Form No.
Revision History Revision Date -- 2010 A 03/2018 Added revision history. B 03/2019 Updated Chassis chapter. C 07/2020 Updated Electrical chapter and Foldout Drawings. © THE TORO COMPANY 2020 Description Initial Issue. This document and all information contained herein is the sole property of The Toro Company (and/or its affiliated companies). No intellectual property rights are granted by the delivery of this document or the disclosure of its content.
Reader Comments The Toro Company Technical Assistance Center maintains a continuous effort to improve the quality and usefulness of its publications. To do this effectively, we encourage user feedback. Please comment on the completeness, accuracy, organization, usability, and readability of this manual by an e-mail to servicemanuals@toro.
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Part No. 10178SL (Rev. C) Service Manual GroundsmasterR 4300--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 4300--D. REFER TO THE OPERATOR’S MANUAL FOR OPERATING, MAINTENANCE AND ADJUSTMENT INSTRUCTIONS. Space is provided in Chapter 2 of this book to insert the Operator’s Manual and Parts Catalog for your machine.
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General Information . . . . . . . . . . . . . . . . . . . . . . . . 5 -- 3 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 -- 4 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 -- 6 Electrical System Quick Checks . . . . . . . . . . . . . 5 -- 17 Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 -- 19 Component Testing . . . . . . . . . . . . . . . . . . . . . . . . 5 -- 22 Service and Repairs . . . . . . . . . . . . . . . . . . .
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Safety Table of Contents SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . Before Operating . . . . . . . . . . . . . . . . . . . . . . . . . . . . While Operating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Maintenance and Service . . . . . . . . . . . . . . . . . . . . JACKING INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . SAFETY AND INSTRUCTION DECALS . . . . . . . . . .
Safety Instructions Your Groundsmaster meets or exceeds safety standard specifications when weights are installed according to information in the Operator’s Manual. Although hazard control and accident prevention are partially 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.
While Operating 5. Before getting off the seat: A. Ensure that traction pedal is in NEUTRAL. 2. Before starting the engine: B. Lower and disengage cutting decks and wait for all movement to stop. A. Apply the parking brake. B. Make sure the 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.
Maintenance and Service 2. Make sure machine is in safe operating condition by keeping all nuts, bolts and screws tight. 12.Disconnect battery before servicing the machine. Disconnect negative battery cable first and positive cable last. If battery voltage is required for troubleshooting or test procedures, temporarily connect the battery. Reconnect positive battery cable first and negative cable last. 3.
Jacking Instructions Safety CAUTION When changing attachments, tires or performing other service, use correct supports, hoists and jacks. Make sure machine is parked on a solid, level surface such as a concrete floor. Prior to raising machine, remove any attachments that may interfere with the safe and proper raising of the machine. Always chock or block wheels. Use jack stands or other appropriate load holding devices to support the raised machine.
Safety and Instruction Decals Numerous safety and instruction decals are affixed to the traction unit and cutting units of your Groundsmaster. If any decal becomes illegible or damaged, install a new decal. Part numbers for decals are listed in your Part Catalog. Order replacement decals from your Authorized Toro Distributor.
Chapter 2 Product Records and Maintenance PRODUCT RECORDS . . . . . . . . . . . . . . . . . . . . . . . . . MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EQUIVALENTS AND CONVERSIONS . . . . . . . . . . . Decimal and Millimeter Equivalents . . . . . . . . . . . . U.S. to Metric Conversions . . . . . . . . . . . . . . . . . . . TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . Fastener Identification . . . . . . . . . . . . . . . . . . . . . . .
Equivalents and Conversions 0.
Recommended fastener torque values are listed in the following tables. For critical applications, as determined by Toro, either the recommended torque or a torque that is unique to the application is clearly identified and specified in this Service Manual. These Torque Specifications for the installation and tightening of fasteners shall apply to all fasteners which do not have a specific requirement identified in this Service Manual.
Standard Torque for Dry, Zinc Plated and Steel Fasteners (Inch Series) Thread Size # 6 -- 32 UNC Grade 1, 5 & 8 with Thin Height Nuts SAE Grade 1 Bolts, Screws, Studs & Sems with Regular Height Nuts (SAE J995 Grade 2 or Stronger Nuts) in--lb in--lb N--cm 10 + 2 13 + 2 147 + 23 # 6 -- 40 UNF # 8 -- 32 UNC 13 + 2 25 + 5 282 + 30 # 8 -- 36 UNF # 10 -- 24 UNC 18 + 2 30 + 5 339 + 56 # 10 -- 32 UNF SAE Grade 5 Bolts, Screws, Studs & Sems with Regular Height Nuts (SAE J995 Grade 2 or Stronger N
Standard Torque for Dry, Zinc Plated and Steel Fasteners (Metric Series) Class 8.8 Bolts, Screws and Studs with Regular Height Nuts (Class 8 or Stronger Nuts) Class 10.9 Bolts, Screws and Studs with Regular Height Nuts (Class 10 or Stronger Nuts) M5 X 0.8 57 + 6 in--lb 644 + 68 N--cm 78 + 8 in--lb 881 + 90 N--cm M6 X 1.0 96 + 10 in--lb 1085 + 113 N--cm 133 + 14 in--lb 1503 + 158 N--cm M8 X 1.25 19 + 2 ft--lb 26 + 3 N--m 28 + 3 ft--lb 38 + 4 N--m M10 X 1.
Other Torque Specifications SAE Grade 8 Steel Set Screws Wheel Bolts and Lug Nuts Recommended Torque Thread Size Thread Size Square Head Hex Socket 1/4 -- 20 UNC 140 + 20 in--lb 73 + 12 in--lb 5/16 -- 18 UNC 215 + 35 in--lb 145 + 20 in--lb 3/8 -- 16 UNC 35 + 10 ft--lb 18 + 3 ft--lb 1/2 -- 13 UNC 75 + 15 ft--lb 50 + 10 ft--lb Recommended Torque** 7/16 -- 20 UNF Grade 5 65 + 10 ft--lb 88 + 14 N--m 1/2 -- 20 UNF Grade 5 80 + 10 ft--lb 108 + 14 N--m M12 X 1.25 Class 8.
Chapter 3 Kubota Diesel Engine 1 1 1 2 3 3 SERVICE AND REPAIRS . . . . . . . . . . . . . . . . . . . . . . 4 Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Specifications Item Description Make / Designation Kubota V1505--T--E3B, 4--stroke, Liquid Cooled, OHV, Turbocharged Diesel Number of Cylinders 4 Bore x Stroke 3.07 in x 3.09 in (78 mm x 78.4 mm) Total Displacement 91.4 in3 (1498 cc) Compression Ratio 23:1 Firing Order 1 (fan end) -- 3 -- 4 (flywheel end) -- 2 Fuel No. 2--D Diesel Fuel (ASTM D975) Fuel Injection Pump Bosch MD Type Mini Fuel Injector Nozzle Mini Nozzle (DNOPD) Fuel Tank Capacity 14 U.S.
Adjustments Adjust Throttle Control Proper throttle operation is dependent upon proper adjustment of throttle control. 2 NOTE: The throttle cable swivel should be positioned in the lowest hole in the speed control lever. 1 5 3 2. Check position of the engine speed control lever on fuel injection pump. The speed control lever should be contacting the high speed screw when the throttle control lever is in the FAST position. 3.
Service and Repairs Fuel System 8 7 12 15 1 6 11 9 10 16 2 17 13 18 14 19 4 3 5 RIGHT 4 FRONT Figure 2 1. 2. 3. 4. 5. 6. 7. Fuel cap Bushing Washer head screw (2 used) Flange nut (3 used) Clamp (2 used) Return fitting Suction fitting Kubota Diesel Engine 8. 9. 10. 11. 12. 13. Hose clamp Hose clamp Fuel tank Grommet Fuel gauge Hose clamp Page 3 -- 4 14. 15. 16. 17. 18. 19.
3. Open draincock on bottom of fuel tank and allow tank to fully drain. Close draincock. Because diesel fuel is highly flammable, use caution when storing or handling it. Do not smoke while filling the fuel tank. Do not fill fuel tank while engine is running, when engine is hot or when machine is in an enclosed area. Always fill fuel tank outside and wipe up any spilled diesel fuel before starting the engine. Store fuel in a clean, safety--approved container and keep container cap in place.
Air Cleaner 8 11 7 11 14 17 14 18 19 Thread Sealant 1 11 6 4 12 to 15 in--lb (1.4 to 1.6 N--m) 3 16 5 2 12 VACUATOR DIRECTION 12 9 13 20 10 15 RIGHT FRONT 12 12 Figure 4 1. 2. 3. 4. 5. 6. 7. Air cleaner assembly Indicator Adapter Spring Hex nut Bolt Hose Kubota Diesel Engine 8. 9. 10. 11. 12. 13. 14. Hose Mount bracket Air cleaner stand Hose clamp (3 used) Flange nut (8 used) Cap screw (2 used) Hose clamp (2 used) Page 3 -- 6 15. 16. 17. 18. 19. 20.
Removal (Fig. 4) 1. Park machine on a level surface, lower cutting decks, stop engine, engage parking brake and remove key from the ignition switch. Raise and support hood. 2. Remove air cleaner components as needed using Figures 4 as a guide. 1 3. See Operator’s Manual for air cleaner service and maintenance procedures. 2 3 4 Installation (Fig. 4) Figure 5 1. Air cleaner assembly 2. Service indicator 3. Adapter 4.
Exhaust System 13 3 RIGHT 1 FRONT 10 6 11 2 12 16 5 7 4 8 9 5 14 6 17 15 Figure 6 1. 2. 3. 4. 5. 6. Gasket Lock washer (2 used) Flange nut (4 used) Cap screw (2 used) Carriage screw (4 used) Flange nut (4 used) Kubota Diesel Engine 7. 8. 9. 10. 11. 12. Muffler support bracket Flange head screw (2 used) Tail pipe bracket Hex nut (2 used) Upper clamp Flange nut (4 used) Page 3 -- 8 13. 14. 15. 16. 17.
Removal (Fig. 6) 1. Park machine on a level surface, lower cutting decks, stop engine, engage parking brake and remove key from the ignition switch. Raise and support hood. 3 2 1 (FIRST) 4 (LAST) CAUTION The muffler and exhaust pipe may be hot. To avoid possible burns, allow the engine and exhaust system to cool before working on the exhaust system. Installation (Fig. 6) NOTE: Make sure muffler flange and exhaust manifold sealing surfaces are free of debris or damage that may prevent a tight seal. 1.
Radiator 9 40 16 45 RIGHT 28 36 35 41 16 20 FRONT 19 20 12 22 8 37 43 15 42 44 46 18 5 13 17 5 27 7 47 5 29 4 11 17 13 14 10 25 31 39 12 30 26 15 10 30 32 2 3 10 2 2 1 34 23 33 24 13 38 5 6 13 21 Figure 8 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16.
Removal (Fig. 8) 1. Park machine on a level surface, lower cutting decks, stop engine, apply parking brake and remove key from the ignition switch. 2. Raise and support the hood. 10.Carefully pull radiator assembly from the machine. Plug radiator and hose openings to prevent contamination. 11. Inspect all foam seals placed between radiator, fan shroud and radiator frame. Replace damaged foam seals. Installation (Fig. 8) Do not open radiator cap or drain coolant if the radiator or engine is hot.
Engine 30 1 11 3 18 20 16 15 26 19 10 17 5 21 4 31 14 7 27 5 4 24 22 5 23 12 23 13 9 25 2 29 32 9 9 22 6 34 to 42 ft--lb (47 to 56 N--m) 9 8 RIGHT 9 FRONT 6 28 8 Figure 9 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. Engine assembly Cap screw (12 used) Temperature sender Engine mount (4 used) Flange head screw (13 used) Snubbing washer (4 used) Cap screw (4 used) Flange nut (4 used) Flange nut (14 used) Fan clutch Stud (4 used) Kubota Diesel Engine 12. 13. 14. 15. 16. 17. 18. 19. 20.
Removal (Fig. 9) 1. Park machine on a level surface, lower cutting decks, stop engine and remove key from the ignition switch. Chock wheels to keep the machine from moving. 1 2 2. Open and support hood. 3 3. Disconnect negative (--) cable and then positive (+) cable from the battery. CAUTION Figure 10 1. Throttle cable end 2. Swivel 3. Cable clamp Kubota Diesel Engine Do not open radiator cap or drain coolant if the radiator or engine is hot. Pressurized, hot coolant can escape and cause burns.
9. Disconnect hydraulic transmission drive shaft from engine (see Hydraulic Transmission Drive Shaft Removal in the Service and Repairs section of Chapter 4 -- Hydraulic System). Support drive shaft away from engine. Installation (Fig. 9) 10.Disconnect wire harness connectors from the following engine components: 2. Make sure that all parts removed from the engine during maintenance or rebuilding are installed to the engine.
