arm assembly using Figure 7 as a guide. Note: early models use rear arm components as shown in Figure 9. On these models, roll pin removal will allow coupler to be separated from spring shaft. Assembly (Figure 7) 1.
Page 214 Installation 1. Position rear arm assembly to cutting deck and frame. 2. Slide pivot shaft through rear arm clevis and hub. Se- cure pivot shaft with lock washer and locknut. 3. Connect damper link to cutting deck with clevis pin and hair pin (Fig.
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Page 216: Lift Arm Yoke Joint
Lift Arm Yoke Joint 150 to 180 ft−lb (203 to 244 N−m) RIGHT FRONT 27 to 33 ft−lb (37 to 44 N−m) Figure 11 Side cutting deck (LH shown) Cap screw 13. Cotter pin Deck mount (LH shown) Flat washer 14.
Page 217 Yoke Joint Assembly 1. Apply a coating of grease to bearing bores of yoke. 2. Press one bearing partially into yoke. 3. Insert cross into yoke and bearing. 4. Hold cross in alignment and press bearing in until it hits the yoke. 5.
Page 218: Hood
Hood 25 29 RIGHT FRONT 22 21 24 23 Figure 13 Hood 11. Clevis pin 21. Flexible latch draw Latch bracket (RH) 12. Hood rod 22. Latch bracket (LH) Screen assembly 13. Hair pin 23. Flange head nut 4. Bulb seal 14.
Page 219 Removal 1. Park machine on a level surface, lower cutting units, stop engine, engage parking brake, and remove key from the ignition switch. 2. Remove hood using Figure 13 as a guide. Installation 1. Install hood using Figure 13 as a guide. Figure 14 2.
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Page 221 Chapter 8 Cutting Units Table of Contents SPECIFICATIONS ......SERVICE AND REPAIRS ..... . TROUBLESHOOTING .
Page 222: Specifications
Specifications MOUNTING: Cutting decks are supported by lift arms WIDTH OF CUT: Front deck provides 62” (157.5 cm) controlled with individual hydraulic lift levers. width of cut. Each side deck has 42” (106.7 cm) width of cut. Total width of cut is 132” (335.3 cm) with 7” (12.8 cm) CONSTRUCTION: Deck chamber is welded 12 gauge overlap.
Page 223: Troubleshooting
Troubleshooting There are a number of factors that can contribute to un- Remember that the “effective” or actual height−of−cut satisfactory quality of cut, some of which may be turf depends on cutting unit weight, tire pressures, hydraulic conditions. Turf conditions such as excessive thatch, counterbalance settings, and turf conditions.
Page 224: Adjustments
Adjustments CAUTION Never install or work on the cutting units or lift arms with the engine running. Always stop en- gine and remove key first. See Operator’s Manual for adjustment procedures for the cutting units on the Groundsmaster 4000−D. Castor Wheel Tire Pressure Castor tires on the front and side decks should be in- flated to 50 psi (3.5 bar).
Page 225 This page is intentionally blank. Groundsmaster 4000−D Page 8 − 5 Cutting Units...
Page 226: Service And Repairs
Service and Repairs CAUTION Never install or work on the cutting units or lift arms with the engine running. Always stop en- gine and remove key first. Front Cutting Unit RIGHT FRONT Figure 1 Spider Ball joint 17. Clevis pin Mounting shim (if required) 10.
