Toro Groundsmaster 4000?D Service Manual

Toro Groundsmaster 4000?D Service Manual

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PRELIMINARY – For Toro Distributor and Toro Company use only.
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
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.
AND ADJUSTMENT INSTRUC-
E The Toro Company − 2008
(Serial No. 290000001 and Above)
Groundsmaster
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.
PART NO.

Service Manual

R
4000−D

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Summary of Contents for Toro Groundsmaster 4000?D

  • Page 1: Service Manual

    PART NO. PRELIMINARY – For Toro Distributor and Toro Company use only. Service Manual (Serial No. 290000001 and Above) Groundsmaster 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.
  • Page 2 PRELIMINARY – For Toro Distributor and Toro Company use only. This page is intentionally blank. Groundsmaster 4000−D...
  • Page 3: Table Of Contents

    Table Of Contents PRELIMINARY – For Toro Distributor and Toro Company use only. Chapter 1 − Safety Chapter 5 − Electrical System General Safety Instructions ....
  • Page 4 PRELIMINARY – For Toro Distributor and Toro Company use only. This page is intentionally blank. Groundsmaster 4000−D...
  • Page 5 PRELIMINARY – For Toro Distributor and Toro Company use only. Chapter 1 Safety Table of Contents GENERAL SAFETY INSTRUCTIONS ... . Before Operating ......
  • Page 6: General Safety Instructions

    PRELIMINARY – For Toro Distributor and Toro Company use only. 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.
  • Page 7: Jacking Instructions

    PRELIMINARY – For Toro Distributor and Toro Company use only. Maintenance and Service 1. Before servicing or making adjustments, lower 10.Do not overspeed the engine by changing governor decks, stop engine, set parking brake, and remove key setting. To assure safety and accuracy, check maximum from the switch.
  • Page 8: Jacking Instructions

    PRELIMINARY – For Toro Distributor and Toro Company use only. 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...
  • Page 9: Safety And Instruction Decals

    PRELIMINARY – For Toro Distributor and Toro Company use only. 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.
  • Page 10 PRELIMINARY – For Toro Distributor and Toro Company use only. This page is intentionally blank. Safety Groundsmaster 4000−D Page 1 − 6...
  • Page 11: Product Records

    PRELIMINARY – For Toro Distributor and Toro Company use only. Chapter 2 Product Records and Maintenance Table of Contents PRODUCT RECORDS ......
  • Page 12: Equivalents And Conversions

    PRELIMINARY – For Toro Distributor and Toro Company use only. Equivalents and Conversions 0.09375 Product Records and Maintenance Page 2 − 2 Groundsmaster 4000−D...
  • Page 13: Torque Specifications

    PRELIMINARY – For Toro Distributor and Toro Company use only. Torque Specifications Recommended fastener torque values are listed in the As noted in the following tables, torque values should be following tables. 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.
  • Page 14 PRELIMINARY – For Toro Distributor and Toro Company use only. 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 &...
  • Page 15 PRELIMINARY – For Toro Distributor and Toro Company use only. Standard Torque for Dry, Zinc Plated and Steel Fasteners (Metric Series) Class 8.8 Bolts, Screws and Studs with Class 10.9 Bolts, Screws and Studs with Thread Size Thread Size Regular Height Nuts...
  • Page 16: Specifications

    PRELIMINARY – For Toro Distributor and Toro Company use only. 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...
  • Page 17 PRELIMINARY – For Toro Distributor and Toro Company use only. Chapter 3 Kubota Diesel Engine Table of Contents GENERAL INFORMATION .....
  • Page 18: General Information

    PRELIMINARY – For Toro Distributor and Toro Company use only. General Information This Chapter gives information about specifications and tools are described in the Kubota Workshop Manual, repair of the diesel engine used in the Groundsmaster Diesel Engine, V2403−M−T−E3B. The use of some spe- 4000−D.
  • Page 19: Specifications

    PRELIMINARY – For Toro Distributor and Toro Company use only. Specifications Item Description Make / Designation Kubota Model V2403−M−T−E3B: 4−Cycle, 4 Cylinder, Water Cooled, Turbocharged, Diesel Engine Bore 3.43” (87.0 mm) Stroke 4.031” (102.4 mm) Total Displacement 148.5 in (2434 cc) Firing Order 1−3−4−2...
  • Page 20: Service And Repairs

    PRELIMINARY – For Toro Distributor and Toro Company use only. 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.
  • Page 21 PRELIMINARY – For Toro Distributor and Toro Company use only. 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 22: Exhaust System

    PRELIMINARY – For Toro Distributor and Toro Company use only. Exhaust System 16 to 22 ft−lb (21 to 29 N−m) 16 to 22 ft−lb (21 to 29 N−m) RIGHT 16 to 22 ft−lb FRONT (21 to 29 N−m) Figure 5 1.
  • Page 23 PRELIMINARY – For Toro Distributor and Toro Company use only. 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 24: Fuel System

    PRELIMINARY – For Toro Distributor and Toro Company use only. 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.
  • Page 25: Check Fuel Lines And Connections

    PRELIMINARY – For Toro Distributor and Toro Company use only. Fuel Tank Installation (Fig. 7) DANGER 1. Install fuel tank using Figure 7 as a guide. A. Torque two (2) flange nuts (item 7) 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...
  • Page 26: Radiator

    PRELIMINARY – For Toro Distributor and Toro Company use only. Radiator RIGHT FRONT Figure 8 1. Radiator cap 17. Bulb seal 33. Flange head screw 2. Foam strip 18. Radiator support assembly 34. Bulb seal 3. Foam strip 19. Retaining ring 35.
  • Page 27 PRELIMINARY – For Toro Distributor and Toro Company use only. 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.
  • Page 28: Engine

    PRELIMINARY – For Toro Distributor and Toro Company use only. 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.
  • Page 29: Engine Removal

    PRELIMINARY – For Toro Distributor and Toro Company use only. 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.
  • Page 30: Engine Installation

    PRELIMINARY – For Toro Distributor and Toro Company use only. 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).
  • Page 31 PRELIMINARY – For Toro Distributor and Toro Company use only. shroud. 14.Install air cleaner assembly to the engine (see Air Cleaner Installation in this section). 8. Connect throttle cable to the speed control lever with washer and lock nut. Install cable to mounting bracket 15.Install exhaust system to machine (see Muffler...
  • Page 32: Spring Coupler

    PRELIMINARY – For Toro Distributor and Toro Company use only. Spring Coupler RIGHT FRONT Loctite #242 29 to 33 ft−lb (40 to 44 N−m) 28 to 32 ft−lb (38 to 43 N−m) Figure 15 1. Spring coupler 8. Carriage screw (2 used) 15.
  • Page 33 PRELIMINARY – For Toro Distributor and Toro Company use only. Coupler Removal (Fig. 15) 1. If engine is in machine: Engine Side Hydraulic Pump Side A. The hydraulic pump assembly needs to be re- moved from engine before coupler can be removed (see Piston (Traction) Pump Removal in the Service and Repairs section of Chapter 4 −...
  • Page 34 PRELIMINARY – For Toro Distributor and Toro Company use only. This page is intentionally blank. Kubota Diesel Engine Page 3 − 18 Groundsmaster 4000−D...
  • Page 35: Troubleshooting