7. Remove plugs installed in hoses during disassembly. Connect hoses to the engine: 9. Install air cleaner (see Air Cleaner Installation in this section). A. Connect fuel supply and fuel return hoses to engine fittings (Fig. 11). Secure with hose clamps. 10.Install exhaust system to machine (see Exhaust System Installation in this section). B. Connect upper and lower radiator hoses to the engine. Secure with hose clamps. 11. Make sure radiator draincock is closed (threaded out fully).
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Chapter 4 Hydraulic System SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . 3 Operator’s Manual . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Check Hydraulic Fluid . . . . . . . . . . . . . . . . . . . . . . . 3 Towing Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Hydraulic Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Hydraulic Hose and Tube Installation . . . . . . . . .
Specifications Item Description Piston (Traction) Pump Maximum Pump Displacement (per revolution) Sauer--Danfoss, LPV Closed Circuit Axial Piston Design 2.14 in3 (35 cc) Gear Pump Section P1/P2 Displacement (per revolution) Section P3 Displacement (per revolution) Section P4 Displacement (per revolution) Casappa 4 section, positive displacement gear type pump 1.03 in3 (16.84 cc) 0.37 in3 (6.1 cc) 0.24 in3 (3.
General Information Operator’s Manual The Operator’s Manual provides information regarding the operation, general maintenance and maintenance intervals for your Groundsmaster 4300--D. Refer to that publication for additional information when servicing the machine. Check Hydraulic Fluid The hydraulic system on your Groundsmaster is designed to operate on high quality hydraulic fluid. The hydraulic system reservoir holds approximately 14 U.S. gallons (53 liters) of hydraulic fluid.
Hydraulic Hoses Hydraulic hoses are subject to extreme conditions such as pressure differentials during operation and exposure to weather, sun, chemicals, very warm storage conditions or mishandling during operation and maintenance. These conditions can cause hose damage and deterioration. Some hoses are more susceptible to these conditions than others.
Hydraulic Hose and Tube Installation (O--Ring Face Seal Fitting) 1. Make sure threads and sealing surfaces of the hose/ tube and the fitting are free of burrs, nicks, scratches or any foreign material. C. Use a second wrench to tighten the nut to the correct Flats From Wrench Resistance (F.F.W.R.). The markings on the nut and fitting body will verify that the connection has been properly tightened. 2.
Hydraulic Fitting Installation (SAE Straight Thread O--Ring Fitting into Component Port) Non--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. 5. If a torque wrench is not available, or if space at the port prevents use of a torque wrench, an alternate method of assembly is the Flats From Finger Tight (F.F.F.T.) method. 2.
Adjustable Fitting (Fig. 8) 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 recommended that the O--ring be replaced any time the connection is opened. Lock Nut 3. Lightly lubricate the O--ring with clean hydraulic oil. Fitting threads should be clean with no lubricant applied. Back--up Washer 4. Turn back the lock nut as far as possible.
Relieving Hydraulic System Pressure Before disconnecting or performing any work on the hydraulic system, all pressure in the hydraulic system must be relieved. Park machine on a level surface, lower cutting decks fully, stop engine and engage parking brake. To relieve hydraulic pressure in traction circuit, move traction pedal to both forward and reverse directions. To relieve hydraulic pressure in steering circuit, rotate steering wheel in both directions.
Groundsmaster 4300--D Page 4 -- 9 DECK CONTROL MANIFOLD BYPASS VALVE NOTE: A larger hydraulic schematic is included in Chapter 8 -- Foldout Drawings PISTON (TRACTION) PUMP GEAR PUMP CROSSTRAX MANIFOLD Hydraulic System LIFT CONTROL MANIFOLD STEERING CYLINDER All solenoids are shown as de--energized Groundsmaster 4300--D Hydraulic Schematic STEERING CONTROL VALVE Hydraulic Schematic Hydraulic System
PISTON (TRACTION) PUMP Hydraulic System BYPASS VALVE DECK CONTROL MANIFOLD GEAR PUMP CROSSTRAX MANIFOLD Figure 10 Page 4 -- 10 STEERING CYLINDER Working Pressure Low Pressure (Charge) Return or Suction Flow Groundsmaster 4300--D Traction Circuit (Forward Shown) LIFT CONTROL MANIFOLD STEERING CONTROL VALVE Hydraulic Flow Diagrams Groundsmaster 4300--D
Traction Circuit Forward traction circuit pressure can be measured at a test port located in the hydraulic tube that connects the front wheel motors. Reverse traction circuit pressure can be measured at test ports in the AWD control manifold. Forward Direction (Fig. 10) Pushing the top of the traction pedal angles the traction pump swash plate to create a flow of oil. This oil flow is directed to the wheel motors via hydraulic hoses and tubes to drive the wheels in the forward direction.
Figure 11 Hydraulic System Page 4 -- 12 Groundsmaster 4300--D PISTON (TRACTION) PUMP BYPASS VALVE DECK CONTROL MANIFOLD GEAR PUMP CROSSTRAX MANIFOLD Working Pressure Low Pressure (Charge) Return or Suction Flow Groundsmaster 4300--D Mow Circuit LIFT CONTROL MANIFOLD STEERING CONTROL VALVE STEERING CYLINDER
Mow Circuit The deck control manifold contains two (2) independent control circuits for the front and rear cutting decks. Each circuit is supplied by its own pump section. Pump section (P1) supplies hydraulic power to the rear cutting decks with circuit control by proportional relief valve (PRV1), relief valve (RV1) and logic cartridge (LC1) in the deck control manifold.
Mow Circuit Cutting Deck Blade Braking When the operator turns the PTO switch OFF or if the decks are raised with the PTO switch ON, the deck control manifold proportional relief valves (PRV1 and PRV2) are de--energized causing circuit flow to bypass the deck motors and return to the reservoir out manifold port T (refer to information in Mow Circuit in this section).
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Figure 16 Hydraulic System Page 4 -- 16 Groundsmaster 4300--D PISTON (TRACTION) PUMP BYPASS VALVE DECK CONTROL MANIFOLD GEAR PUMP CROSSTRAX MANIFOLD STEERING CYLINDER Working Pressure Low Pressure (Charge) Return or Suction Flow Groundsmaster 4300--D Lift Circuit: Raise Cutting Decks LIFT CONTROL MANIFOLD STEERING CONTROL VALVE
Lift Circuit: Raise Cutting Decks A four section gear pump is coupled to the piston (traction) pump. Gear pump section (P4) supplies hydraulic flow to the lift control manifold and lift cylinders. The gear pump takes its suction from the hydraulic reservoir. LIFT CIRCUIT: NOT RAISING OR LOWERING The lift control manifold includes three (3) electrically operated valves. Solenoid valve (S1) is used to direct oil flow to extend the lift cylinders when energized or retract them when de--energized.
Figure 18 Hydraulic System Page 4 -- 18 Groundsmaster 4300--D PISTON (TRACTION) PUMP BYPASS VALVE DECK CONTROL MANIFOLD GEAR PUMP CROSSTRAX MANIFOLD STEERING CYLINDER Working Pressure Low Pressure (Charge) Return or Suction Flow Groundsmaster 4300--D Lift Circuit: Lower Cutting Decks LIFT CONTROL MANIFOLD STEERING CONTROL VALVE
Lift Circuit: Lower Cutting Decks The lift control manifold includes three (3) electrically operated valves. Solenoid valve (S1) is used to direct oil flow to extend the lift cylinders when energized or retract them when de--energized. Solenoid valve (S2) allows hydraulic flow from the rod end of the lift cylinders when energized and prevents oil passage from the lift cylinders when de--energized.
Figure 20 Hydraulic System Page 4 -- 20 Groundsmaster 4300--D STEERING CYLINDER STEERING CONTROL VALVE TO TRACTION CHARGE CIRCUIT R10 FROM PUMP (P3) RIGHT TURN PISTON MOVEMENT STEERING CONTROL VALVE STEERING CYLINDER TO TRACTION CHARGE CIRCUIT PISTON MOVEMENT Working Pressure Low Pressure (Charge) Return or Suction Flow Groundsmaster 4300--D Steering Circuit R10 FROM PUMP (P3) LEFT TURN
Steering Circuit With the steering wheel in the neutral position and the engine running, hydraulic flow enters the steering control valve at the P port and goes through the steering control spool valve, bypassing the rotary meter (V1) and steering cylinder. Flow leaves the control valve through the T port to the transmission oil filter and traction charge circuit. Left Turn (Fig.
Special Tools Order Special 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. Kit contains one each: 1000 PSI (70 Bar), 5000 PSI (350 Bar) and 10000 PSI (700 Bar) gauges. Use gauges as recommended in the Testing section of this chapter.
40 GPM Hydraulic Tester (Pressure and Flow) Use to test hydraulic circuits and components for flow and pressure capacities as recommended in the Testing section of this chapter. This tester includes the following: 1. LOAD VALVE: A simulated working load is created in the circuit by turning the valve to restrict flow. 2. PRESSURE GAUGE: Glycerine filled 0 to 5000 PSI gauge to provide operating circuit pressure. 3.
High Flow Hydraulic Filter Kit The high flow hydraulic filter kit is designed with large flow (40 GPM/150 LPM) and high pressure (5000 PSI/345 bar) capabilities. This kit provides for bi--directional filtration which prevents filtered debris from being allowed back into the circuit regardless of flow direction. If a component failure occurs in the closed loop traction circuit, contamination from the failed part will remain in the circuit until removed.
Wheel Hub Puller The wheel hub puller allows safe removal of the wheel hub from the wheel motor shaft. Toro Part Number: TOR6004 Figure 29 Measuring Container Hydraulic System Use this graduated container for doing hydraulic motor efficiency testing (motors with case drain lines only). Measure efficiency of a hydraulic motor by restricting the outlet flow from the motor and measuring leakage from the case drain line while the motor is pressurized by the hydraulic system.
Troubleshooting The cause of an improperly functioning hydraulic system is best diagnosed with the use of proper testing equipment and a thorough understanding of the complete hydraulic system. A hydraulic system with an excessive increase in heat or noise has a potential for failure. Should either of these conditions be noticed, immediately stop the machine, turn off the engine, locate the cause of the trouble and correct it before allowing the machine to be used again.
Traction Circuit Problems Problem Possible Causes Neutral is difficult to find or machine operates in one direction only Traction control linkage is misadjusted, disconnected, binding or damaged. Piston (traction) pump check relief valve is not seating or is damaged (NOTE: Piston (traction) pump check relief valves for forward and reverse are identical and can be reversed for testing purposes). Piston (traction) pump is worn or damaged. Traction response is sluggish Hydraulic oil is very cold.
Traction Circuit Problems (Continued) Problem Possible Causes Wheel motor will not turn Brakes are binding. Wheel motor is worn or damaged (NOTE: If a traction circuit component has internal wear or damage, it is possible that other traction circuit components are also damaged). Wheel motors will not hold load when traction pedal is in neutral Charge pressure is low.
Lift Circuit Problems Problem Possible Causes Single cutting deck raises slowly or not Cutting deck has excessive debris buildup. at all Lift arm or lift cylinder is binding. Flow control orifice in lift control manifold for the affected cutting deck is plugged, stuck or damaged. Lift cylinder leaks internally. None of the cutting decks will raise or lower Oil level in hydraulic reservoir is low (other hydraulic systems are affected as well).
Steering Circuit Problems Problem Possible Causes Steering inoperative or sluggish Steering components (e.g. tie rods, steering cylinder ends) are worn or binding. Steering cylinder is binding. Oil level in hydraulic reservoir is low (other hydraulic systems are affected as well). Steering relief valve (R10) in steering control valve is stuck or damaged. Steering cylinder leaks internally. Steering control valve is worn or damaged.
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Testing The most effective method for isolating problems in the hydraulic system is by using hydraulic test equipment such as pressure gauges and flow meters in the circuits during various operational checks (see the Special Tools section in this chapter). 2. Review all test steps before starting the test procedure. Before Performing Hydraulic Tests 4. All hydraulic tests should be made with the hydraulic oil at normal operating temperature.
Which Hydraulic Tests Are Necessary? Before beginning any hydraulic test, identify if the problem is related to the traction circuit, cutting (mow) circuit, lift circuit or steering circuit. Once the faulty system has been identified, perform tests that relate to that circuit. 1.
Traction Circuit Relief Valve (R3) and (R4) Pressure Test TO STEERING CONTROL VALVE AND CHARGE CIRCUIT TO MOW CONTROL (FRONT CUTTING UNITS) TO LIFT CONTROL MANIFOLD TO MOW CONTROL (REAR CUTTING UNITS) FORWARD (R3) RELIEF VALVE TEST SHOWN GEAR PUMP BYPASS VALVE CROSSTRAX PRESSURE GAUGE MANIFOLD PISTON (TRACTION) PUMP FROM STEERING CONTROL VALVE Figure 32 The traction circuit relief pressure test should be performed to make sure that forward and reverse traction circuit relief pressures are correct.
