Toro 08161SL Service Owners Manual Model 30412 Groundsmaster 4000 D Preface Publication - English

Part No. 08161SL Service Manual (Model 30412) GroundsmasterR 4000-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 OPERATING, 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 available on the internet at www.Toro.com. 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 INSTRUCTION. 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 repair of the machine. IMPORTANT: The IMPORTANT notice will give important instructions which must be followed to prevent damage to systems or components on the machine. E The Toro Company – 2008 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 . Maintenance . Equivalents and Conversions Torque Specifications . 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 PISTON PUMP REPAIR INFORMATION EATON MODEL 74318 and 74348 PISTON MOTORS: FIXED DISPLACEMENT, VALVE PLATE DESIGN REPAIR INFORMATION 2 -2 -2 -2 -1 1 2 3 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 General Information Troubleshooting Service and Repairs Chapter 9 – Foldout Drawings Hydraulic Schematic 9 — 3 Electrical Schematics . 9 — 4 Circuit Diagrams . 9 — 6 Wire Harness Drawings 9 — 12 8 -8 -8 -8 -2 3 4 6 Safety Foldout Drawings Cutting Decks Groundsmaster 4000–D Chassis Axles, Planetaries and Brakes Electrical System Hydraulic System Kubota Diesel Engine Product Records and Maintenance This page is intentionally blank. Groundsmaster 4000–D Safety Table of Contents GENERAL SAFETY INSTRUCTIONS Before Operating While Operating . Maintenance and Service JACKING INSTRUCTIONS . SAFETY AND INSTRUCTION DECALS 2 2 2 3 4 5 Groundsmaster 4000–D Page 1 – 1 – Safety Safety Chapter 1 General Safety Instructions The GROUNDSMASTER 4000-D is tested and certified by Toro for compliance with existing safety standards and specifications. Although hazard control and accident prevention partially are dependent upon the design and configuration of the machine, these factors are also dependent upon the awareness, concern and proper training of the personnel involved in the operation, transport, maintenance 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. Review and understand the contents of the Operator’s Manual and Operator’s DVD before starting and operating the vehicle. Become familiar with the controls and know how to stop the vehicle and engine quickly. Additional copies of the Operator’s Manual are available on the internet at www.Toro.com. 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 decks are DISENGAGED. 4. Since diesel fuel is highly flammable, handle it carefully: 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 machine. 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. 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 adequate 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. Safety Page 1 – 2 Groundsmaster 4000–D 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 or long term), the cutting decks 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. Do not park on slopes unless wheels are chocked or blocked. 1. Before servicing or making adjustments, lower decks, stop engine, apply parking brake and remove key from the switch.

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