    PRELIMINARY – For Toro Distributor and Toro Company use only. Chapter 4 Hydraulic System Table of Contents SPECIFICATIONS ......
  • Page 36: Specifications

    PRELIMINARY – For Toro Distributor and Toro Company use only. 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)
  • Page 37: General Information

    PRELIMINARY – For Toro Distributor and Toro Company use only. General Information Traction Unit Operator’s Manual The Traction Unit Operator’s Manual provides informa- tion regarding the operation, general maintenance and maintenance intervals for your Groundsmaster ma- chine. Refer to that publication for additional information when servicing the machine.
  • Page 38: Hydraulic Hoses

    PRELIMINARY – For Toro Distributor and Toro Company use only. 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 and maintenance.
  • Page 39: Hydraulic Hose And Tube Installation

    PRELIMINARY – For Toro Distributor and Toro Company use only. Hydraulic Hose and Tube Installation (O−Ring Face Seal Fitting) 1. Make sure threads and sealing surfaces of the hose/ C. Use a second wrench to tighten the nut to the cor- tube and the fitting are free of burrs, nicks, scratches or rect Flats From Wrench Resistance (F.F.W.R.).
  • Page 40: Hydraulic Fitting Installation

    PRELIMINARY – For Toro Distributor and Toro Company use only. Hydraulic Fitting Installation (SAE Straight Thread O−Ring Fitting into Component Port) Non−Adjustable Fitting (Fig. 4) 5. If a torque wrench is not available, or if space at the port prevents use of a torque wrench, an alternate meth- 1.
  • Page 41 PRELIMINARY – For Toro Distributor and Toro Company use only. Adjustable Fitting (Fig. 6) 1. Make sure all threads and sealing surfaces of fitting and component port are free of burrs, nicks, scratches or any foreign material. 2. As a preventative measure against leakage, it is rec- ommended that the O−ring be replaced any time the...
  • Page 42: Hydraulic Schematic

    PRELIMINARY – For Toro Distributor and Toro Company use only. Hydraulic Schematic The hydraulic schematic for the Groundsmaster 4000−D is located in Chapter 9 − Foldout Drawings. Hydraulic System Page 4 − 8 Groundsmaster 4000−D...
  • Page 43: Hydraulic Flow Diagrams

    PRELIMINARY – For Toro Distributor and Toro Company use only. Hydraulic Flow Diagrams Groundsmaster 4000−D Page 4 − 9 Hydraulic System...
  • Page 44: Traction Circuit

    PRELIMINARY – For Toro Distributor and Toro Company use only. 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.
  • Page 45 PRELIMINARY – For Toro Distributor and Toro Company use only. Groundsmaster 4000−D Page 4 − 11 Hydraulic System...
  • Page 46: Lower Cutting Unit

    PRELIMINARY – For Toro Distributor and Toro Company use only. Lower Cutting Unit A four section gear pump is coupled to the piston (trac- To lower the front cutting unit, the center lift lever on the tion) pump. The third gear pump section supplies hy-...
  • Page 47 PRELIMINARY – For Toro Distributor and Toro Company use only. Groundsmaster 4000−D Page 4 − 13 Hydraulic System...
  • Page 48: Raise Cutting Unit

    PRELIMINARY – For Toro Distributor and Toro Company use only. Raise Cutting Unit A four section gear pump is coupled to the piston (trac- To raise the front cutting unit, the center lift lever on the tion) pump. The third gear pump section supplies hy-...
  • Page 49 PRELIMINARY – For Toro Distributor and Toro Company use only. Groundsmaster 4000−D Page 4 − 15 Hydraulic System...
  • Page 50: Mow

    PRELIMINARY – For Toro Distributor and Toro Company use only. 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.
  • Page 51 PRELIMINARY – For Toro Distributor and Toro Company use only. Groundsmaster 4000−D Page 4 − 17 Hydraulic System...
  • Page 52: Steering Circuit

    PRELIMINARY – For Toro Distributor and Toro Company use only. Steering Circuit A four section gear pump is coupled to the piston (trac- the cylinder is proportional to the amount of the turning tion) pump. The third gear pump section supplies hy- on the steering wheel.
  • Page 53: Special Tools

    PRELIMINARY – For Toro Distributor and Toro Company use only. Special Tools Order these tools from your Toro Distributor. Hydraulic Pressure Test Kit 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 54: Hydraulic Test Fitting Kit

    PRELIMINARY – For Toro Distributor and Toro Company use only. Hydraulic Test Fitting Kit 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.
  • Page 55: Troubleshooting

    PRELIMINARY – For Toro Distributor and Toro Company use only. 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.
  • Page 56 PRELIMINARY – For Toro Distributor and Toro Company use only. Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á...
  • Page 57 PRELIMINARY – For Toro Distributor and Toro Company use only. Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á...
  • Page 58: Testing

    PRELIMINARY – For Toro Distributor and Toro Company use only. 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 59: Traction Circuit Charge Pressure

    PRELIMINARY – For Toro Distributor and Toro Company use only. Traction Circuit Charge Pressure (Using Pressure Gauge) High Pressure Low Pressure Return or Suction Flow Groundsmaster 4000−D Page 4 − 25 Hydraulic System...
  • Page 60 PRELIMINARY – For Toro Distributor and Toro Company use only. 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.
  • Page 61: Traction Circuit Relief Pressure

    PRELIMINARY – For Toro Distributor and Toro Company use only. Traction Circuit Relief Pressure (Forward Shown) (Using Pressure Gauge) Working Pressure Low Pressure Return or Suction Flow Groundsmaster 4000−D Page 4 − 27 Hydraulic System...
  • Page 62 PRELIMINARY – For Toro Distributor and Toro Company use only. 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.
  • Page 63: Cutting Deck Circuit Pressure

    PRELIMINARY – For Toro Distributor and Toro Company use only. Cutting Deck Circuit Pressure (Front Deck Shown) (Using Pressure Gauge) Working Pressure Low Pressure Return or Suction Flow Groundsmaster 4000−D Page 4 − 29 Hydraulic System...
  • Page 64 PRELIMINARY – For Toro Distributor and Toro Company use only. 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.
  • Page 65: Cutting Deck Gear Pump Flow

    PRELIMINARY – For Toro Distributor and Toro Company use only. Cutting Deck Gear Pump Flow (Front Deck Shown) (Using Tester with Pressure Gauges and Flow Meter) Working Pressure Low Pressure Return or Suction Flow Groundsmaster 4000−D Page 4 − 31...
  • Page 66 PRELIMINARY – For Toro Distributor and Toro Company use only. Procedure for Cutting Deck Gear Pump Flow Test 6. Start engine and move throttle to full speed (2870 RPM). Do not engage the cutting units. NOTE: Over a period of time, the gears and wear plates in the pump can wear.
  • Page 67: Cutting Deck Manifold Relief Pressure