5. Connect a 5000 PSI (350 bar) pressure gauge to test port. 2 6. After installing pressure gauge, start engine and run at idle speed. Check for any hydraulic leakage from test connections and correct before proceeding with test. 7. Move throttle to full speed (3200 RPM). 8. Sit on seat, and with brakes applied, slowly depress the traction pedal in the direction to be tested (forward or reverse). While pushing traction pedal down, carefully watch the pressure gauge needle.
Traction Circuit Charge Pressure Test TO STEERING CONTROL VALVE AND CHARGE CIRCUIT TO MOW CONTROL (FRONT CUTTING UNITS) TO LIFT CONTROL MANIFOLD TO MOW CONTROL (REAR CUTTING UNITS) GEAR PUMP BYPASS VALVE CROSSTRAX MANIFOLD PISTON (TRACTION) PUMP PRESSURE GAUGE FROM STEERING CONTROL VALVE OIL FILTER REMOVED Figure 36 The traction circuit charge pressure test should be performed to make sure that the traction charge circuit is functioning correctly. 3.
4. Raise and support operator seat to allow access to hydraulic pump assembly. NOTE: If gear pump (P3) is worn or damaged, both charge circuit and steering circuit will be affected. 5. Thoroughly clean ends of hydraulic tubes that connect to the oil filter (Fig. 37). Disconnect hydraulic tubes from oil filter adapter. Remove two (2) flange head screws that secure oil filter adapter to frame and remove oil filter and adapter assembly from machine. 12.
Gear Pump (P3) Flow Test (Using Tester with Pressure Gauges and Flow Meter) TO STEERING CONTROL VALVE AND CHARGE CIRCUIT TO MOW CONTROL (FRONT CUTTING UNITS) TO LIFT CONTROL MANIFOLD TO MOW CONTROL (REAR CUTTING UNITS) GEAR PUMP BYPASS VALVE CROSSTRAX MANIFOLD PISTON (TRACTION) PUMP TESTER FROM STEERING CONTROL VALVE OIL FILTER AND TUBE REMOVED Figure 39 The gear pump (P3) flow test should be performed to make sure that the traction charge circuit and steering circuit have adequate hydraulic flow.
FLOW TESTER READING TO BE: A pump in good condition should have a flow of approximately 4.9 GPM (18.5 LPM) at 800 PSI (55 bar). Before opening hydraulic system, operate all hydraulic controls to relieve system pressure and avoid injury from pressurized hydraulic oil. See Relieving Hydraulic System Pressure in the General Information section of this chapter. 4. Raise and support operator seat to allow access to hydraulic pump. 5.
Front Wheel Motor Efficiency Test TO STEERING CONTROL VALVE AND CHARGE CIRCUIT TO MOW CONTROL (FRONT CUTTING UNITS) TO LIFT CONTROL MANIFOLD TO MOW CONTROL (REAR CUTTING UNITS) GEAR PUMP BYPASS VALVE CROSSTRAX MANIFOLD TESTER CAP CAP PISTON (TRACTION) PUMP RH FRONT WHEEL MOTOR EFFICIENCY TEST SHOWN FROM STEERING CONTROL VALVE Figure 41 Procedure for Front Wheel Motor Efficiency Test NOTE: Over a period of time, a wheel motor can wear internally.
14.To test individual front wheel motors: Before opening hydraulic system, operate all hydraulic controls to relieve system pressure and avoid injury from pressurized hydraulic oil. See Relieving Hydraulic System Pressure in the General Information section of this chapter. 5. Attach a heavy chain to the rear of the machine frame and an immovable object to prevent the machine from moving during testing. 6. Chock front wheels to prevent wheel rotation. Make sure parking brake is applied. 7.
Piston (Traction) Pump Flow Test (Using Tester with Flow Meter and Pressure Gauge) TO STEERING CONTROL VALVE AND CHARGE CIRCUIT TO MOW CONTROL (FRONT CUTTING UNITS) TO LIFT CONTROL MANIFOLD TO MOW CONTROL (REAR CUTTING UNITS) GEAR PUMP BYPASS VALVE CROSSTRAX MANIFOLD TESTER PISTON (TRACTION) PUMP FROM STEERING CONTROL VALVE Figure 43 Procedure for Piston (Traction) Pump Flow Test This test measures piston (traction) pump output (flow).
5. Raise and support machine so all wheels are off the ground (see Jacking Instructions in Chapter 1 -- Safety). 6. Thoroughly clean junction of hydraulic hose and right side fitting on bottom of traction pump (Fig. 44). Disconnect hose from right side pump fitting. IMPORTANT: Make sure that the oil flow indicator arrow on the flow meter is showing that the oil will flow from the pump, through the tester and into the disconnected hydraulic hose. 7.
Relief Valve (PRV1) and (PRV2) Pressure Test ROTATION DIRECTION TO STEERING CONTROL VALVE AND CHARGE CIRCUIT TO LIFT CONTROL MANIFOLD MOTOR INLET GEAR PUMP BYPASS VALVE MOTOR OUTLET CASE DRAIN CROSSTRAX MANIFOLD PISTON (TRACTION) PUMP FROM STEERING CONTROL VALVE TESTER RELIEF VALVE (PRV1) TEST SHOWN DECK CONTROL MANIFOLD FROM LIFT CONTROL MANIFOLD Figure 45 The relief valve (PRV1) and (PRV2) pressure test should be performed to make sure that the cutting deck circuit relief pressures are correc
3. Read Precautions For Hydraulic Testing in this section. CAUTION 10.Watch pressure gauge carefully while slowly closing the tester flow control valve. As the relief valve lifts, the pressure gauge needle will momentarily stop. NOTE: Once the relief valve has opened, system pressure may continue to increase. 4. Raise and support operator seat to allow access to hydraulic deck control manifold. 5.
Gear Pump (P1) and (P2) Flow Test (Using Tester with Pressure and Flow Capabilities) TO STEERING CONTROL VALVE AND CHARGE CIRCUIT TO LIFT CONTROL MANIFOLD TESTER GEAR PUMP (P1) FLOW TEST SHOWN GEAR PUMP BYPASS VALVE CROSSTRAX MANIFOLD PISTON (TRACTION) PUMP FROM STEERING CONTROL VALVE DECK CONTROL MANIFOLD FROM LIFT CONTROL MANIFOLD Figure 47 Over a period of time, the gears and wear plates in the gear pump can wear. A worn pump will by-pass oil and make the pump less efficient.
3. Read Precautions For Hydraulic Testing in this section. CAUTION Before opening hydraulic system, operate all hydraulic controls to relieve system pressure and avoid injury from pressurized hydraulic oil. See Relieving Hydraulic System Pressure in the General Information section of this chapter. 4. Raise and support operator seat to allow access to hydraulic pump. 5. Identify suspected faulty pump section to be tested (Fig. 48). Thoroughly clean junction of gear pump fitting and hydraulic outlet hose.
Deck Motor Efficiency Test (Using Tester with Pressure Gauges and Flow Meter) ROTATION DIRECTION MOTOR INLET MOTOR OUTLET CASE DRAIN Install tester in series between fitting and return hose at motor outlet. CAP Disconnect case drain hose at traction deck bulkhead MEASURING CONTAINER #5 (RH FRONT) DECK MOTOR EFFICIENCY TEST SHOWN TO RESERVOIR TESTER MOW CONTROL MANIFOLD Figure 49 NOTE: Over a period of time, a deck motor can wear internally.
9. While watching pressure gauges, slowly close flow control valve on tester until a pressure of 1200 PSI (83 bar) is obtained. Before opening hydraulic system, operate all hydraulic controls to relieve system pressure and avoid injury from pressurized hydraulic oil. See Relieving Hydraulic System Pressure in the General Information section of this chapter. NOTE: The deck motors are connected in series.
Lift Relief Valve (PRV) Pressure Test TO STEERING CONTROL VALVE TO DECK CONTROL MANIFOLD (FRONT CUTTING UNITS) TO DECK CONTROL MANIFOLD (REAR CUTTING UNITS) GEAR PUMP PUMP (P5) INTERNAL CASE DRAIN PRESSURE GAUGE FROM MOW CONTROL MANIFOLD LIFT CONTROL MANIFOLD Figure 51 The lift relief valve (PRV) pressure test should be performed to make sure that the lift circuit relief pressure is correct. Procedure for Lift Relief Valve (PRV) Pressure Test 1.
5. Thoroughly clean test port (G4) on bottom of lift control manifold. Connect a 5000 PSI (350 bar) pressure gauge to test port. 2 6. After installing pressure gauge to manifold test port, start engine and run at idle speed. Check for any hydraulic leakage from test connections and correct before proceeding with test. 4 3 7. Move throttle to full speed (3200 RPM). IMPORTANT: Do not allow pressure to exceed 2500 PSI (172 bar).
Gear Pump (P4) Flow Test (Using Tester with Pressure Gauges and Flow Meter) TO STEERING CONTROL VALVE TO DECK CONTROL MANIFOLD (FRONT CUTTING UNITS) TO DECK CONTROL MANIFOLD (REAR CUTTING UNITS) GEAR PUMP TESTER PUMP (P5) INTERNAL CASE DRAIN FROM MOW CONTROL MANIFOLD LIFT CONTROL MANIFOLD Figure 53 The gear pump (P4) flow test should be performed to make sure that the cutting deck lift circuit has adequate hydraulic flow. 3. Read Precautions For Hydraulic Testing in this section.
4. Raise and support operator seat to allow access to hydraulic pump. 5. Thoroughly clean both ends of the hydraulic hose that connects gear pump (P4) outlet (Fig. 54) and lift control manifold P4 port. Remove hydraulic hose. Access to hydraulic hose at lift control manifold can be obtained from below the machine. IMPORTANT: Make sure that the oil flow indicator arrow on the flow meter is showing that the oil will flow from pump (P4), through the tester and to the lift control manifold. 13.
Lift Cylinder Internal Leakage Test TO STEERING CONTROL VALVE TO DECK CONTROL MANIFOLD (FRONT CUTTING UNITS) TO DECK CONTROL MANIFOLD (REAR CUTTING UNITS) (PARTIALLY RAISED) GEAR PUMP PLUG CAP PUMP (P5) INTERNAL CASE DRAIN CHECK FOR CYLINDER EXTENDING FROM MOW CONTROL MANIFOLD LIFT CONTROL MANIFOLD LEFT FRONT (#4) LIFT CYLINDER TEST SHOWN Figure 55 The lift cylinder internal leakage test should be performed if a cutting deck raise and lower problem is identified.
IMPORTANT: When capping lift cylinder fitting and hydraulic hose end, use a steel cap and plug to ensure that fluid leakage will not occur. Plastic plugs will not hold hydraulic pressure that will be developed during this test procedure. 3 2 4. Place a steel cap on the open lift cylinder fitting to seal the lift cylinder. Also, install a steel plug in the open end of the disconnected hose to prevent leakage or contamination. 1 5. Slowly lower the jack and remove it from under the lift arm.
Steering Relief Valve (R10) Pressure Test TO DECK CONTROL MANIFOLD (FRONT CUTTING UNITS) TO LIFT CONTROL MANIFOLD TO DECK CONTROL MANIFOLD (REAR CUTTING UNITS) GEAR PUMP PUMP (P5) INTERNAL CASE DRAIN TO TRACTION CHARGE CIRCUIT OUT T P IN R10 V1 STEERING WHEEL TURNED FOR RIGHT TURN STEERING CONTROL VALVE L R PRESSURE GAUGE STEERING CYLINDER Figure 59 Hydraulic System Page 4 -- 56 Groundsmaster 4300--D
The steering relief valve (R10) pressure test should be performed to make sure that the steering circuit relief pressure is correct. 12.If specification is not met, inspect steering control valve (see Steering Control Valve Service in the Service and Repairs section of this chapter). Procedure for Steering Relief Valve Pressure Test: 13.
Steering Cylinder Internal Leakage Test R10 STEERING WHEEL TURNED FOR RIGHT TURN STEERING CONTROL VALVE CAP LOOK FOR LEAKAGE STEERING CYLINDER (FULLY EXTENDED) Figure 61 The steering cylinder internal leakage test should be performed if a steering problem is identified. This test will determine if the steering cylinder is faulty.
Procedure for Steering Cylinder Internal Leakage Test: 1 1. Make sure hydraulic oil is at normal operating temperature. 2. Park machine on a level surface with the cutting decks lowered and PTO switch off. Make sure engine is off. Apply the parking brake. 3. Read Precautions For Hydraulic Testing. 2 CAUTION Before opening hydraulic system, operate all hydraulic controls to relieve system pressure and avoid injury from pressurized hydraulic oil.