Page 227 Removal 1. Position machine on a clean, level surface. Lower cutting units, stop engine, engage parking brake, and remove key from the ignition switch. NOTE: Removal of clevis pin from deck and height−of− cut chain is easier if deck is lifted slightly. 2.
Page 228: Side Cutting Unit
Side Cutting Unit RIGHT FRONT Figure 5 Side cutting deck (LH shown) Lock nut Jam nut Deck mount (LH shown) Clevis pin Rod end Flange head screw Hair pin 10. Damper link tube Flat washer Page 8 − 8 Cutting Units Groundsmaster 4000−D...
Page 229 Removal 1. Position machine on a clean, level surface. Lower cutting units, stop engine, engage parking brake, and remove key from the ignition switch. 2. Remove hydraulic motor from cutting deck (see Cut- ting Deck Motor Removal in the Service and Repairs Section of Chapter 4 −...
Page 230: Blade Spindle Service
Blade Spindle Service Disassembly 1. Park machine on a level surface, lower cutting units, stop engine, engage parking brake, and remove key 130 to 150 ft−lb from the ignition switch. (176 to 203 N−m) 2. Remove belt covers from top of cutting deck. Loosen idler pulley to release belt tension.
Page 231 Assembly 10.Install pulley (hub down), washer, and lock nut to spindle shaft. Tighten lock nut from 130 to 150 ft−lb (176 IMPORTANT: If new bearings are installed into a to 203 N−m). used spindle housing, it may not be necessary to re- place the original large snap ring.
Page 232: Castor Forks And Wheels
Castor Forks and Wheels FRONT CUTTING DECK SIDE CUTTING DECK 60 to 80 ft−lb (81 to 108 N−m) CASTOR WHEEL 29 30 60 to 80 ft−lb (81 to 108 N−m) Figure 12 Castor arm (front deck) 11. Retaining ring 21. Hairpin 22.
Page 233 Chapter 9 Electrical Diagrams Table of Contents ELECTRICAL SCHEMATICS ....Electrical Schematic (S/N below 220999999) . . . Electrical Schematic (S/N above 230000001) .
Page 234 This page is intentionally blank. Page 9 - 2 Electrical Diagrams (Rev. B) Groundsmaster 4000−D...
Page 235: Electrical Schematic (S/N Below 220999999)
ALTERNATOR RUN SOLENOID (HOLD) R/BK TEMP FUEL (PULL) (−) TEMP SENDER ENGINE OIL PRESSURE ENGINE OVER TEMP. FUEL SENDER 110 C FUEL PUMP R/BK GLOW PLUGS (4) R/BK ALARM (−) ALARM RELAY FUSIBLE LINK Start −7 ENGINE ENGINE GROUND SILENCE ALARM SWITCH SERVICE BRAKE SERVICE BRAKE (−)
Page 236: Electrical Schematic (S/N Above 230000001)
ALTERNATOR RUN SOLENOID (HOLD) R/BK TEMP FUEL (PULL) (−) TEMP SENDER ENGINE OIL PRESSURE ENGINE OVER TEMP. FUEL SENDER 110 C FUEL PUMP R/BK GLOW PLUGS (4) R/BK ALARM (−) ALARM RELAY FUSIBLE LINK Start −7 ENGINE ENGINE GROUND SILENCE ALARM (−) FRAME GROUND BATTERY...
Page 237: Glow Plug Circuit
ALTERNATOR RUN SOLENOID (HOLD) R/BK TEMP FUEL (PULL) (−) TEMP SENDER ENGINE OIL PRESSURE ENGINE OVER TEMP. FUEL SENDER 110 C FUEL PUMP R/BK GLOW PLUGS (4) R/BK ALARM (−) ALARM RELAY FUSIBLE LINK Start −7 ENGINE ENGINE GROUND SILENCE ALARM SWITCH SERVICE BRAKE SERVICE BRAKE (−)
Page 238: Crank Circuit
ALTERNATOR RUN SOLENOID (HOLD) R/BK TEMP FUEL (PULL) (−) TEMP SENDER ENGINE OIL PRESSURE ENGINE OVER TEMP. FUEL SENDER 110 C FUEL PUMP R/BK GLOW PLUGS (4) R/BK ALARM (−) ALARM RELAY FUSIBLE LINK Start −7 ENGINE ENGINE GROUND SILENCE ALARM SWITCH SERVICE BRAKE SERVICE BRAKE (−)