    PRELIMINARY – For Toro Distributor and Toro Company use only. Cutting Deck Manifold Relief Pressure (Front Deck Shown) (Using Tester with Pressure Gauges and Flow Meter) Working Pressure Low Pressure Return or Suction Flow Groundsmaster 4000−D Page 4 − 33...
  • Page 68 PRELIMINARY – For Toro Distributor and Toro Company use only. 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.
  • Page 69: Cutting Deck Motor Case Drain Leakage

    PRELIMINARY – For Toro Distributor and Toro Company use only. Cutting Deck Motor Case Drain Leakage (Using Tester with Pressure Gauges and Flow Meter) Working Pressure Low Pressure Return or Suction Flow Groundsmaster 4000−D Page 4 − 35 Hydraulic System...
  • Page 70 PRELIMINARY – For Toro Distributor and Toro Company use only. Procedure for Cutting Deck Motor Case Drain 5. Sit on seat and start the engine. Move throttle to full Leakage Test speed (2870 RPM). Move PTO switch to ON. NOTE: Over a period of time, a deck motor can wear in- 6.
  • Page 71: Steering Circuit Relief Pressure

    PRELIMINARY – For Toro Distributor and Toro Company use only. Steering Circuit Relief Pressure (Using Pressure Gauge) High Pressure Low Pressure Return or Suction Flow Groundsmaster 4000−D Page 4 − 37 Hydraulic System...
  • Page 72 PRELIMINARY – For Toro Distributor and Toro Company use only. 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.
  • Page 73: Lift/Lower Circuit Relief Pressure

    PRELIMINARY – For Toro Distributor and Toro Company use only. Lift/Lower Circuit Relief Pressure (Using Pressure Gauge) High Pressure Low Pressure Return or Suction Flow Groundsmaster 4000−D Page 4 − 39 Hydraulic System...
  • Page 74 PRELIMINARY – For Toro Distributor and Toro Company use only. 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 75: Steering And Lift/Lower Gear Pump Flow

    PRELIMINARY – For Toro Distributor and Toro Company use only. Steering and Lift/Lower Gear Pump Flow (Using Tester with Pressure Gauges and Flow Meter) High Pressure Low Pressure Return or Suction Flow Groundsmaster 4000−D Page 4 − 41 Hydraulic System...
  • Page 76 PRELIMINARY – For Toro Distributor and Toro Company use only. 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.
  • Page 77: Counterbalance Pressure

    PRELIMINARY – For Toro Distributor and Toro Company use only. Counterbalance Pressure (Using Pressure Gauge) High Pressure Low Pressure Return or Suction Flow Groundsmaster 4000−D Page 4 − 43 Hydraulic System...
  • Page 78 PRELIMINARY – For Toro Distributor and Toro Company use only. 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.
  • Page 79: Rear Traction Circuit (Rv5) Relief Pressure

    PRELIMINARY – For Toro Distributor and Toro Company use only. Rear Traction Circuit (RV5) Relief Pressure (Using Pressure Gauge) Working Pressure Low Pressure Return or Suction Flow Groundsmaster 4000−D Page 4 − 45 Hydraulic System...
  • Page 80 PRELIMINARY – For Toro Distributor and Toro Company use only. 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.
  • Page 81: Traction Circuit Reducing Valve (Pr) Pressure

    PRELIMINARY – For Toro Distributor and Toro Company use only. Traction Circuit Reducing Valve (PR) Pressure (Using Pressure Gauge) Working Pressure Low Pressure Return or Suction Flow Groundsmaster 4000−D Page 4 − 47 Hydraulic System...
  • Page 82 PRELIMINARY – For Toro Distributor and Toro Company use only. 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.
  • Page 83: Adjustments

    PRELIMINARY – For Toro Distributor and Toro Company use only. 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 cutting deck lowers. Adjust flow control valve as follows: 1.
  • Page 84 PRELIMINARY – For Toro Distributor and Toro Company use only. This page is intentionally blank. Hydraulic System Page 4 − 50 Groundsmaster 4000−D...
  • Page 85: Service And Repairs

    PRELIMINARY – For Toro Distributor and Toro Company use only. 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.
  • Page 86: Flush Hydraulic System

    PRELIMINARY – For Toro Distributor and Toro Company use only. 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.
  • Page 87: Charge Hydraulic System

    PRELIMINARY – For Toro Distributor and Toro Company use only. 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 lift...
  • Page 88: Gear Pump

    PRELIMINARY – For Toro Distributor and Toro Company use only. Gear Pump RIGHT FRONT 79 to 84 ft−lb (108 to 113 N−m) Figure 37 1. 90 hydraulic fitting 10. O−ring 19. Flat washer 2. O−ring 11. Clamp 20. Engine 3. O−ring 12.
  • Page 89 PRELIMINARY – For Toro Distributor and Toro Company use only. Removal (Fig. 37) Installation (Fig. 37) 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.
  • Page 90: Gear Pump Service

    PRELIMINARY – For Toro Distributor and Toro Company use only. Gear Pump Service 33 ft−lb (45 N−m) Figure 38 1. Dust seal 10. Seal (8 used) 19. Body 2. Retaining ring 11. Idler gear 20. Body 3. Flange washer 12. Drive shaft 21.
  • Page 91 PRELIMINARY – For Toro Distributor and Toro Company use only. IMPORTANT: Use caution when clamping gear 8. Clean all parts. Check all components for burrs, pump in a vise to avoid distorting any pump compo- scoring, nicks and other damage.
  • Page 92: Piston (Traction) Pump

    PRELIMINARY – For Toro Distributor and Toro Company use only. Piston (Traction) Pump 79 to 84 ft−lb (108 to 113 N−m) RIGHT FRONT 79 to 84 ft−lb (108 to 113 N−m) Figure 40 1. Hydraulic T fitting 11. O−ring 21. Clamp 2.
  • Page 93 PRELIMINARY – For Toro Distributor and Toro Company use only. Removal (Fig. 40) Installation (Fig. 40) 1. Park machine on a level surface, lower cutting units, 1. Carefully lower piston pump into the machine, align stop engine, engage parking brake and remove key pump input shaft to spring coupler on engine and posi- from the ignition switch.
  • Page 94: Piston (Traction) Pump Service

    PRELIMINARY – For Toro Distributor and Toro Company use only. 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)
  • Page 95 PRELIMINARY – For Toro Distributor and Toro Company use only. Disassembly (Fig. 41) 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 PRELIMINARY – For Toro Distributor and Toro Company use only. 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.
  • Page 97 PRELIMINARY – For Toro Distributor and Toro Company use only. 8. Place exterior retaining ring (3), thrust race (12), 16.Apply a small amount of petroleum jelly to the steel thrust bearing (13), second thrust race (12) and second side of valve plate (18) to hold in place for installation.
  • Page 98: Piston Pump Control Assembly