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 system, park machine on a level surface, engage parking brake, lower cutting decks and stop engine. Remove key from the ignition switch. 1. If a component failure occurred in the closed loop traction circuit (e.g.
Check Hydraulic Lines and Hoses Check hydraulic lines and hoses daily for leaks, kinked lines, loose mounting supports, wear, loose fittings or deterioration. Make all necessary repairs before operating the machine. CAUTION Keep body and hands away from pin hole leaks or nozzles that eject hydraulic fluid under high pressure. Use paper or cardboard, not hands, to search for leaks. Hydraulic fluid escaping under pressure can have sufficient force to penetrate the skin and cause serious injury.
Filtering Closed--Loop Traction Circuit Filtering of a closed--loop hydraulic system after a major component failure (e.g. traction (piston) pump or wheel motor) is a requirement to prevent debris from transmitting throughout the system. If a closed--loop hydraulic system filtering tool is not used to ensure system cleanliness, repeat failures, as well as subsequent damage to other hydraulic components in the affected system, will occur.
Hydraulic System Start--up 1. After the hydraulic system components have been properly installed and if the traction pump was rebuilt or replaced, make sure traction pump housing is at least half full of clean hydraulic oil. 2. Make sure all hydraulic connections and lines are secured tightly. 3. Drain, flush and refill hydraulic system and change hydraulic oil filters if component failure was severe or system is contaminated (see Flush Hydraulic System in this section). 4.
Hydraulic Reservoir 105 to 115 ft--lb (143 to 155 N--m) 2 3 5 16 25 1 17 17 18 9 26 to 32 ft--lb (36 to 43 N--m) 12 10 11 13 12 13 6 22 4 23 8 15 24 14 14 7 22 26 RIGHT 26 24 20 21 FRONT 19 Figure 64 1. 2. 3. 4. 5. 6. 7. 8. 9. Suction strainer Tank cap Hydraulic reservoir Adapter Manifold O--ring Hydraulic hose O--ring Cap screw Hydraulic System 10. 11. 12. 13. 14. 15. 16. 17. 18.
Removal (Fig. 64) Installation (Fig. 64) 1. Park the machine on a level surface, engage parking brake, lower cutting decks and stop engine. Remove key from the ignition switch. 1. If fittings were removed from reservoir, lubricate and place new O--rings onto fittings. Install fittings into reservoir openings using marks made during the removal process to properly orientate fittings. Tighten fittings (see Hydraulic Fitting Installation in the General Information section of this chapter). 3.
Hydraulic Pump Drive Shaft RIGHT 5 FRONT 3 8 9 2 6 9 4 7 Permatex Threadlocker 10 34 to 42 ft--lb (46 to 56 N--m) 1 Antiseize Lubricant Figure 65 1. 2. 3. 4. Piston (traction) pump Flange nut (2 used) Flange head screw (2 used) Guard hoop Hydraulic System 5. Cap screw (2 used) 6. Engine flywheel 7. Cap screw (6 used) Page 4 -- 66 8. Drive shaft assembly 9. Flange nut (4 used) 10.
Removal (Fig. 65) Installation (Fig. 65) 1. Park the machine on a level surface, engage parking brake, lower cutting decks and stop engine. Remove key from the ignition switch. 1. Apply antiseize lubricant to traction pump input shaft. 3. Remove two (2) cap screws (item 5) and flange nuts (item 9) that secure drive shaft yoke to piston pump input shaft. 4. Remove six (6) cap screws (item 7) that secure drive shaft flange to engine flywheel. 5. Remove drive shaft assembly from machine.
Hydraulic Pump Assembly 24 22 2 23 21 10 9 15 3 15 30 18 1 4 17 17 14 19 11 16 33 21 25 26 37 33 8 32 39 32 35 20 23 38 36 29 12 Antiseize Lubricant 25 34 5 15 5 RIGHT 6 FRONT 31 13 25 7 6 27 25 28 Figure 67 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13.
NOTE: Traction pump and gear pump should be removed from machine as an assembly. Once removed from machine, pumps can be separated for service. 3 Removal (Fig. 67) 1. Park the machine on a level surface, engage parking brake, lower cutting decks and stop engine. Remove key from the ignition switch. 2 1 2. Read the General Precautions for Removing and Installing Hydraulic System Components at the beginning of the Service and Repairs section of this chapter. Figure 68 1. Piston (traction) pump 2.
9. Loosen and remove two (2) carriage screws (item 12) and flange nuts (item 15) that secure pump support bracket (item 8) to frame. 10.Remove two (2) flange screws (item 3) and flange nuts (item 9) that secure traction pump flange to machine frame. IMPORTANT: Make sure to not damage machine components while removing the pump assembly. 4 5 3 6 7 2 9 1 11. Carefully lift pump assembly from the machine. 12.Separate traction and gear pumps (Fig. 70): 8 A.
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Piston (Traction) Pump Service 18 19 5 23 4 15 20 14 12 9 2 13 8 1 7 5 6 24 25 26 17 24 16 9 11 13 27 26 12 34 36 30 29 53 10 28 32 33 31 3 8 22 21 54 35 40 43 52 41 51 44 42 37 45 46 50 49 39 47 38 48 Figure 71 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18.
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Gear Pump Service 33 ft--lb (45 N--m) 12 11 10 9 1 2 7 6 13 8 21 22 23 19 17 6 3 4 5 8 16 21 14 24 20 18 33 ft--lb (45 N--m) 15 Figure 72 1. 2. 3. 4. 5. 6. 7. 8. Front cover Dowel pin (16 used) Square section seal (8 used) Back--up ring (8 used) Pressure seal (8 used) Thrust plate (8 used) Drive shaft Driven gear (2 used) 9. 10. 11. 12. 13. 14. 15. 16.
IMPORTANT: Mark the relative positions of the gear teeth and the thrust plates so they can be reassembled in the same position. Do not touch the gear surfaces as residue on hands may be corrosive to gear finish. DIAGONAL LINE 7. Remove the thrust plates and seals from each pump section. Before removing each gear set, apply marking dye to mating teeth to retain ”timing”. Pump efficiency may be affected if the teeth are not installed in the same position during assembly.
Front Wheel Motors 25 5 11 14 9 10 28 6 23 29 30 7 31 32 33 16 80 to 100 ft--lb (109 to 135 N--m) 12 13 24 21 26 27 22 19 8 18 5 11 15 20 14 1 28 3 17 2 RIGHT FRONT 9 70 to 90 ft--lb (95 to 122 N--m) 315 to 385 ft--lb (427 to 521 N--m) 4 Figure 74 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11.
12.Thoroughly clean hydraulic line ends and fittings on wheel motor to prevent hydraulic system contamination. Before opening hydraulic system, operate all hydraulic controls to relieve system pressure and avoid injury from pressurized hydraulic oil. See Relieving Hydraulic System Pressure in the General Information section of this chapter. Removal (Fig. 74) 1. Park the machine on a level surface, engage parking brake, lower cutting decks and stop engine. Remove key from the ignition switch. 2.
6. Install new lock nut (item 17) onto the wheel motor shaft to secure wheel hub to motor shaft. 7. Remove caps or plugs from disconnected hydraulic lines and fittings. 10.Install front wheel to machine (see Front Wheel Installation in the Service and Repairs section of Chapter 6 -- Chassis). 11. Lower machine to ground. 8. Lubricate and position new O--rings to fittings on wheel motor.
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Rear Wheel Motors 11 15 12 70 to 90 ft--lb (95 to 122 N--m) 16 2 3 4 7 6 5 13 10 RIGHT FRONT 9 1 8 270 to 330 ft--lb (366 to 447 N--m) 14 Figure 75 1. 2. 3. 4. 5. Lug nut (5 used per wheel) Rear axle assembly Hydraulic fitting (2 used per motor) Wheel assembly Tie rod Hydraulic System 6. 7. 8. 9. 10. Wheel stud (5 used per hub) O--ring Woodruff key Cap screw (4 used per motor) Lock washer (4 used per motor) Page 4 -- 80 11. 12. 13. 14. 15.
Removal (Fig. 75) 10.Label all hydraulic hoses for assembly purposes. Remove hydraulic hoses from fittings on wheel motor. Allow hoses to drain into a suitable container. CAUTION 11. Put clean plugs in disconnected hydraulic hoses and fittings to prevent system contamination. 1. Park the machine on a level surface, engage parking brake, lower cutting decks and stop engine. Remove key from the ignition switch. 2.
8. Place wheel hub on motor shaft and secure with new lock nut (item 14). 11. Torque wheel hub lock nut (item 14) from 270 to 330 ft--lb (366 to 447 N--m). 9. Install wheel assembly to the machine and secure with five (5) lug nuts. 12.Torque wheel lug nuts evenly in a crossing pattern from 70 to 90 ft--lb (95 to 122 N--m). 10.Lower the machine to the ground. 13.Make sure hydraulic tank is full. Add correct oil if necessary.
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Wheel Motor Service 14 17 16 15 12 18 21 20 19 13 22 23 4 1 10 3 5 3 3 6 2 45 to 55 ft--lb (61 to 75 N--m) 7 8 9 3 3 11 Figure 76 1. 2. 3. 4. 5. 6. 7. 8. Cap screw (7 used) End cover Body seal (5 used) Commutator ring Commutator Commutator ring Manifold Stator 9. 10. 11. 12. 13. 14. 15. 16.
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CrossTraxTM AWD Manifold 11 15 12 8 9 14 13 10 6 7 14 6 1 6 5 RIGHT 2 4 FRONT 3 Figure 77 1. 2. 3. 4. 5. AWD manifold Hydraulic tube Hydraulic tube Hydraulic tube O--ring 6. 7. 8. 9. 10. Hydraulic fitting (7 used) O--ring Dust cap (2 used) Diagnostic fitting (2 used) O--ring Removal (Fig. 77) 1. Park the machine on a level surface, engage parking brake, lower cutting decks and stop engine. Remove key from the ignition switch. 2.
6. Put caps or plugs on disconnected lines and fittings to prevent contamination. 3. Remove caps and plugs from disconnected lines and fittings. 7. Support manifold to prevent it from falling. Remove three (3) cap screws and lock washers that secure manifold to machine frame. Locate and retrieve three (3) spacers from between bracket and manifold. 4. Lubricate and install new O--ring(s) on manifold fittings.
CrossTraxTM AWD Manifold Service 220 in--lb (24.8 N--m) 25 ft--lb (33 N--m) 12 3 2 5 11 4 220 in--lb (24.8 N--m) 1 25 ft--lb (33 N--m) 2 2 220 in--lb (24.8 N--m) 3 3 10 4 5 9 8 7 7 6 6 46 ft--lb (62 N--m) 120 in--lb (13.5 N--m) Figure 78 1. 2. 3. 4. AWD manifold O--ring Plug (zero leak #6) Seal kit 5. 6. 7. 8. Check valve Plug (zero leak #4) O--ring Orifice (.040) For control manifold service procedures, see Deck Control Manifold Service in this section.
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Deck Control Manifold 4 3 1 2 12 2 13 3 6 4 7 5 8 6 6 11 10 7 9 RIGHT FRONT Figure 79 1. 2. 3. 4. 5. Deck control manifold O--ring Diagnostic fitting Dust cap Hydraulic tube Hydraulic System 6. 7. 8. 9. O--ring Hydraulic hose O--ring Hydraulic tube Page 4 -- 90 10. 11. 12. 13.
Removal (Fig. 79) 1. Park the machine on a level surface, engage parking brake, lower cutting decks and stop engine. Remove key from the ignition switch. 2. Read the General Precautions for Removing and Installing Hydraulic System Components at the beginning of the Service and Repairs section of this chapter. 3. Tilt operator seat and engage seat prop to retain seat in the raised position. 2. Position deck control manifold to frame. Install three (3) flange head screws but do not fully tighten. 3.
Deck Control Manifold Service 8 UP 25 ft--lb (33 N--m) 35 ft--lb (47 N--m) 50 ft--lb (68 N--m) 1 9 20 ft--lb (27 N--m) 2 3 7 6 4 50 ft--lb (68 N--m) 8 6 10 20 ft--lb (27 N--m) 20 ft--lb (27 N--m) 3 4 5 35 ft--lb (47 N--m) 2 8 60 in--lb (6.7 N--m) 25 ft--lb (33 N--m) 11 50 ft--lb (68 N--m) 11 8 UP Figure 81 1. 2. 3. 4. Deck control manifold Logic element (LC1/LC2) Proportional relief valve (PRV1/PRV2) Solenoid coil 5. 6. 7. 8. Nut Plug (zero leak #4) O--ring Plug (zero leak #8) 9.
NOTE: The deck control manifold uses several zero leak plugs. These plugs have a tapered sealing surface on the plug head that is designed to resist vibration induced plug loosening. The zero leak plugs also have an O--ring to provide a secondary seal. If zero leak plug removal is necessary, lightly rap the plug head using a punch and hammer before using an allen wrench to remove the plug: the impact will allow plug removal with less chance of damage to the socket head of the plug.