Page 239: Run (Transport) Circuit
ALTERNATOR RUN SOLENOID (HOLD) R/BK TEMP FUEL (PULL) (−) TEMP SENDER ENGINE OIL PRESSURE ENGINE OVER TEMP. FUEL SENDER 110 C FUEL PUMP R/BK GLOW PLUGS (4) R/BK ALARM (−) ALARM RELAY FUSIBLE LINK Start −7 ENGINE ENGINE GROUND SILENCE ALARM SWITCH SERVICE BRAKE SERVICE BRAKE (−)
Page 240: Run (Mow) Circuit
ALTERNATOR RUN SOLENOID (HOLD) R/BK TEMP FUEL (PULL) (−) TEMP SENDER ENGINE OIL PRESSURE ENGINE OVER TEMP. FUEL SENDER 110 C FUEL PUMP R/BK GLOW PLUGS (4) R/BK ALARM (−) ALARM RELAY FUSIBLE LINK Start −7 ENGINE ENGINE GROUND SILENCE ALARM SWITCH SERVICE BRAKE SERVICE BRAKE (−)
Page 241 SILENCE ALARM HIGH TEMP OVERRIDE DIODE PACK CAPACITOR (1) 4 WD SWITCH FUEL GAUGE HOUR METER PTO SWITCH PTO RELAY OVERRIDE SHUT DOWN CAPACITOR (2) YELLOW PINK WHITE PINK PINK BLUE PINK WHITE YELLOW YELLOW SILENCE BLUE ALARM BLUE ORANGE BLUE BLACK BLACK...
Page 242 Groundsmaster 4000−D Main Wire Harness (Serial Numbers below 220999999) Page 9 - 10...
Page 243 J1 J2 ORANGE YELLOW YELLOW WHITE YELLOW YELLOW YELLOW BLUE BLACK BLACK BLACK VIOLET/BLACK GRAY GREEN GRAY GRAY GREEN/BLACK BLACK WHITE GREEN GRAY BLACK YELLOW PINK GREEN BLACK BLACK WHITE ORANGE VIOLET ORANGE BLUE BLACK BLACK BLACK VIOLET ORANGE YELLOW BROWN BLACK WHITE...
Page 244 Groundsmaster 4000−D Main Wire Harness (Serial Numbers above 230000000) Page 9 - 12...
Page 245: Engine Wire Harness
FUSIBLE LINK BLACK BLACK BLACK BLACK RED/BLACK RED/BLACK WHITE PINK BLACK ORANGE BLUE WHITE GRAY YELLOW/BLACK YELLOW WHITE YELLOW BROWN BLUE WHITE ORANGE VIOLET/BLACK YELLOW/BLACK GREEN BLACK BLACK BLACK BLACK BLACK YELLOW YELLOW BROWN ORANGE VIO/BLK VIO/BLK YEL/BLk YEL/BLK BLACK BLACK (−) Groundsmaster 4000−D...
Page 246: Engine Wire Harness
Groundsmaster 4000−D Engine Wire Harness Page 9 - 14...
Page 247 TEMP GAUGE TEMP GAUGE LIGHT GRAY SERVICE BRAKE LEFT SIDE ign. A PINK ground BLACK INTERCONNECT FRONT t. sender GRAY SERVICE BRAKE pto relay ORANGE CONNECTOR RIGHT SIDE GREEN/BLACK diode pack capacitor BLUE shutdown DIODE (8) PINK oil press GREEN PINK WARNING LIGHT CLUSTER alt ”L”...
Page 248 SERVICE BRAKE RIGHT SIDE SERVICE BRAKE LEFT SIDE CRUISE DIODE CRUISE COIL DIODE PARKING BRAKE WARNING LIGHT CLUSTER CRUISE CONTROL COIL INTERCONNECT FRONT DECK POSITION SW WARNING LIGHT CLUSTER ”OVERTEMP GLOW” INTERCONNECT DIODE FRONT DECK PTO COIL TEMP GAUGE LIGHT Groundsmaster 4000−D Front Wire Harness (Serial Numbers below 220999999)
Page 249 BROWN YELLOW PINK GRAY BLACK PINK GREEN/BLACK GRAY GREEN WHITE BLUE ORANGE VIOLET/BLACK BLACK ORANGE ORANGE BLACK Groundsmaster 4000−D Front Wire Harness (Serial Numbers above 230000000) Page 9 - 17...
Page 250 Groundsmaster 4000−D Front Wire Harness (Serial Numbers above 230000000) Page 9 - 18...

Toro Groundsmaster 4000-D Service Manual

Chapter 1 Safety

Chapter 2 Product Records and Maintenance

Chapter 3 Kubota Diesel Engine

Chapter 4 Hydraulic System

Chapter 5 Electrical System

Chapter 6 Axles, Planetaries, and Brakes

Chapter 7 Chassis

Chapter 8 Cutting Units

Quick Links

Service Manual

Chapters

Troubleshooting

Related Manuals for Toro Groundsmaster 4000-D

Summary of Contents for Toro Groundsmaster 4000-D