    PRELIMINARY – For Toro Distributor and Toro Company use only. 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 46 1.
  • Page 99 PRELIMINARY – For Toro Distributor and Toro Company use only. 5. Apply Loctite #242 or equivalent to set screw (18) ent position, the light should be on. Move the control arm and install into control housing. Adjust set screw until it out of detent, the light should go off.
  • Page 100: Hydraulic Control Manifold: 4 Wheel Drive

    PRELIMINARY – For Toro Distributor and Toro Company use only. Hydraulic Control Manifold: 4 Wheel Drive RIGHT FRONT Figure 48 1. Frame assembly 8. Fitting cap 14. Hydraulic fitting 2. Manifold 9. Hydraulic fitting 15. Adapter 3. 90 hydraulic fitting 10.
  • Page 101 PRELIMINARY – For Toro Distributor and Toro Company use only. Removal (Fig. 48) Installation (Fig. 48) 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 48 as guide.
  • Page 102: Hydraulic Control Manifold Service: 4 Wheel Drive

    PRELIMINARY – For Toro Distributor and Toro Company use only. Hydraulic Control Manifold Service: 4 Wheel Drive 35 ft−lb REAR (47 N−m) DOWN 50 ft−lb 25 ft−lb (67 N−m) (34 N−m) FRONT 20 ft−lb (27 N−m) PLUG TORQUE #4 Zero Leak: 20 ft−lb (27 N−m) 5 ft−lb...
  • Page 103 PRELIMINARY – For Toro Distributor and Toro Company use only. Cartridge Valve Service 6. Clean cartridge valve using clean mineral spirits. Submerge valve in clean mineral spirits to flush out con- 1. Make sure the manifold is clean before removing the tamination.
  • Page 104: Hydraulic Control Manifold: Deck Drive

    PRELIMINARY – For Toro Distributor and Toro Company use only. Hydraulic Control Manifold: Deck Drive RIGHT FRONT Figure 50 1. Hydraulic manifold (front deck) 10. O−ring 19. Elbow (90 2. Quick fitting 11. Cap screw 20. Hydraulic fitting 3. Flange nut 12.
  • Page 105: Hydraulic Control Manifold Service: Deck Drive

    PRELIMINARY – For Toro Distributor and Toro Company use only. 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...
  • Page 106: Hydraulic Control Manifold: Cutting Deck Lift/Lower

    PRELIMINARY – For Toro Distributor and Toro Company use only. Hydraulic Control Manifold: Cutting Deck Lift/Lower RIGHT FRONT Figure 52 1. Lift/lower hydraulic manifold 7. Lock nut 12. Cap screw 2. Valve plate 8. Hydraulic fitting 13. 90 hydraulic fitting 3.
  • Page 107: Hydraulic Control Manifold Service: Cutting Deck Lift/Lower

    PRELIMINARY – For Toro Distributor and Toro Company use only. 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 53 1.
  • Page 108: Filter Manifold

    PRELIMINARY – For Toro Distributor and Toro Company use only. Hydraulic Manifold: Filter Manifold RIGHT FRONT Figure 54 1. Filter manifold 9. Flat washer 17. 90 hydraulic elbow 2. 45 hydraulic elbow 10. Hydraulic fitting 18. Hydraulic hose 3. Test nipple 11.
  • Page 109 PRELIMINARY – For Toro Distributor and Toro Company use only. 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 55 1. Filter manifold assembly 7. Seal kit 12.
  • Page 110 PRELIMINARY – For Toro Distributor and Toro Company use only. Hydraulic Manifold: Flow Divider RIGHT FRONT Figure 56 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.
  • Page 111: Flow Divider

    PRELIMINARY – For Toro Distributor and Toro Company use only. 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)
  • Page 112: Rear Axle Motor

    PRELIMINARY – For Toro Distributor and Toro Company use only. Rear Axle Motor Arrow on side of motor case points up 59 to 73 ft−lb (80 to 99 N−m) RIGHT FRONT Figure 58 1. Wheel motor 7. External snap ring 12.
  • Page 113 PRELIMINARY – For Toro Distributor and Toro Company use only. Removal (Fig. 58) Installation (Fig. 58) 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.
  • Page 114: Front Wheel Motors

    PRELIMINARY – For Toro Distributor and Toro Company use only. Front Wheel Motors Arrow on side of motor case points up RIGHT 75 to 85 ft−lb (101 to 115 N−m) FRONT Figure 59 1. Front wheel motor 9. Flange head screw 16.
  • Page 115 PRELIMINARY – For Toro Distributor and Toro Company use only. Removal (Fig. 59) Installation (Fig. 59) 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.
  • Page 116: Rear Axle/Front Wheel Motor Service

    PRELIMINARY – For Toro Distributor and Toro Company use only. Rear Axle/Front Wheel Motor Service 15 to 18 ft−lb (20 to 24 N−m) Figure 60 1. Drive shaft 7. Cap screw 13. Thrust bearing 2. Backplate (front motor shown) 8. Shaft seal 14.
  • Page 117 PRELIMINARY – For Toro Distributor and Toro Company use only. 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.
  • Page 118 PRELIMINARY – For Toro Distributor and Toro Company use only. This page is intentionally blank. Hydraulic System Page 4 − 84 Groundsmaster 4000−D...
  • Page 119: Cutting Deck Motor

    PRELIMINARY – For Toro Distributor and Toro Company use only. 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

    PRELIMINARY – For Toro Distributor and Toro Company use only. Cutting Deck Motor Service 33 to 40 ft−lb (45 to 55 N−m) Figure 64 1. Rear cover 7. Spider hub 12. Idler gear 2. Drive gear 8. Pressure seal 13. Cap screw 3.
  • Page 121 PRELIMINARY – For Toro Distributor and Toro Company use only. 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.
  • Page 122 PRELIMINARY – For Toro Distributor and Toro Company use only. Assembly (Fig. 64) 8. Install dowel pins in body. NOTE: When assembling the motor, check the identifi- IMPORTANT: Do not dislodge O−rings, pressure cation marks made during disassembly to make sure seals or back−up rings during final assembly.
  • Page 123 PRELIMINARY – For Toro Distributor and Toro Company use only. This page is intentionally blank. Groundsmaster 4000−D Page 4 − 89 Hydraulic System...
  • Page 124: Lift/Lower Control Valve

    PRELIMINARY – For Toro Distributor and Toro Company use only. Lift/Lower Control Valve RIGHT FRONT Figure 69 1. Control valve assembly 10. Cotter pin (6 used) 18. O−ring 2. Valve bracket 11. RH lever assembly 19. Cap screw (2 used) 3.
  • Page 125 PRELIMINARY – For Toro Distributor and Toro Company use only. Removal (Fig. 69) Installation (Fig. 69) 1. Park machine on a level surface, lower cutting units, 1. Install control valve using Figure 69 as a guide. stop engine, engage parking brake and remove key A.
  • Page 126: Lift/Lower Control Valve Service