Cutting Deck Motor 22 19 21 8 6 4 17 19 4 3 4 2 2 20 3 3 3 22 2 8 17 4 6 3 2 19 4 2 18 23 6 21 10 15 16 2 3 2 8 4 19 3 11 4 6 10 14 4 13 2 12 3 1 8 4 2 5 2 RIGHT 3 FRONT 6 4 7 8 9 5 Figure 82 1. 2. 3. 4. 5. 6. 7. 8. Hydraulic deck motor (#4) O--ring 90o hydraulic fitting O--ring Hydraulic hose O--ring 45o hydraulic fitting O--ring 9. 10. 11. 12. 13. 14. 15. 16.
5. Put caps or plugs on disconnected hoses and fittings to prevent contamination. #4 6. Remove two (2) socket head screws and flat washers that secure hydraulic motor to the cutting deck (Fig. 84). Remove hydraulic motor and O--ring from deck. 7. Cover top of spindle to prevent debris from entering spindle. A spindle plug (see Special Tools in this chapter) can be used to cover spindle. 8. If hydraulic fittings are to be removed from motor, mark fitting orientation to allow correct assembly.
Cutting Deck Motor Service 33 ft--lb (45 N--m) 26 ft--lb (35 N--m) 18 19 16 13 10 14 10 9 6 5 15 3 17 6 7 1 12 26 ft--lb (35 N--m) 12 4 7 8 10 11 2 Figure 86 1. 2. 3. 4. 5. 6. 7. Dust seal Retaining ring Flange washer Shaft seal Front flange Pressure seal Backup gasket 8. 9. 10. 11. 12. 13. Front wear plate Drive gear Dowel pin Idler gear O--ring Body 14. 15. 16. 17. 18. 19.
5. Remove motor from the vise. Turn motor so that the shaft end is facing down. Remove cap screws. 6. Separate rear cover from body. Lift rear cover from motor. 7. Carefully remove body. Lift body straight up to remove. Make sure the rear wear plate remains on the drive and idler gear shafts. Remove and discard O-rings from the body. Locate and retrieve dowel pins. IMPORTANT: Note position of the open and closed side of the wear plates before removing.
Assembly (Fig. 86) NOTE: When assembling the motor, check the marker line on each part to make sure the parts are properly aligned during assembly. 1. Lubricate O--rings, pressure seals, back--up gaskets and wear plate grooves with a thin coat of petroleum jelly. Lubricate all other internal parts freely with clean hydraulic oil. 2. Install new seals into front flange (Fig. 88): A. Press shaft seal into front flange until it reaches the bottom of the bore. B.
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Lift Control Manifold 5 10 11 12 12 6 3 4 12 13 1 8 7 3 15 3 14 17 9 16 RIGHT FRONT 2 Figure 90 1. 2. 3. 4. 5. 6. Lift control manifold Flange head screw (2 used) O--ring Hydraulic hose Hydraulic hose Hydraulic hose 7. 8. 9. 10. 11. 12. Hydraulic hose Hydraulic hose Hydraulic hose Hydraulic tube Hydraulic tube O--ring Removal (Fig. 90) 1. Park the machine on a level surface, engage parking brake, lower cutting decks and stop engine. Remove key from the ignition switch. 2.
2. Position lift control manifold to frame. Install two (2) flange head screws but do not fully tighten. Make sure that cutting decks are fully lowered before loosening hydraulic lines, cartridge valves or plugs from lift control manifold. If decks are not fully lowered as manifold components are loosened, decks may drop unexpectedly. 5. Disconnect hydraulic hoses and lines from fittings in manifold. Allow lines to drain into a suitable container. Remove and discard O--rings. 6.
Lift Control Manifold Service 60 in--lb (6.7 N--m) 5 7 6 4 60 in--lb (6.7 N--m) 7 20 ft--lb (27 N--m) 20 ft--lb (27 N--m) 3 8 2 20 ft--lb (27 N--m) 25 ft--lb (33 N--m) 9 RIGHT FRONT 1 Figure 92 1. Lift control manifold 2. Solenoid valve (S1) 3. Solenoid valve (S2) 4. Solenoid coil 5. Nut 6. Nut NOTE: The ports on the lift control manifold are marked for easy identification of components.
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Lift Cylinder RIGHT FRONT 6 11 7 10 8 12 9 13 1 2 5 3 12 4 11 67 to 83 ft--lb (91 to 112 N--m) Figure 93 1. 2. 3. 4. 5. Lift cylinder Pivot shaft Flange head screw Lift arm (#1 shown) Flat washer 6. 7. 8. 9. Hydraulic hose O--ring 90o hydraulic fitting O--ring 10. 11. 12. 13. NOTE: The procedure for lift cylinder removal and installation is the same for all Groundsmaster 4300--D lift cylinders. Figure 93 shows the center, front (deck #1) lift cylinder.
4. Label all hydraulic connections for assembly purposes. Thoroughly clean hydraulic connections prior to loosening hydraulic lines from lift cylinder. CAUTION Before opening hydraulic system, operate all hydraulic controls to relieve system pressure and avoid injury from pressurized hydraulic oil. See Relieving Hydraulic System Pressure in the General Information section of this chapter. 5. Disconnect hydraulic hoses from fittings in lift cylinder that is to be removed.
Lift Cylinder Service 1 14 9 8 7 4 40 ft--lb (54 N--m) 13 6 10 2 11 12 5 3 1 13 9 8 3 5 14 2 12 4 11 10 7 6 Figure 96 1. 2. 3. 4. 5. Grease fitting Shaft Dust seal Head Head seal 6. 7. 8. 9. 10. Retaining ring Back up washer O--ring Piston Piston seal 11. 12. 13. 14. O--ring Grease fitting Lock nut Barrel NOTE: The lift cylinders used on Groundsmaster 4300--D machines are very similar. Service procedures for all lift cylinders are the same.
Disassembly (Fig. 96) Assembly (Fig. 96) 1. Remove oil from lift cylinder into a drain pan by slowly pumping the cylinder shaft. Plug both ports and clean the outside of the cylinder. 1. Make sure all lift cylinder parts are clean before assembly. 2. Mount lift cylinder securely in a vise by clamping on the clevis end of the barrel. Use of a vise with soft jaws is recommended. 3. Using a spanner wrench, rotate head clockwise until the edge of the retaining ring (item 6) appears in the barrel opening.
Steering Control Valve 4 Antiseize Lubricant 20 1 84 to 120 in--lb (9.5 to 13.5 N--m) 20 to 26 ft--lb (28 to 35 N--m) 21 3 Antiseize Lubricant 6 17 16 5 11 10 8 2 12 9 22 19 14 7 19 RIGHT FRONT 15 13 7 18 Figure 97 1. 2. 3. 4. 5. 6. 7. 8. Steering column Hydraulic fitting (4 used) Steering wheel Steering wheel cover Gear pump Socket head screw (4 used) Flange nut O--ring 9. 10. 11. 12. 13. 14. 15.
7. Position steering column brace (item 13) to machine and secure with four (4) screws and flange nuts. CAUTION 8. Slide rubber bellows to bottom of steering column. Before opening hydraulic system, operate all hydraulic controls to relieve system pressure and avoid injury from pressurized hydraulic oil. See Relieving Hydraulic System Pressure in the General Information section of this chapter. 7. Disconnect hydraulic lines from steering control valve. Allow lines to drain into a suitable container. 8.
Steering Control Valve Service 26 25 24 23 21 22 20 19 18 16 14 12 11 9 17 8 10 15 7 4 6 13 5 4 3 2 20 to 24 ft--lb (27 to 33 N--m) 1 Figure 100 1. 2. 3. 4. 5. 6. 7. 8. 9. Screw (5 used) O--ring (5 used) End cover O--ring Outer gearwheel Inner gearwheel Distributor plate O--ring Cardan shaft 10. 11. 12. 13. 14. 15. 16. 17. 18. Spool Sleeve Cross pin Spring set Ring Thrust washer Bearing Shaft seal Ball stop 19. 20. 21. 22. 23. 24. 25. 26.
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Steering Cylinder 90 to 120 ft--lb (123 to 162 N--m) 27 6 10 8 9 11 23 36 4 15 35 30 21 24 37 22 7 28 29 14 18 12 20 29 16 7 28 70 to 90 ft--lb (95 to 122 N--m) 19 2 3 20 33 26 34 5 13 25 RIGHT FRONT 1 32 31 270 to 330 ft--lb (366 to 447 N--m) 17 Figure 101 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13.
Removal (Fig. 101) 1. Park the machine on a level surface, engage the parking brake, lower the cutting decks and stop the engine. Remove the key from the ignition switch. 2. Read the General Precautions for Removing and Installing Hydraulic System Components at the beginning of the Service and Repairs section of this chapter. CAUTION 2. If removed, press ball joint into barrel and secure with retaining ring. 3.
Steering Cylinder Service 6 11 8 14 1 3 12 17 7 5 2 16 4 15 8 9 10 13 Figure 103 1. 2. 3. 4. 5. 6. Front shaft (1”) Rear shaft (1.250”) Front head (1”) Rear head (1.250”) Roll pin Dust seal 7. 8. 9. 10. 11. 12. O--ring External collar (2 used) Piston Rear head seal Front head seal Wear ring Disassembly (Fig. 103) 1. Remove oil from steering cylinder into a drain pan by slowly pumping the cylinder shaft. Plug both ports and clean the outside of the cylinder. 13. 14. 15. 16. 17.
Inspection IMPORTANT:Make sure to not damage O--ring (item 7) as piston is installed over roll pin hole in front shaft. Use eye protection such as goggles when using compressed air. 1. Wash all cylinder components in solvent. Dry parts with compressed air. 2. Inspect internal surface of barrel for deep scratches, out--of--roundness and bending. 3. Inspect head, shaft and piston for excessive pitting, scoring and wear. 4. Replace steering cylinder if internal components are found to be worn or damaged.
Oil Cooler 18 19 9 RIGHT 10 8 20 FRONT 10 12 1 13 12 17 15 16 17 21 3 5 2 6 7 3 11 4 14 Figure 104 1. 2. 3. 4. 5. 6. 7. Screen assembly Oil cooler bracket Flange head screw (8 used) Foam seal (2 used) Draw latch Rivet (2 used) Oil cooler Hydraulic System 8. 9. 10. 11. 12. 13. 14. Hydraulic hose (2 used) 90o hydraulic fitting (2 used) Hose clamp (4 used) Foam seal (2 used) Washer (4 used) Cap screw (2 used) Mount plate (2 used) Page 4 -- 116 15. 16. 17. 18. 19. 20. 21.
Removal (Fig. 104) Installation (Fig. 104) 1. Park machine on a level surface, lower cutting decks, stop engine, engage parking brake and remove key from the ignition switch. 1. If removed, install hydraulic fittings, clamps and brackets to oil cooler using Figure 104 as a guide. 2. Unlatch and open the rear screen. 3. Label all hydraulic connections for assembly purposes. Thoroughly clean hydraulic connections prior to loosening hydraulic hoses. 2.
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Chapter 5 Electrical System GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . 3 Operator’s Manual . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Toro Electronic Controller (TEC) . . . . . . . . . . . . . . . 3 CAN--bus Communications . . . . . . . . . . . . . . . . . . . 3 Electrical Drawings . . . . . . . . . . . . . . . . . . . . . . . . . . 3 SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . .
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General Information Operator’s Manual The Operator’s Manual provides information regarding the operation, general maintenance and maintenance intervals for your Groundsmaster 4300--D machine. Refer to that publication for additional information when servicing the machine.
Special Tools Order Special Tools from your Toro Distributor. Some tools may be available locally. Multimeter The multimeter can test electrical components and circuits for current, resistance or voltage. Obtain this tool locally. NOTE: Toro recommends the use of a DIGITAL Volt-Ohm--Amp multimeter when testing electrical circuits. The high impedance (internal resistance) of a digital meter in the voltage mode will make sure that excess current is not allowed through the meter.
Diagnostic Display The Diagnostic Display (Fig. 4) can be connected to the wiring harness connector located inside the control arm to verify correct electrical functions of the machine. TEC controller inputs and outputs can be checked using the Diagnostic Display. Toro Part Number for Diagnostic Display: 85--4750 Toro Part Number for Overlay (English): 117--0171 NOTE: Diagnostic Display overlays are available in several languages for your Groundsmaster.
Troubleshooting CAUTION Remove all jewelry, especially rings and watches, before doing any electrical troubleshooting or testing. Disconnect the battery cables unless the test requires battery voltage. For effective troubleshooting and repairs, there must be a good understanding of the electrical circuits and components used on this machine (see Chapter 8 -- Foldout Drawings). If the machine has any interlock switches by--passed, they must be reconnected for proper troubleshooting and safety.