    PRELIMINARY – For Toro Distributor and Toro Company use only. Lift/Lower Control Valve Service 20 to 25 ft−lb (27 to 33 N−m) Figure 70 1. Poppet 13. Washer 25. O−ring 2. Spacer 14. Washer 26. Backup washer 3. Wiper 15. Washer 27.
  • Page 127 PRELIMINARY – For Toro Distributor and Toro Company use only. Disassembly (Fig. 70) Assembly (Fig. 70) 1. Plug all ports and thoroughly clean outside of control 1. Thoroughly clean and dry all parts. Apply a light coat- valve. ing of clean hydraulic oil to parts prior to assembly.
  • Page 128: Steering Valve

    PRELIMINARY – For Toro Distributor and Toro Company use only. Steering Valve 18 to 22 ft−lb (25 to 29 N−m) RIGHT FRONT Figure 71 1. Hex nut 11. O−ring 21. Steering column assembly 2. Flat washer 12. Flange head screw 22.
  • Page 129 PRELIMINARY – For Toro Distributor and Toro Company use only. Removal (Fig. 71) Installation (Fig. 71) 1. Park machine on a level surface, lower cutting units, 1. Install steering valve using Figure 71 as a guide. stop engine, engage parking brake and remove key 2.
  • Page 130: Steering Valve Service

    PRELIMINARY – For Toro Distributor and Toro Company use only. Steering Valve Service 150 in−lb (17 N−m) 140 to 160 in−lb (16 to 18 N−m) Figure 72 1. Steering valve housing 9. Cap screw 17. Geroter drive 2. Dust seal 10.
  • Page 131 PRELIMINARY – For Toro Distributor and Toro Company use only. 8. Put the thrust bearing and races into the housing. CAUTION The thrust bearing goes between the two races (Fig. 73). IMPORTANT: Do not damage the dust or quad seals The centering springs are under tension.
  • Page 132: Engine Cooling Fan Motor Service

    PRELIMINARY – For Toro Distributor and Toro Company use only. Engine Cooling Fan Motor Service 33 ft−lb (45 N−m) Figure 74 1. Flange washer 7. Shaft seal 12. Idler gear 2. O−ring 8. Backup gasket 13. Cap screw (4 used) 3.
  • Page 133 PRELIMINARY – For Toro Distributor and Toro Company use only. 8. Remove and discard back−up gaskets and pressure seals from wear plates. 9. Turn front flange over, with seal side up. IMPORTANT: Make sure not to damage the front flange counter bore when removing the seals from the front flange.
  • Page 134 PRELIMINARY – For Toro Distributor and Toro Company use only. 4. Install the pressure seals, flat side outward, into the 10.Install locating dowels in body. Align marker line on grooves in the wear plates. Follow by carefully placing the body and front flange.
  • Page 135 PRELIMINARY – For Toro Distributor and Toro Company use only. This page is intentionally blank. Groundsmaster 4000−D Page 4 − 101 Hydraulic System...
  • Page 136: Side Deck Lift Cylinder

    PRELIMINARY – For Toro Distributor and Toro Company use only. Side Deck Lift Cylinder RIGHT FRONT Figure 78 1. Lift arm assembly (LH shown) 5. Flange locking nut 9. Cylinder pin 2. Shoulder screw 6. 90 hydraulic fitting (2 used) 10.
  • Page 137 PRELIMINARY – For Toro Distributor and Toro Company use only. Removal (Fig. 78) Installation (Fig. 78) 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.
  • Page 138: Front Deck Lift Cylinder

    PRELIMINARY – For Toro Distributor and Toro Company use only. Front Deck Lift Cylinder RIGHT FRONT Figure 79 1. Lift cylinder 5. Cap screw 9. O−ring 2. Upper lift pin 6. Flat washer 10. Straight hydraulic fitting 3. Cotter pin 7.
  • Page 139 PRELIMINARY – For Toro Distributor and Toro Company use only. Removal (Fig. 79) Installation (Fig. 79) 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.
  • Page 140: Lift Cylinder Service

    PRELIMINARY – For Toro Distributor and Toro Company use only. Lift Cylinder Service 100 to 120 ft−lb (136 to 162 N−m) SIDE DECK LIFT CYLINDER Figure 80 1. Barrel with clevis 7. Back−up ring 12. Lock nut 2. Retaining ring 8.
  • Page 141 PRELIMINARY – For Toro Distributor and Toro Company use only. Disassembly (Figs. 80 and 81) Assembly (Figs. 80 and 81) 1. Remove oil from lift cylinder into a drain pan by slowly 1. Make sure all cylinder components are clean before pumping the cylinder shaft.
  • Page 142: Steering Cylinder

    PRELIMINARY – For Toro Distributor and Toro Company use only. Steering Cylinder See text for tightening procedure RIGHT See text for tightening FRONT procedure Figure 82 1. Steering cylinder 6. Grease fitting 11. Ball joint spacer 2. Ball joint 7. 90 hydraulic fitting 12.
  • Page 143 PRELIMINARY – For Toro Distributor and Toro Company use only. Removal (Fig. 82) Installation (Fig. 82) 1. Park machine on a level surface, lower cutting units, 1. If removed, install ball joints into steering cylinder. stop engine, engage parking brake and remove key 2.
  • Page 144: Steering Cylinder Service

    PRELIMINARY – For Toro Distributor and Toro Company use only. Steering Cylinder Service 45 to 55 ft−lb (62 to 74 N−m) Figure 83 1. Tube assembly 5. Retaining ring 9. Rod seal 2. Rod 6. Backup ring 10. O−ring 3. Piston assembly 7.
  • Page 145 PRELIMINARY – For Toro Distributor and Toro Company use only. Disassembly (Fig. 83) 7. Wash parts in clean solvent. Dry parts with com- pressed air. Do not wipe parts dry with paper towels or 1. Pump oil out of cylinder into a drain pan by SLOWLY cloth.
  • Page 146: Hydraulic Reservoir

    PRELIMINARY – For Toro Distributor and Toro Company use only. Hydraulic Reservoir 30 to 40 in−lb (minimum) (3.4 to 4.5 N−m) RIGHT FRONT Figure 84 1. Hydraulic reservoir 9. Stand pipe 17. Hose clamp 2. Petcock 10. Hose clamp 18. Hose 3.
  • Page 147: Hydraulic Oil Cooler

    PRELIMINARY – For Toro Distributor and Toro Company use only. 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.
  • Page 148 PRELIMINARY – For Toro Distributor and Toro Company use only. Chapter 5 Electrical System Table of Contents ELECTRICAL DRAWINGS .....
  • Page 149: Electrical Drawings

    PRELIMINARY – For Toro Distributor and Toro Company use only. Electrical Drawings The electrical schematic, circuit diagrams and wire har- ness drawings for the Groundsmaster 4000−D are lo- cated in Chapter 9 − Foldout Drawings. Electrical System Page 5 − 2...
  • Page 150: Special Tools

    PRELIMINARY – For Toro Distributor and Toro Company use only. Special Tools Order special tools from your Toro Distributor. Some tools may also be available from a local supplier. Multimeter The meter can test electrical components and circuits for current, resistance or voltage.
  • Page 151 PRELIMINARY – For Toro Distributor and Toro Company use only. Battery Terminal Protector Aerosol spray that should be used on battery terminals to reduce corrosion problems. Apply terminal protector after the battery cable has been secured to the battery terminal.
  • Page 152: Troubleshooting

    PRELIMINARY – For Toro Distributor and Toro Company use only. 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 − Foldout Drawings). Remove all jewelry, especially rings and If the machine has any interlock switches by−passed,...
  • Page 153: General Run & Transport Problems

    PRELIMINARY – For Toro Distributor and Toro Company use only. 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).
  • Page 154: Cutting Unit Operating Problems

    PRELIMINARY – For Toro Distributor and Toro Company use only. 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.
  • Page 155: Component Testing

    PRELIMINARY – For Toro Distributor and Toro Company use only. 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.
  • Page 156: Component Testing

    PRELIMINARY – For Toro Distributor and Toro Company use only. 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).
  • Page 157: Fuses

    PRELIMINARY – For Toro Distributor and Toro Company use only. Fuses The fuse blocks are located under the operator’s control panel. Identification, Function and Wiring The fuses are held in three (3) fuse blocks. Use Figures 9 and 10 to identify each individual fuse and its correct amperage.
  • Page 158: Warning Lights

    PRELIMINARY – For Toro Distributor and Toro Company use only. 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 159: Pto Switch

    PRELIMINARY – For Toro Distributor and Toro Company use only. PTO Switch The PTO switch is attached to the control console next to the operator seat (Fig. 13). The switch terminals are marked as shown in Figure 14. The circuitry of the PTO switch is shown in the chart be- low.
  • Page 160: Transport, Alarm Silence And Temperature Override Switches

    PRELIMINARY – For Toro Distributor and Toro Company use only. Transport, Alarm Silence and Temperature Override Switches The transport, alarm silence and temperature override rocker switches are located on the control console (Fig. 15). These switches have common switching logic.
  • Page 161: Seat Switch

    PRELIMINARY – For Toro Distributor and Toro Company use only. 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.
  • Page 162: Hour Meter

    PRELIMINARY – For Toro Distributor and Toro Company use only. 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.
  • Page 163: Glow Relay

    PRELIMINARY – For Toro Distributor and Toro Company use only. Glow Relay The glow relay is attached to the the right side of the fuel tank support under the hood. When energized, the glow relay provides current for the engine glow plugs.
  • Page 164: Start, Engine Shutdown, Seat, Pto, Alarm And Over Temperature Relays

    PRELIMINARY – For Toro Distributor and Toro Company use only. Start, Engine Shutdown, Seat, PTO, Alarm and Over Temperature Relays These six (6) relays are located under the console hous- ing cover. The wiring harness is tagged to identify each relay.
  • Page 165: Hydraulic Valve Solenoids

    PRELIMINARY – For Toro Distributor and Toro Company use only. Hydraulic Valve Solenoids There are several hydraulic valve solenoids on the Groundsmaster 4000−D (Fig. 25). Testing of these sole- noids can be done with the solenoid on the hydraulic valve.
  • Page 166: Fuel Sender

    PRELIMINARY – For Toro Distributor and Toro Company use only. 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.
  • Page 167: Fuel Gauge

    PRELIMINARY – For Toro Distributor and Toro Company use only. 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...
  • Page 168: Fuel Pump

    PRELIMINARY – For Toro Distributor and Toro Company use only. Fuel Pump The fuel pump is attached to the frame above the fuel Fuel Pump Specifications water separator. Pump Capacity 64 fl oz/min (1.9 l/min) Operational Test Pressure 7 PSI (48.3 kPa) 1.
  • Page 169: Glow Controller

    PRELIMINARY – For Toro Distributor and Toro Company use only. Glow Controller The glow controller is located under the console cover. NOTE: Refer to Chapter 9 − Foldout Drawings 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 approximately 10 seconds.
  • Page 170: Temperature Sender

    PRELIMINARY – For Toro Distributor and Toro Company use only. Temperature Sender The temperature sender is located near the alternator on the water flange attached to the engine cylinder head (Fig. 30). There is a gray wire attached to the terminal of the switch.
  • Page 171: Dual Temperature Switch

    PRELIMINARY – For Toro Distributor and Toro Company use only. Dual Temperature Switch The dual temperature switch is attached to the engine B. Screw switch into the cylinder head and tighten. near the alternator on the water flange attached to the engine cylinder head (Fig.
  • Page 172: Temperature Gauge

    PRELIMINARY – For Toro Distributor and Toro Company use only. 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...
  • Page 173: Traction Neutral Switch

    PRELIMINARY – For Toro Distributor and Toro Company use only. 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.
  • Page 174: Diode Circuit Board

    PRELIMINARY – For Toro Distributor and Toro Company use only. 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.
  • Page 175: Cutting Deck Position Switch

    PRELIMINARY – For Toro Distributor and Toro Company use only. 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 176: Service And Repairs

    PRELIMINARY – For Toro Distributor and Toro Company use only. Service and Repairs NOTE: For more component repair information, see Kubota Workshop Manual, Diesel Engine, V2403−M−T−E3B Series at the end of Chapter 3 − Ku- bota Diesel Engine. Battery Storage If the machine will be stored for more than 30 days: 4.
  • Page 177: Battery Service

    PRELIMINARY – For Toro Distributor and Toro Company use only. 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.
  • Page 178 PRELIMINARY – For Toro Distributor and Toro Company use only. 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-...
  • Page 179 PRELIMINARY – For Toro Distributor and Toro Company use only. 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-...
  • Page 180 PRELIMINARY – For Toro Distributor and Toro Company use only. This page is intentionally blank. Groundsmaster 4000−D Page 5 − 33 Electrical System...
  • Page 181 PRELIMINARY – For Toro Distributor and Toro Company use only. Chapter 6 Axles, Planetaries and Brakes Table of Contents SPECIFICATIONS ......
  • Page 182: Specifications

    PRELIMINARY – For Toro Distributor and Toro Company use only. 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...
  • Page 183: Adjustments

    PRELIMINARY – For Toro Distributor and Toro Company use only. 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...
  • Page 184: Service And Repairs

    PRELIMINARY – For Toro Distributor and Toro Company use only. 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.
  • Page 185 PRELIMINARY – For Toro Distributor and Toro Company use only. 3. Chock rear wheels and jack up front of machine (see Jacking Instructions in Chapter 1 − Safety). Support ma- WARNING chine with jack stands or solid wood blocks. 4. Remove wheel assembly.
  • Page 186: Brake Inspection And Repair

    PRELIMINARY – For Toro Distributor and Toro Company use only. 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.
  • Page 187 PRELIMINARY – For Toro Distributor and Toro Company use only. This page is intentionally blank. Groundsmaster 4000−D Page 6 − 7 Axles, Planetaries and Brakes...
  • Page 188: Planetary Wheel Drive Assembly

    PRELIMINARY – For Toro Distributor and Toro Company use only. 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.
  • Page 189 PRELIMINARY – For Toro Distributor and Toro Company use only. Planetary Wheel Drive Removal WARNING 1. Park machine on a level surface, lower cutting units, stop engine, engage parking brake and remove key from the ignition switch. Failure to maintain proper wheel lug nut torque could result in failure or loss of wheel and may 2.
  • Page 190: Planetary Wheel Drive Service