All machine fault codes are retained in the TEC controller memory. The three (3) most recent fault codes that have occurred within the last forty (40) hours of operation can be retrieved using the diagnostic light. To retrieve these fault codes from the controller memory, perform the following switch sequence: 1. Operator seat should be UNOCCUPIED, traction pedal in neutral, parking brake released and PTO switch in the OFF position. 2. Place mow speed limiter in the TRANSPORT position. 3.
Diagnostic Display Groundsmaster 4300--D machines are equipped with a TEC controller which controls machine electrical functions. The controller monitors various input switches (e.g. ignition switch, seat switch, etc.) and energizes outputs to actuate solenoids or relays for the requested machine function. 3 For the controller to control the machine as desired, each of the input switches, output solenoids and relays must be connected and functioning properly.
6. The Diagnostic Display will illuminate the LED associated with each of the inputs when that input is in the position identified on the Diagnostic Display overlay. Individually, change the position of each of the inputs (i.e. sit on seat, press traction pedal, etc.), and note that the appropriate LED on the Diagnostic Display toggles on and off when the input state is changed (see chart below). Repeat for all inputs that can be changed by hand. 7.
Verify Diagnostic Display Output Functions B. If the output LED’s are on as specified, but the machine does not function properly, consider that the controller is operating correctly and a problem exists with some other component. Inspect electrical components and circuit for the affected function. Also, suspect a non-electrical problem (e.g. hydraulic component problem). Repair as necessary.
TEC Controller Logic Chart Start (Operator in Seat) Run (No Operator in Seat) X X X X X X X Mow (C.U.
Starting Problems Problem Possible Causes No electrical power to machine (including gauges). Battery is discharged. Ignition switch or circuit wiring is faulty. Fusible link harness at the engine starter motor is faulty. Battery cables are loose or corroded. Fuse F1--1 (15 amp) or F1--2 (10 amp) is faulty. Starter solenoid clicks, but starter will not crank. Battery is discharged. NOTE: If the starter solenoid clicks, the problem is not Battery cables are loose or corroded. in the interlock circuit.
Starting Problems (Continued) Problem Possible Causes Engine cranks, but should not, when the traction pedal is depressed. Traction neutral switch is out of adjustment. Nothing happens when start attempt is made. Control panel lights and gauges operate with the ignition switch in RUN. Traction pedal is not in neutral position. Traction neutral switch or circuit wiring is faulty. Operator seat is unoccupied OR the parking brake is not applied. Cutting decks are engaged (PTO switch is ON).
General Run and Transport Problems Problem Possible Causes Engine continues to run, but should not, when the ignition switch is turned off. Engine fuel stop solenoid is faulty. Ignition switch or circuit wiring is faulty. Main power relay or circuit wiring is faulty. Engine continues to run, but should not, when the traction pedal is engaged with no operator in the seat. Seat switch or circuit wiring is faulty. Traction neutral switch is out of adjustment.
Cutting Deck Operating Problems Problem Possible Causes The cutting decks remain engaged, but should not, with no operator in the seat. Seat switch or circuit wiring is faulty. TEC controller is faulty. Cutting decks run, but should not, when raised. Cutting A hydraulic problem in cutting deck circuit exists (see decks shut off with PTO switch. Troubleshooting section of Chapter 4 - Hydraulic System). TEC controller is faulty. Cutting decks run, but should not, when raised.
Cutting Deck Operating Problems (Continued) Problem Possible Causes The rear cutting decks do not operate. Front cutting decks operate. Cutting decks are able to raise and lower. Deck control manifold PRV1 solenoid coil or circuit wiring is faulty. A hydraulic problem in rear mow circuit exists (see Troubleshooting section of Chapter 4 - Hydraulic System). TEC controller is faulty. None of the cutting decks will lower. Mow speed limiter is in the transport position.
Electrical System Quick Checks Battery Test (Open Circuit Test) Use a digital multimeter to measure the battery voltage. Voltage Measured Battery Charge Level Set the multimeter to the DC volts setting. The battery should be at a temperature of 60o to 100oF (16o to 38oC). The ignition switch should be in the OFF position and all accessories turned off. Connect the positive (+) multimeter lead to the positive battery post and the negative (--) multimeter lead to the negative battery post.
Check Operation of Interlock Switches CAUTION The interlock switches are for the protection of the operator and bystanders and to ensure correct operation of the machine. Do not bypass or disconnect switches. Check the operation of the interlock switches daily for proper operation. Replace any malfunctioning switches before operating the machine.
Adjustments Traction Neutral Switch The traction neutral switch is a normally open proximity switch that closes when the traction pedal is in the neutral position. The switch mounts to a bracket on the traction pump (Fig. 14). The sensing plate for the traction neutral switch is the traction lever bracket that is secured to the pump control arm. FRONT 3 5 6 4 Adjustment 1.
Parking Brake Switch The parking brake switch is a normally open proximity switch. The parking brake switch is attached to the bottom of the brake pedal (Fig. 16). When the parking brake is not applied, the parking brake detent is positioned near the target end of the parking brake switch so the switch is closed. The parking brake detent is moved away from the switch when the parking brake is applied causing the switch to open. 5 Adjustment 1.
Mow/Transport Switch The mow/transport switch is a normally closed proximity switch that opens when the mow speed limiter is placed in the transport position. The switch mounts to a bracket on the footrest platform (Fig. 17). The sensing plate for the mow/transport switch is a tab on the mow speed limiter. 3 Adjustment 2 1. The gap between the mow/transport switch and the mow speed limiter should be from 0.070” to 0.100” (1.8 to 2.5 mm). 2.
Component Testing For accurate resistance and/or continuity checks, electrically disconnect the component being tested from the circuit (e.g. unplug the ignition switch connector before doing a continuity check of the switch). NOTE: For engine component testing information, see the Kubota Workshop Manual, Diesel Engine, 05--E3B Series at the end of Chapter 3 -- Kubota Diesel Engine.
Indicator Lights Glow Plug Indicator Light 3. Apply 12 VDC to terminals 1A and 2A (Fig. 20). The glow plug indicator light should come on when the ignition switch is placed in the RUN position prior to placing the ignition switch in START. The light should stay lit for approximately six (6) seconds while the ignition switch is left in the RUN position. The indicator light should also be illuminated when the ignition switch is in the START position. 4. Ground terminals 1B and 2B (Fig. 20). 6.
Hour Meter The hour meter is located on the outside of the control arm. Hobbs 1. Remove control arm covers to gain access to hour meter and meter terminals (see Control Arm Disassembly in the Service and Repairs section of Chapter 6 -Chassis). QUARTZ 00001 HOURS 2. Make sure ignition switch is in the OFF position. Locate the hour meter and disconnect the wire harness electrical connector from the meter. 1 10 + 3.
PTO Switch The PTO switch is mounted on the control panel and allows the cutting decks to operate when the front of the switch is depressed. An indicator light on the switch identifies when the PTO switch is engaged. The TEC controller monitors the position of the PTO switch (up or down). Using inputs from the PTO switch and other switches in the interlock system, the controller controls the energizing of the hydraulic solenoid valves used to drive the cutting deck motors. 7.
Headlight Switch The headlight switch is located on the operator side of the control arm. This rocker switch allows the headlights to be turned on and off. Testing 1. Remove inside control arm cover to gain access to headlight switch (see Control Arm Disassembly in the Service and Repairs section of Chapter 6 -- Chassis). 1 2. Make sure ignition switch is in the OFF position. Disconnect wire harness electrical connector from the headlight switch. 3.
Seat Switch The seat switch is normally open and closes when the operator seat is occupied. This switch is used as an input for the TEC controller. If the traction system or PTO switch is engaged when the operator raises out of the seat, the engine will stop. The seat switch is located directly under the operator seat. 1 Testing 1.
Joystick Raise and Lower Switches Two (2) micro switches for the joystick are located on the lift control that is attached to the control arm. The rear switch on the control is used to lower (and engage) the cutting decks and the front switch to raise (and disengage) them. These switches are used as inputs for the TEC controller. A normally open contact in the switch closes when the joystick is positioned to either lower or raise the cutting decks.
Traction Neutral Switch The traction neutral switch is a normally open proximity switch that closes when the traction pedal is in the neutral position. The switch mounts to a bracket on the traction pump (Fig. 31). The sensing plate for the traction neutral switch is the traction lever bracket that is secured to the pump control arm. The neutral switch is used as an input for the TEC controller. D.
Parking Brake Switch The parking brake switch is a normally open proximity switch. The parking brake switch is attached to the bottom of the brake pedal (Fig. 32). The parking brake switch is used as an input for the TEC controller. D. Turn ignition switch to the ON position (do not start engine) and verify with a multimeter that machine wire harness connector terminal for pink wire has system voltage (12 VDC) present.
Mow/Transport Switch The mow/transport switch is a normally closed proximity switch that opens when the mow speed limiter is placed in the transport position. The switch mounts to a bracket on the footrest platform. The sensing plate for the mow/ transport switch is the mow speed limiter. The mow/ transport switch is used as an input for the TEC controller. 4.
Start Relay The start relay is used in the engine starting circuit. When energized by the TEC controller, the start relay provides a current path to energize the engine starter solenoid. The start relay is attached to a frame bracket under the hood next to the hydraulic pump drive shaft (Fig. 34). The TEC controller controls and monitors the operation of the start relay.
Main Power and Glow Relays The Groundsmaster electrical system includes two identical relays for current control. The main power and glow relays are attached to a frame bracket under the hood next to the hydraulic pump drive shaft (Fig. 36). Relays can be identified by a tag on the wire harness. 6. Disconnect voltage and test leads from the relay terminals. Replace relay if necessary.
Toro Electronic Controller (TEC) The Groundsmaster 4300--D uses a Toro Electronic Controller (TEC) to monitor the condition of various switches (inputs) and then direct power output to allow certain machine functions. The controller is located behind the control arm access cover next to the fuse block (Fig. 38).
Fuses The fuse block is located behind the control arm access cover (Fig. 39). In addition to the fuses in the fuse block, a 2 amp fuse (F3) is included in the wire harness to protect the logic power circuit for the TEC controller. This fuse resides in a fuse holder near the battery (Fig. 41). 1 Identification and Function Use Figure 40 to identify each individual fuse and its correct amperage.
Diode Assembly A diode assembly (Fig. 42) is used in the Groundsmaster 4300--D engine wire harness. The diode is used for circuit protection from voltage spikes that occur when the engine starter solenoid is de--energized. Refer to wire harness drawings in Chapter 8 -- Foldout Drawings for additional diode assembly information. 2 Testing Locate diode assembly and remove cable tie that secures diode to wire harness. Unplug the diode from the wire harness for testing. The diode (Fig.
Fusible Link Harness The Groundsmaster 4300--D uses four (4) fusible links for circuit protection. Three (3) of these fusible links are located in a harness that connects the starter B+ terminal to the wire harness (Figs. 44 and 45). The remaining fusible link is included in the wire harness and connects the starter terminal to the engine run solenoid pull coil. If any of these links should fail, current to the protected circuit will cease.
Hydraulic Solenoid Valve Coil The Groundsmaster 4300--D hydraulic system uses several hydraulic solenoid valve coils for system control. The deck control manifold includes two (2) solenoid valves (Fig. 46) and the lift control manifold includes three (3) solenoid valves (Fig. 47). When the solenoid coils are energized, hydraulic valve shift occurs to control hydraulic flow. Testing of the coils can be done with the coil installed on the hydraulic valve. Testing 1.
Temperature Sender The changing resistance of the temperature sender signals the console temperature gauge to indicate engine coolant temperature level during machine operation. When coolant temperature rises to approximately 221oF (105oC), temperature sender resistance causes the temperature gauge to provide an input to the TEC controller. This controller input causes the high temperature warning light to illuminate and the cutting decks to shut down.
High Temperature Shutdown Switch The high temperature shutdown switch is located on the water pump housing (Fig. 50). The high temperature shutdown switch is normally open and closes when engine coolant temperature reaches approximately 239oF (115oC). When excessive coolant temperature causes the shutdown switch to close, the engine shuts down. There is a tan wire attached to the shutdown switch. 5. Replace shutdown switch if specifications are not met. 6.
Oil Pressure Switch The engine oil pressure switch is located on the engine near the oil filter (Fig.52). The oil pressure switch is a normally closed switch that opens with pressure. The oil pressure switch should open at approximately 8 PSI (0.56 kg/cm2). The TEC controller monitors the operation of the oil pressure switch. The switch and its circuit wiring should be tested as a controller input with the Diagnostic Display (see Special Tools and Troubleshooting in this chapter).
Fuel Stop Solenoid The fuel stop solenoid used on your Groundsmaster must be energized for the diesel engine to run. The solenoid is mounted to the injection pump on the engine (Fig. 53). The TEC controller monitors the operation of the fuel stop solenoid. The solenoid and its circuit wiring should be tested as a controller output with the Diagnostic Display (see Special Tools and Troubleshooting in this chapter).