    PRELIMINARY – For Toro Distributor and Toro Company use only. 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.
  • Page 191 PRELIMINARY – For Toro Distributor and Toro Company use only. Planetary Wheel Drive Disassembly (Figure 7) Planetary Wheel Drive Assembly (Figure 7) 1. Remove retaining ring (item 12). NOTE: Use new seal kit when assembling planetary wheel drive. 2. Remove cover plate (item 14).
  • Page 192: Rear Axle Assembly

    PRELIMINARY – For Toro Distributor and Toro Company use only. Rear Axle Assembly RIGHT FRONT See text for tightening procedure Figure 8 1. Frame assembly 8. Rear axle assembly 14. Lock nut 2. Cap screw 9. Thrust washer (thin) 15. Flange nut 3.
  • Page 193 PRELIMINARY – For Toro Distributor and Toro Company use only. 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 194 PRELIMINARY – For Toro Distributor and Toro Company use only. 9. Install steering cylinder to axle assembly (see Steer- ing Cylinder in the Service and Repairs section of Chap- ter 4 − Hydraulic System). 10.Install hydraulic motor to axle assembly (see Rear Axle Motor in the Service and Repairs section of Chap- ter 4 −...
  • Page 195: Bevel Gear Case And Axle Case

    PRELIMINARY – For Toro Distributor and Toro Company use only. 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.
  • Page 196 PRELIMINARY – For Toro Distributor and Toro Company use only. 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). 6. While holding the bevel gear case, tap the upper end 17 to 20 ft−lb...
  • Page 197 PRELIMINARY – For Toro Distributor and Toro Company use only. 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 198 PRELIMINARY – For Toro Distributor and Toro Company use only. 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.
  • Page 199 PRELIMINARY – For Toro Distributor and Toro Company use only. 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.
  • Page 200: Differential Shafts

    PRELIMINARY – For Toro Distributor and Toro Company use only. 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.
  • Page 201: Axle Shafts

    PRELIMINARY – For Toro Distributor and Toro Company use only. 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 202: Input Shaft/Pinion Gear

    PRELIMINARY – For Toro Distributor and Toro Company use only. 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.
  • Page 203 PRELIMINARY – For Toro Distributor and Toro Company use only. 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...
  • Page 204: Differential Gear

    PRELIMINARY – For Toro Distributor and Toro Company use only. 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 205 PRELIMINARY – For Toro Distributor and Toro Company use only. 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.
  • Page 206 PRELIMINARY – For Toro Distributor and Toro Company use only. 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).
  • Page 207: Pinion Gear To Ring Gear Engagement

    PRELIMINARY – For Toro Distributor and Toro Company use only. 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.
  • Page 208 PRELIMINARY – For Toro Distributor and Toro Company use only. 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.
  • Page 209 PRELIMINARY – For Toro Distributor and Toro Company use only. Chapter 7 Chassis Table of Contents SERVICE AND REPAIRS ..... .
  • Page 210: Service And Repairs

    PRELIMINARY – For Toro Distributor and Toro Company use only. Service and Repairs Steering Tower 16 to 20 ft−lb (22 to 27 N−m) RIGHT FRONT Figure 1 Hex nut 15. Lock nut 29. Cap screw Flat washer 16. Parking brake switch 30.
  • Page 211 PRELIMINARY – For Toro Distributor and Toro Company use only. Disassembly (Fig. 1) Assembly (Fig. 1) 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 A.
  • Page 212: Front Deck Lift Arm

    PRELIMINARY – For Toro Distributor and Toro Company use only. Front Deck Lift Arm 60 to 70 ft−lb (81 to 94 N−m) 90 to 100 ft−lb (123 to 135 N−m) 150 to 175 ft−lb RIGHT (203 to 237 N−m) FRONT...
  • Page 213 PRELIMINARY – For Toro Distributor and Toro Company use only. Removal (Fig. 2) 6. If removed, install ball joint to lift arm. Distance from end of lift arm to center of ball joint should be from 2.210” 1. Park machine on a level surface, lower cutting units, to 2.390”...
  • Page 214: Side Deck Lift Arm

    PRELIMINARY – For Toro Distributor and Toro Company use only. Side Deck Lift Arm 16 17 19 18 Thread locking Compound 9 10 Anti−seize Lubricant 77 to 96 ft−lb (105 to 130 N−m) RIGHT 30 33 FRONT Figure 5 Lift arm (LH shown) 14.
  • Page 215 PRELIMINARY – For Toro Distributor and Toro Company use only. Removal (Fig. 5) 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.
  • Page 216: Side Deck Rear Arm Assembly

    PRELIMINARY – For Toro Distributor and Toro Company use only. Side Deck Rear Arm Assembly Thread locking Compound 24 25 35 36 270 to 330 in−lb (31 to 37 N−m) 114 ft−lb (155 N−m) RIGHT FRONT Figure 7 Cutting deck (LH shown) 16.
  • Page 217 PRELIMINARY – For Toro Distributor and Toro Company use only. Rear Arm Removal (Fig. 7) 10.Thoroughly pack spring with grease. Install spring shaft assembly into housing and secure plate with four 1. Park machine on a level surface, lower cutting units, (4) cap screws and lock nuts.
  • Page 218 PRELIMINARY – For Toro Distributor and Toro Company use only. Rear Arm Installation (Fig. 7) 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.
  • Page 219 PRELIMINARY – For Toro Distributor and Toro Company use only. This page is intentionally blank. Groundsmaster 4000−D Page 7 − 11 Chassis...
  • Page 220: Lift Arm Yoke Joint

    PRELIMINARY – For Toro Distributor and Toro Company use only. 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 10 Side cutting deck (LH shown) Cap screw 13.
  • Page 221 PRELIMINARY – For Toro Distributor and Toro Company use only. Yoke Joint Disassembly 1. Remove snap rings from yoke (Fig. 11). IMPORTANT: Support yoke when removing and installing cross and bearings to prevent yoke dam- age. 2. Use a press to remove cross and bearing assembly from yoke.
  • Page 222: Operator Seat

    PRELIMINARY – For Toro Distributor and Toro Company use only. Operator Seat RIGHT FRONT Figure 12 Seat assembly R−clamp (2 used) 17. Screw (2 used) Flat washer (5 used) 10. Manual tube 18. Hair pin (2 used) Seat belt 11. Screw 19.
  • Page 223 PRELIMINARY – For Toro Distributor and Toro Company use only. Removal (Fig. 12) 1. Park machine on a level surface, lower cutting decks, stop engine, apply parking brake and remove key from the ignition switch. 2. Remove seat from seat suspension (Fig. 13): A.
  • Page 224: Operator Seat Service

    PRELIMINARY – For Toro Distributor and Toro Company use only. Operator Seat Service Figure 14 Backrest cushion 11. Washer 21. Torx screw (5 used) Seat cushion 12. Cap screw (2 used) 22. RH adjustment rail Armrest cover 13. Seat 23. Rail stop LH armrest 14.
  • Page 225 PRELIMINARY – For Toro Distributor and Toro Company use only. Disassembly (Fig. 14) Assembly (Fig. 14) 1. Disassemble operator seat as necessary using Fig- 1. Assemble operator seat using Figure 14 as a guide. ure 14 as a guide. Groundsmaster 4000−D Page 7 −...
  • Page 226: Operator Seat Suspension

    PRELIMINARY – For Toro Distributor and Toro Company use only. Operator Seat Suspension RIGHT FRONT Figure 15 Cover 14. Washer (2 used) 27. Clamp (2 used) Cover 15. Tether 28. Hose nipple Level control 16. Rivet (2 used) 29. Screw Air control valve 17.
  • Page 227 PRELIMINARY – For Toro Distributor and Toro Company use only. NOTE: Most of the seat suspension components can Assembly (Fig. 15) be serviced with the seat suspension base mounted to 1. Install all removed seat suspension components us- the frame platform. If the air spring assembly (item 6) re- ing Figure 15 as a guide.
  • Page 228: Hood

    PRELIMINARY – For Toro Distributor and Toro Company use only. Hood 25 29 RIGHT FRONT 22 21 24 23 Figure 16 Hood 11. Clevis pin 21. Flexible latch draw Latch bracket (RH) 12. Hood rod 22. Latch bracket (LH) Screen assembly 13.
  • Page 229 PRELIMINARY – For Toro Distributor and Toro Company use only. 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 16 as a guide.
  • Page 230 PRELIMINARY – For Toro Distributor and Toro Company use only. This page is intentionally blank. Chassis Page 7 − 22 Groundsmaster 4000−D...
  • Page 231 PRELIMINARY – For Toro Distributor and Toro Company use only. Chapter 8 Cutting Units Table of Contents SPECIFICATIONS ......
  • Page 232: Specifications

    PRELIMINARY – For Toro Distributor and Toro Company use only. Specifications MOUNTING: Cutting decks are supported by lift arms WIDTH OF CUT: Front deck provides 62” (1575 mm) controlled with individual hydraulic lift levers. width of cut. Each side deck has 42” (1067 mm) width of cut.
  • Page 233: Troubleshooting

    PRELIMINARY – For Toro Distributor and Toro Company use only. 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.
  • Page 234: Adjustments

    PRELIMINARY – For Toro Distributor and Toro Company use only. 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.
  • Page 235 PRELIMINARY – For Toro Distributor and Toro Company use only. This page is intentionally blank. Groundsmaster 4000−D Page 8 − 5 Cutting Units...
  • Page 236: Service And Repairs

    PRELIMINARY – For Toro Distributor and Toro Company use only. 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...
  • Page 237 PRELIMINARY – For Toro Distributor and Toro Company use only. Removal (Fig. 1) 1. Position machine on a clean, level surface. Lower cutting units, stop engine, engage parking brake and re- move key from the ignition switch. NOTE: Removal of clevis pin from deck and height−of−...
  • Page 238: Side Cutting Unit

    PRELIMINARY – For Toro Distributor and Toro Company use only. 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 −...
  • Page 239 PRELIMINARY – For Toro Distributor and Toro Company use only. Removal (Fig. 5) 1. Position machine on a clean, level surface. Lower cutting units, stop engine, engage parking brake and re- move 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 240: Blade Spindle Service

    PRELIMINARY – For Toro Distributor and Toro Company use only. 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.
  • Page 241 PRELIMINARY – For Toro Distributor and Toro Company use only. Assembly 11. Install pulley (hub down), washer and lock nut to spindle shaft. Tighten lock nut from 130 to 150 ft−lb IMPORTANT: If new bearings are installed into a (176 to 203 N−m).
  • Page 242: Castor Forks And Wheels

    PRELIMINARY – For Toro Distributor and Toro Company use only. 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)
  • Page 243 PRELIMINARY – For Toro Distributor and Toro Company use only. Chapter 9 Foldout Drawings Table of Contents HYDRAULIC SCHEMATIC .....
  • Page 244 PRELIMINARY – For Toro Distributor and Toro Company use only. This page is intentionally blank. Page 9 - 2 Foldout Drawings Groundsmaster 4000−D...
  • Page 245: Hydraulic Schematic

    PRELIMINARY – For Toro Distributor and Toro Company use only. Groundsmaster 4000−D Hydraulic Schematic Page 9 - 3...
  • Page 246: Electrical Schematic

    PRELIMINARY – For Toro Distributor and Toro Company use only. CONTINUES TO SHEET 2 CONTINUES TO SHEET 2 CONTINUES TO SHEET 2 Groundsmaster 4000−D Electrical Schematic Sheet 1 CONTINUES TO SHEET 2 All relays and solenoids are shown as de−energized.
  • Page 247: Sheet 2

    PRELIMINARY – For Toro Distributor and Toro Company use only. CONTINUES FROM SHEET 1 CONTINUES FROM SHEET 1 CONTINUES FROM SHEET 1 CONTINUES FROM SHEET 1 Groundsmaster 4000−D Electrical Schematic Sheet 2 All relays and solenoids are shown as de−energized.
  • Page 248: Console Wire Harness

    PRELIMINARY – For Toro Distributor and Toro Company use only. Groundsmaster 4000−D Console Wire Harness Page 9 - 6...
  • Page 249 PRELIMINARY – For Toro Distributor and Toro Company use only. WHITE YELLOW ORANGE GRAY YELLOW/BLACK VIOLET YELLOW SHEET 2 WHITE YELLOW SHEET 2 YELLOW YELLOW YELLOW GREEN GRAY BLACK GRAY WHITE GRAY BLACK YELLOW BLACK BLACK ORANGE BLUE BLACK BLACK...
  • Page 250 PRELIMINARY – For Toro Distributor and Toro Company use only. SHEET 1 YELLOW SHEET 1 BLACK BLACK BLACK TAN/BLACK TAN/BLACK BLACK GRAY Groundsmaster 4000−D Console Wire harness Sheet 2 Page 9 - 8...
  • Page 251: Engine Wire Harness

    PRELIMINARY – For Toro Distributor and Toro Company use only. Groundsmaster 4000−D Engine Wire Harness Page 9 - 9...
  • Page 252 PRELIMINARY – For Toro Distributor and Toro Company use only. BLACK BLACK WHITE RED/BLACK RED/BLACK PINK ORANGE BLUE WHITE GRAY GREEN YELLOW WHITE/BLACK YELLOW BROWN BLUE WHITE ORANGE VIOLET/BLACK YELLOW/BLACK GREEN BROWN/WHITE YELLOW/WHITE BLACK BLACK BLACK GREEN BLACK BLACK BLACK ORANGE Groundsmaster 4000−D...
  • Page 253: Front Wire Harness

    PRELIMINARY – For Toro Distributor and Toro Company use only. Groundsmaster 4000−D Front Wire Harness Page 9 - 11...
  • Page 254 PRELIMINARY – For Toro Distributor and Toro Company use only. 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 Page 9 - 12...

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