Fuel Pump The fuel pump used on the Groundsmaster 4300--D is attached to the inside of the left side frame rail near the fuel tank (Fig. 55). IMPORTANT: When testing fuel pump, make sure that pump is not operated without fuel. 10.Connect wire harness electrical connector to the engine fuel stop solenoid. 11. Bleed the fuel system. 12.Lower and secure operator seat and hood. Fuel Pump Specifications DANGER 64 fl oz/min (1.
Service and Repairs NOTE: See the Kubota Workshop Manual, Diesel Engine, 05--E3B Series at the end of Chapter 3 -- Kubota Diesel Engine for engine electrical component repair information. Battery Storage If the machine will be stored for more than 30 days: 1. Remove the battery from the machine and charge it fully (see Battery Service in this section). 2. Either store battery on a shelf or on the machine. 4. Store battery in a cool atmosphere to avoid quick deterioration of the battery charge. 5.
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. 8 1 CAUTION 4 FRONT 3 When working with batteries, use extreme caution to avoid splashing or spilling electrolyte. Electrolyte can destroy clothing and burn skin or eyes. Always wear safety goggles and a face shield when working with batteries. 2 Electrolyte Specific Gravity Fully charged: 1.
Battery Testing B. If the battery has recently been charged, remove the battery surface charge before performing the load test. Disconnect the engine fuel stop solenoid to prevent the engine from starting. Engage the starter motor for ten (10) seconds to remove battery surface charge. Reconnect the fuel stop solenoid. 1. Conduct a hydrometer test of the battery electrolyte. IMPORTANT: Make sure the area around the cells is clean before opening the battery caps. A.
Battery Charging CAUTION Follow the battery charger manufacturer’s instructions when using a battery charger. NOTE: Using specific gravity of the battery cells is the most accurate method of determining battery condition. 1. Determine the battery charge level from either its specific gravity or open circuit voltage. Battery Charge Level Specific Gravity Open Circuit Voltage 100% 1.265 12.68 75% 1.225 12.45 50% 1.190 12.24 25% 1.155 12.06 0% 1.120 11.89 2.
Hydraulic Solenoid Valve Coil A hydraulic solenoid valve coil on the deck control manifold (Fig. 58) or lift control manifold (Fig. 59) can be replaced without opening the hydraulic system. FRONT Removal 2 1. Park machine on a level surface, lower cutting decks, stop engine and engage parking brake. Remove key from ignition switch. 2. Locate the solenoid valve coil that is to be replaced. A. Tilt operator seat up to gain access to hydraulic deck control manifold.
Chapter 6 Chassis Table of Contents Chassis SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . 2 Operator’s Manual . . . . . . . . . . . . . . . . . . . . . . . . . . 2 SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 SERVICE AND REPAIRS . . . . . . . . . . . . . . . . . . . . . . 4 Wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Steering Column . . . . . . . . .
Specifications Item Description Front Tire Pressure (26.5 x 14.0 -- 12, 4 ply, tubeless) 12 to 15 PSI (83 to 103 kPa) Rear Tire Pressure (20 x 12.0 -- 10, 4 ply, tubeless) 12 to 15 PSI (83 to 103 kPa) Wheel Lug Nut Torque 70 to 90 ft--lb (95 to 122 N--m) General Information Operator’s Manual The Operator’s Manual provides information regarding the operation, general maintenance and maintenance intervals for your Groundsmaster 4300--D machine.
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Service and Repairs Wheels 10 8 9 11 7 2 3 1 5 6 70 to 90 ft--lb (95 to 122 N--m) 4 RIGHT 7 FRONT Figure 2 1. 2. 3. 4. Front wheel motor (LH shown) Brake assembly (LH shown) Front wheel hub Lock nut Chassis 5. 6. 7. 8. Brake drum Front wheel Lug nut (5 used per wheel) Rear wheel motor (LH shown) Page 6 -- 4 9. Rear wheel hub 10. Rear wheel 11.
Removal (Fig. 2) Installation (Fig. 2) 1. Park machine on a level surface, lower cutting decks, stop engine, engage parking brake and remove key from the ignition switch. 1. Install wheel and secure with five (5) lug nuts. 2. Chock wheels to prevent machine from shifting. 3. Torque lug nuts evenly in a crossing pattern from 70 to 90 ft--lb (95 to 122 N--m). 3. Loosen wheel lug nuts. 2. Lower machine to ground.
Steering Column 4 Antiseize Lubricant 1 84 to 120 in--lb (9.5 to 13.5 N--m) 20 to 26 ft--lb (28 to 35 N--m) 20 21 3 Antiseize Lubricant 6 17 16 5 11 10 8 2 12 9 22 14 7 19 19 RIGHT 15 13 7 FRONT 18 Figure 3 1. 2. 3. 4. 5. 6. 7. 8. Steering column Hydraulic fitting (4 used) Steering wheel Steering wheel cover Gear pump Socket head screw (4 used) Flange nut O--ring 9. 10. 11. 12. 13. 14. 15.
5. Remove platform shroud from machine to allow access to steering column fasteners (Fig. 4). 9. Install steering wheel cover to steering wheel. 3 A. Remove cover plate from platform. 1 B. Remove fasteners that secure shroud to machine. 2 4 C. Remove shroud from machine. D. Locate and retrieve two (2) rubber bushings and spacers. 5 3 6. Slide rubber bellows up steering column to allow access to fasteners that secure steering column to machine. 6 7 8 7.
Brake Service 25 5 11 14 9 10 28 6 23 29 30 7 31 32 33 16 12 13 24 21 26 27 9 22 8 18 19 15 20 14 11 1 28 3 17 2 RIGHT FRONT 5 70 to 90 ft--lb (95 to 122 N--m) 315 to 385 ft--lb (427 to 521 N--m) 4 Figure 6 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. LH wheel motor Lug nut (5 used per wheel) Hub Wheel assembly Hydraulic fitting (2 used per motor) Hydraulic tube Hydraulic tube Cap screw (2 used per wheel shield) O--ring Hydraulic tube O--ring 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22.
6. Remove return spring and clevis pin that secure brake cable to brake actuator lever. Position brake cable end away from lever. 7. Remove brake drum. 8. Install brake drum. 9. Position brake cable end to brake actuator lever. Secure cable to actuator lever with clevis pin and return spring. IMPORTANT: DO NOT hit wheel hub, puller or wheel motor with a hammer during wheel hub removal or installation. Hammering may cause damage to the wheel motor. 10.
Rear Axle Motor Housings 30 35 34 22 33 32 24 21 31 23 4 25 12 13 3 37 9 11 10 20 2 37 14 36 29 9 70 to 90 ft- lb (95 to 122 N- m) 20 27 5 8 7 26 3 6 1 17 18 RIGHT 19 28 15 FRONT 16 270 to 330 ft- lb (366 to 447 N- m) Figure 8 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13.
C. Apply grease to the inside and outside of the new flange bushings. Removal (Fig. 8) 1. Park machine on a level surface, lower cutting decks, stop engine, engage parking brake and remove key from the ignition switch. D. Press new flange bushings into the top and bottom of the axle tube until bushing flange bottoms on tube. 2. Chock front wheels to prevent machine from shifting. E. After bushing installation, make sure that motor housing shaft slides easily into bushings.
Rear Axle 6 90 to 120 ft- lb (123 to 162 N- m) 8 9 10 27 36 23 4 11 15 35 30 21 24 37 22 41 7 44 42 43 28 45 14 11 28 20 29 16 7 2 45 40 70 to 90 ft- lb (95 to 122 N- m) 31 29 20 18 39 19 12 5 3 33 14 26 34 1 RIGHT 25 FRONT 32 38 13 270 to 330 ft- lb (366 to 447 N- m) 17 Figure 9 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15.
Rear Axle Removal (Fig. 9) D. Press new bushings into the axle pivot bore until bushing is flush with axle. 1. Park machine on a level surface, lower cutting decks, stop engine, engage parking brake and remove key from the ignition switch. E. After bushing installation, make sure that pivot pin slides easily into bushings. If binding is noted, locate and correct source of binding. 2. Chock front wheels to prevent machine from shifting. 3.
Rear Axle Installation (Fig. 9) 1. Position the rear axle assembly to the frame. Install thrust washer (item 7) between each side of axle and frame. Slide pivot pin through frame, thrust washers and axle. Make sure that roll pin on pivot pin is positioned in frame reliefs. 2. Install thrust washer (item 9) and jam nut (item 10) onto pivot pin. Torque jam nut (item 10) from 90 to 120 ft--lb (123 to 162 N--m). Make sure that rear axle can still pivot freely after jam nut is tightened. 3.
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Control Arm 1 2 FRONT 5 RIGHT 3 16 4 19 17 22 22 6 23 24 26 8 13 29 11 12 27 28 9 7 18 8 10 25 14 5 20 15 16 21 Figure 12 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. Arm rest Headlight switch LH control arm cover Screw (2 used) Lock nut Screw RH control arm cover Bushing Control arm assembly Seat wire harness Chassis 11. 12. 13. 14. 15. 16. 17. 18. 19. 20.
Disassembly (Fig. 12) 4 1. Park machine on a level surface, lower cutting decks, stop engine and engage parking brake. Remove key from ignition switch. 3 2 2. Loosen latches and remove access cover from outside of control arm. 3. At front of control arm, remove screw (item 6) and lock nut (item 5) that secure control arm covers to each other. 1 4. Remove five (5) washer head screws (item 16) that secure each cover to control arm. Figure 13 1. Wire harness 2. Harness foam seal 3.
Operator Seat 12 10 11 1 14 9 5 6 8 17 7 20 2 21 4 21 15 16 22 13 3 23 24 24 RIGHT 23 25 26 FRONT 19 18 Figure 15 1. 2. 3. 4. 5. 6. 7. 8. 9. Seat Seat base Seat adjuster w/latch Flat washer (4 used) Seat switch harness Seat switch Washer head screw (2 used) Armrest bracket Spacer 10. 11. 12. 13. 14. 15. 16. 17. 18. Armrest Cap screw Flange nut Flat washer (4 used) Flange head screw (3 used) Socket head screw (4 used) Seat adjuster Flat washer Seat bracket (2 used) 19. 20. 21. 22.
Removal (Fig. 15) 1. Park machine on a level surface, lower cutting decks, stop engine, engage parking brake and remove key from the ignition switch. 1 2 2. Disconnect negative battery cable from battery (see Battery Service in the Service and Repairs section of Chapter 5 -- Electrical System). 3. Disconnect seat switch electrical connector from wire harness (Fig. 16). 4 4. Remove two (2) flange head screws and flat washers that secure control arm assembly to seat base (Figs. 16 and 17).
Mechanical Seat Suspension 31 18 40 37 34 11 41 1 19 28 29 26 20 38 30 6 8 23 4 24 10 22 7 2 27 16 21 33 36 14 12 13 25 17 35 9 32 3 39 15 42 5 Figure 18 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. Upper housing Weight adjust knob Lower housing Scissor assembly Lock nut Weight adjuster Drive arm Extension spring (2 used) Roller guide Weight adjust knob Cap Suspension boot Pivot block (2 used) Damper Chassis 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28.
IMPORTANT: When removing the seat suspension, make sure to support the control arm to prevent damage to the throttle cable, control arm electrical components and control arm wiring harness. 13 14 FRONT 12 Removal (Figs. 18 and 19) 11 1 1. Park machine on a level surface, lower cutting decks, stop engine, engage parking brake and remove key from the ignition switch. 8 2 5 3 9 7 2.
Front Lift Arms 75 to 95 ft--lb (102 to 128 N--m) Permatex Threadlocker Permatex Threadlocker 18 2 5 3 6 11 17 15 Antiseize Lubricant 13 2 1 Permatex 14 Threadlocker 7 18 11 12 11 14 10 2 13 19 8 75 to 95 ft--lb (102 to 128 N--m) 15 12 4 16 RIGHT FRONT Antiseize Lubricant 2 9 9 6 Permatex Threadlocker 10 135 to 165 ft--lb (183 to 223 N--m) Figure 20 1. 2. 3. 4. 5. 6. 7.
1. Park machine on a level surface, lower cutting decks, stop engine, engage parking brake and remove key from the ignition switch. 2. Remove cutting deck from front lift arm to be removed (see Cutting Deck Carrier Frame Removal in the Service and Repairs section of Chapter 7 -- Cutting Decks). 2. If pivot shaft (item 16) was removed from lift arm, insert pivot shaft in lift arm and secure with cap screw (item 19). 3. Slide front lift arm onto pivot shaft. 4. Secure front lift arm to machine: A.
Rear Lift Arms 135 to 165 ft--lb (183 to 223 N--m) RIGHT 3 FRONT Permatex Threadlocker Antiseize Lubricant 1 9 16 135 to 165 ft--lb (183 to 223 N--m) Permatex Threadlocker Permatex Threadlocker 4 6 12 12 75 to 95 ft--lb (102 to 128 N--m) 10 5 8 6 10 13 11 2 15 12 14 9 7 Antiseize Lubricant Figure 22 1. 2. 3. 4. 5. 6. Bridge plate #2 lift arm #3 lift arm Cap screw Thrust washer (2 used) Cap screw (2 used) 7. 8. 9. 10. 11.
C. Remove screw that secures r--clamp to lift arm. Position r--clamp and hydraulic hoses away from lift arm. C. Install screws, flat washers (items 5 and 10) and flange nut (item 7) to bridge plate, bulkhead bracket, pivot shafts and frame bracket. D. Pivot lift cylinder rod end away from lift arm. D. Torque 1/2” fasteners (items 4 and 8) from 75 to 95 ft--lb (102 to 128 N--m). Then, torque 5/8” fasteners (item 6) from 135 to 165 ft--lb (183 to 223 N--m). 4.
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Chapter 7 Cutting Decks Table of Contents Cutting Decks SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . 3 Operator’s Manual . . . . . . . . . . . . . . . . . . . . . . . . . . 3 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . 4 Factors That Can Affect Quality of Cut . . . . . . . . . 4 SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 ADJUSTMENTS . . . . . . . . . . . . . . .
Specifications MOUNTING: All cutting decks are supported by independent lift arms and are interchangeable to any cutting deck positions. The Groundsmaster 4300--D uses five (5) cutting decks. DISCHARGE: Clippings are discharged from the rear of the mowing decks. Pre--drilled mounting holes in the cutting deck allow attachment of optional mulching baffle. CONSTRUCTION: Deck chamber and frame are welded steel construction reinforced with channels and plates.
General Information CAUTION Never install or work on the cutting decks or lift arms with the engine running. Always stop engine and remove key from ignition switch first. Operator’s Manual Cutting Decks The Cutting Deck Operator’s Manual provides information regarding the operation, general maintenance and maintenance intervals for the cutting deck on your Groundsmaster machine. Refer to that publication for additional information when servicing the cutting deck.
Troubleshooting There are a number of factors that can contribute to unsatisfactory quality of cut, some of which may be turf conditions. Turf conditions such as excessive thatch, “sponginess”, uneven ground conditions or attempting to cut off too much grass height may not always be overcome by adjusting the machine. It is important to remember that the lower the height--of--cut, the more critical these factors are.
Special Tools Order special tools from your Toro Distributor. Rear Roller Bearing and Seal Installation Tools These tools are used to assemble the cutting deck rear roller.
Adjustments CAUTION Never install or work on the cutting decks or lift arms with the engine running. Always stop engine and remove key from ignition switch first. See the Cutting Deck Operator’s Manual for adjustment procedures for cutting decks on the Groundsmaster 4300--D. Blade Stopping Time The blades of the cutting decks are to come to a complete stop in approximately five (5) seconds after the PTO is disengaged.
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Service and Repairs CAUTION Never install or work on the cutting decks or lift arms with the engine running. Always stop engine and remove key from ignition switch first. Blade Spindle Assembly 11 2 12 1 3 4 5 6 RIGHT 7 8 88 to 108 ft--lb (120 to 146 N--m) FRONT 10 9 Figure 3 1. 2. 3. 4. Flange nut (6 used) Hydraulic deck motor Spindle plate Cutting deck Cutting Decks 5. 6. 7. 8. O--ring Spindle assembly Stud (6 used) Cutting blade Page 7 -- 8 9. 10. 11. 12.
Removal (Fig. 3) 1. Park machine on a level surface, lower cutting decks, stop engine, engage parking brake and remove key from the ignition switch. 2. Remove two (2) socket head screws and flat washers that secure hydraulic motor to the cutting deck (Fig. 4). Remove hydraulic motor and O--ring from deck. 3. Cover top of spindle to prevent debris from entering spindle. A spindle plug (see Special Tools in this chapter) can be used to cover spindle. 4. Start the engine and raise the cutting deck.
Blade Spindle Service Disassembly (Fig. 5) 2 6 1. Remove blade spindle from cutting deck (see Blade Spindle Removal in this section). 2. Loosen and remove spindle nut from top of spindle shaft. 4 130 to 160 ft--lb (177 to 216 N--m) 11 10 3. Remove the spindle shaft from the spindle housing which may require the use of an arbor press. The spindle shaft spacer should remain on the spindle shaft as the shaft is being removed. 9 12 8 7 1 4.
3. Using an arbor press, push the bearing cups into the top and bottom of the spindle housing. The top bearing cup must contact the outer bearing spacer previously installed, and the bottom bearing cup must contact the large snap ring. Make sure that the assembly is correct by supporting the first bearing cup and pressing the second cup against it (Fig 7). PRESS 4 4. Pack the bearing cones with grease. Apply a film of grease on lips of oil seals. 5.
Rear Roller 4 29 to 35 ft--lb (40 to 47 N--m) 6 5 3 29 to 35 ft--lb (40 to 47 N--m) 1 2 7 29 to 35 ft--lb (40 to 47 N--m) 3 8 4 6 5 7 8 29 to 35 ft--lb (40 to 47 N--m) RIGHT FRONT Figure 9 1. Deck frame 2. Rear roller assembly 3. Grease fitting Cutting Decks 4. Roller shaft screw 5. Roller mount 6. Flange head screw Page 7 -- 12 7. Skid bracket 8.
Removal (Fig. 9) 1. Park machine on a level surface, lower cutting decks, stop engine, engage parking brake and remove key from the ignition switch. 30 ft--lb (41 N--m) 4 1 3 2. If cutting deck is equipped with a roller scraper (Fig. 10), remove fasteners securing left and right scraper rod brackets to roller mounts. Remove scraper rod assembly. 29 to 35 ft--lb (40 to 47 N--m) 2 3. Remove four (4) flange head screws securing roller mounts to rear of deck frame.
Rear Roller Service Disassembly (Fig. 11) 2 1. Remove bearing lock nut from each end of roller shaft. 50 to 60 ft--lb (68 to 81 N--m) 3 4 2. Loosely secure roller assembly in bench vise and lightly tap one end of roller shaft until outer seals and bearing are removed from opposite end of roller tube. Remove second set of outer seals and bearing from roller tube by tapping on opposite end of shaft. Remove shaft from roller tube. 5 6 7 1 2 4 3 5 3.
3. From the roller tube end with only the inner seal installed, carefully install the roller shaft into the roller tube. Make sure that seals are not damaged as shaft is installed. 4. Install new bearing and outer seals into second end of roller tube: NOTE: After roller is installed to cutting deck, lubricate roller grease fittings, rotate roller to properly distribute grease in bearings and clean excess grease from roller ends. A properly assembled roller should rotate with less than 5 in--lbs (0.
Front Roller Service Disassembly (Fig. 17) 6 1. Park machine on a level surface, lower cutting decks, stop engine, engage parking brake and remove key from the ignition switch. 2. Remove front roller mounting bolt. 3. Remove front roller assembly and spacer from deck frame. 4. To remove bearings and bearing spacer from front roller: 1 5 2 A. Insert punch through end of roller and drive opposite bearing out by alternating taps to opposite side of inner bearing race.
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Cutting Deck Carrier Frame RIGHT FRONT 5 13 4 10 2 6 1 3 11 18 12 3 2 10 9 15 13 1 6 4 11 9 16 7 17 14 7 8 8 Decks #2 and #3 Decks #1, #4 and #5 16 15 14 Figure 18 1. 2. 3. 4. 5. 6. Carrier frame Lynch pin Thrust washer Pivot shaft Lift arm (#4 shown) Flange nut (2 used per deck) Cutting Decks 7. 8. 9. 10. 11. 12.
Removal (Fig. 18) Each cutting deck is suspended from a carrier frame. The cutting deck carrier frame is attached to the lift arm and allows the cutting deck to pivot on the lift arm pivot shaft. Cutting deck positions are identified in Figure 19. #4 #1 #5 To remove cutting decks from the lift arm pivot shaft: 1. Park machine on a level surface, lower cutting decks, stop engine, engage parking brake and remove key from the ignition switch. 2.
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Chapter 8 Foldout Drawings Table of Contents Foldout Drawings HYDRAULIC SCHEMATIC . . . . . . . . . . . . . . . . . . . . . 3 ELECTRICAL SCHEMATIC . . . . . . . . . . . . . . . . . . . . 4 Electrical Schematic Sheet 1 of 2 (Serial numbers below 315000000) . . . . . . . . . . . . . . . . . . 4 Electrical Schematic Sheet 2 of 2 (Serial numbers below 315000000) . . . . . . . . . . . . . . . . . . 5 Electrical Schematic (Serial numbers 315000001 to 403430000) . . . . . . . . . . . . . . . . . . .
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GEAR PUMP BYPASS VALVE CROSSTRAX MANIFOLD STEERING CONTROL VALVE STEERING CYLINDER PISTON (TRACTION) PUMP LIFT CONTROL MANIFOLD DECK CONTROL MANIFOLD Groundsmaster 4300--D Hydraulic Schematic Page 8 -- 3
Groundsmaster 4300--D Electrical Schematic Sheet 1 of 2 All relays and solenoids are shown as de-- energized. All ground wires are black.
(PRV1) (PRV2) TORO ELECTRONIC CONTROLLER Groundsmaster 4300--D Electrical Schematic Sheet 2 of 2 All relays and solenoids are shown as de-- energized. All ground wires are black.
All relays and solenoids are shown as de--energized. All ground wires are black.
All relays and solenoids are shown as de--energized. All ground wires are black.
Groundsmaster 4300--D Main Wire Harness Drawing (Serial numbers below 315000000) Page 8 -- 8
RED PINK RED BROWN/BLACK VIOLET/BLACK RED WHITE BLUE PINK PINK RED BLACK BLACK ORANGE BLACK BLACK RED BLACK WHITE/GREEN GREEN/WHITE BLUE PINK GRAY YELLOW BLACK PINK RED/BLACK WHITE/BLUE BLACK GREEN BLACK GRAY RED/BLACK VIOLET BLACK BLACK BLACK PINK ORANGE BLACK GRAY BLACK GRAY BLACK BLACK BLACK BLACK BLACK BLUE/YELLOW BLACK YELLOW/GREEN GREEN BLACK RED/BLACK RED BROWN WHITE/VIOLET RED TAN Groundsmaster 4300--D Main Wire Harness Diagram (Serial numbers below 31500
120--6384 Rev E Groundsmaster 4300--D Main Wiring Harness Drawing (Serial numbers 315000001 to 403430000) CV Page 8 -- 10
120--6384 Rev E Groundsmaster 4300--D Main Wiring Harness Drawing (Serial numbers 315000001 to 403430000) Page 8 -- 11
122--1457 Rev A Groundsmaster 4300--D Main Wiring Harness Drawing (Serial numbers 403430001 to 405699999) CV Page 8 -- 12
122--1457 Rev A Groundsmaster 4300--D Main Wiring Harness Diagram (Serial numbers 403430001 to 405699999) Page 8 -- 13
122--1727 Rev A Groundsmaster 4300--D Main Wiring Harness Drawing (Serial numbers above 405700000) CV Page 8 -- 14
122--1727 Rev A Groundsmaster 4300--D Main Wiring Harness Diagram (Serial numbers above 405700000) Page 8 -- 15
NOTE CLOCK POSITION Groundsmaster 4300--D Seat Wire Harness Drawing Page 8 -- 16
(PRV2) (PRV1) GRAY GREEN/WHITE WHITE PINK BLACK PINK PINK PINK BLUE/WHITE BLACK PINK BLUE PINK GRAY/BLACK WHITE/BLUE VIOLET TAN/WHITE BLUE BROWN BROWN/WHITE RED/BLACK ORANGE GREEN/YELLOW YELLOW GREEN/WHITE TAN WHITE GREEN/BLACK ORANGE/BLACK BLACK BLUE/YELLOW PINK BLACK YELLOW/BLUE BROWN/YELLOW PINK BLACK RED PINK RED WHITE RED YELLOW/GREEN BLACK TAN/BLACK VIOLET/WHITE GRAY ORANGE BLUE/WHITE VIOLET/BLACK WHITE/BLACK WHITE/VIOLET BROWN BLACK BLACK GREEN (PRV2) (PRV1) BLACK/WHITE RED/WHITE
Groundsmaster 4300--D Engine Wire Harness Drawing Page 8 -- 18
RED BLACK WHITE RED/BLACK FUSIBLE LINK BLUE WHITE PINK ORANGE BLACK GREEN/WHITE TAN GRAY BLUE Groundsmaster 4300--D Engine Wire Harness Diagram Page 8 -- 19
