Form No. 16226SL Rev D Groundsmaster® 4300-D (Model No. 30864 - Serial No. 314000101 & Up) © 2020—The Toro® Company 8111 Lyndale Avenue South Bloomington, MN 55420 Original Instructions (EN) Contact us at www.Toro.com.
Revision History Revision Date A 2016 B 03/2018 Updated Engine, Electrical chapters and Foldout Drawings. Added Revision History and published in new format. C 03/2019 Updated Chassis chapter. D 07/2020 Updated Electrical chapter and Foldout Drawings. Revision History Description Initial issue.
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.
NOTES: NOTES: Page 4 Groundsmaster® 4300-D 16226SL Rev D
Preface The purpose of this publication is to provide the service technician with the information for troubleshooting, testing, and repair of the major systems and components of Groundsmaster 4300-D (Model No. 30864) machines that are powered by a Yanmar diesel engine. Refer to the Operator’s Manuals for operating, maintenance, and adjustment instructions. Space is provided in Torque Specifications (page 2–4) of this book to insert the Operator’s Manuals and Parts Catalog for your machine.
g186523 Figure 1 Service Procedure Icons The following icons appear throughout this Service Manual to bring attention to specific important details of a service procedure. Critical Process This icon is used to highlight: • installing safety equipment (shields, guards, seat belts, brakes and R.O.P.S.
Table of Contents Preface ................................................................................................................ 5 Chapter 1: Safety ............................................................................................ 1–1 Safety Instructions ....................................................................................... 1–2 Jacking Instructions ..................................................................................... 1–6 Safety and Instructional Decals .
Wire Harness Drawing - Main (sheet 2 of 2) (Serial numbers below 403430000) ................................................................................................A–12 Wire Harness Drawing - Main (sheet 1 of 2) (Serial numbers 403430001 to 405699999).............................................................................................A–13 Wire Harness Drawing - Main (sheet 2 of 2) (Serial numbers 403430001 to 405699999).........................................................................
Chapter 1 Safety Table of Contents Safety Instructions ................................................................................................................................ 1–2 Supervisor’s Responsibilities ............................................................................................................. 1–2 Before Operating the Machine ........................................................................................................... 1–2 While Operating the Machine ..........
Safety Instructions The Groundsmaster 4300-D machine 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 the Machine • Sit on the seat when starting and operating the machine. • Anytime you park the machine (short or long term), lower the cutting decks to the ground. IMPORTANT When you lower the cutting deck to the ground, the pressure from the hydraulic lift circuit releases and prevents the cutting deck from accidentally lowering. • If you park the machine on a slope, block or chock the wheels.
Maintenance and Service • Before servicing or making any adjustments to the machine, lower the cutting • • • • • • • • • • • • • • • • Safety: Safety Instructions decks, set the parking brake, shut off the engine, and remove the key from the key switch. Ensure that the machine is in safe operating condition by keeping all the nuts, bolts, and screws tight. Do not store the machine or a fuel container inside where there is an open flame, such as near a water heater or furnace.
Maintenance and Service (continued) battery cable and then the positive cable. Disconnect the engine wire harness from the engine ECU. Also, disconnect the wire harness connector from the machine controller and disconnect the terminal connector from the alternator, attach the welder ground cable not more than 610 mm (2 ft) from the welding location. • At the time of manufacture, the machine conformed to the safety standards for riding mowers.
Jacking Instructions CAUTION Failing to properly support the machine with appropriate jack stands can cause the machine to move or fall and can result in personal injury. When changing the attachments, tires, or performing other services, do the following steps: • Use correct blocks, hoists, and jacks to raise and support the machine. • Park the machine on a solid level surface, such as a concrete floor.
Raising the Rear of the Machine g186591 Figure 3 1. 2. Rear wheel Rear axle pivot bracket 3. Jack stand location 1. Set the parking brake and block the 2 front wheels with chocks to prevent the machine from moving. 2. Position the jack securely at the center of the rear axle under the axle pivot bracket. Lift the rear of the machine off the ground. 3. Position the jack stands under the frame to support the machine (Figure 3).
Safety: Safety and Instructional Decals Page 1–8 Groundsmaster® 4300-D 16226SL Rev D
Chapter 2 Specifications and Maintenance Table of Contents Specifications ....................................................................................................................................... 2–2 Decimal and Millimeter Equivalents ................................................................................................... 2–2 U.S. to Metric Conversions ................................................................................................................
Specifications Insert a copy of the Operator’s Manuals and Parts Catalogs for your machine at the end of this chapter. Additionally, if any optional equipment or accessories are installed to your machine, insert the Installation Instructions, Operator’s Manuals, and Parts Catalogs for those options at the end of this chapter. The maintenance procedures and recommended service intervals for your machine are covered in the Operator’s Manuals.
U.S. to Metric Conversions To Convert Into Multiply By Miles Kilometers 1.609 Yards Meters 0.914 Feet Meters 0.305 Feet Centimeters 30.48 Inches Meters 0.025 Inches Centimeters 2.54 Inches Millimeters 25.4 Square Miles Square Kilometers 2.59 Square Feet Square Meters 0.093 Square Inches Square Centimeters 6.452 Acre Hectare 0.405 Cubic Yards Cubic Meters 0.765 Cubic Feet Cubic Meters 0.028 Cubic Inches Cubic Centimeters 16.39 Tons (Short) Metric Tons 0.
Torque Specifications The 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 the fasteners will apply to all the fasteners which do not have a specific requirement identified in this Service Manual.
Calculating the Torque Values When Using a Drive-Adapter Wrench g034401 Figure 6 Using a drive-adapter wrench (e.g., crowfoot wrench) in any position other than 90º and 270º to the frame of the torque wrench will affect the torque value measured by the torque wrench because of the effective length (lever) of the torque wrench changes.
Standard Torque for Dry, Zinc Plated, and Steel Fasteners (Inch Series) Thread Size # 6 - 32 UNC # 6 - 40 UNF # 8 - 32 UNC # 8 - 36 UNF # 10 - 24 UNC # 10 - 32 UNF Grade 1, 5 and 8 with Thin Height Nuts SAE Grade 1 Bolts, Screws, Studs, and Sems with Regular Height Nuts (SAE J995 Grade 2 or Stronger Nuts) in-lb in-lb N∙cm 10 ± 2 13 ± 2 147 ± 23 13 ± 2 25 ± 5 282 ± 56 18 ± 2 30 ± 5 339 ± 56 SAE Grade 5 Bolts, Screws, Studs, and Sems with Regular Height Nuts (SAE J995 Grade 2 or Stronger Nuts)
Standard Torque for Dry, Zinc Plated, and Steel Fasteners (Metric Fasteners) Thread Size 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 Recommended Torque 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 Thread Cutting Screws (Zinc Plated Steel) Type 1, Type 23 or Type F Thread Size Baseline Torque** No. 6 - 32 UNC 20 ± 5 in-lb No. 8 - 32 UNC 30 ± 5 in-lb No.
Shop Supplies The procedures found in this Service Manual may recommend the use of commonly used shop supplies (lubricants, sealants, and adhesives). A symbol denoting the use of a shop supply may appear in figures that support a procedure. Always refer to the written procedure for specific information regarding the type and the application of a shop supply. IMPORTANT Always follow manufacturers instructions when using or storing shop supplies.
Anti-seize lubricant Used to prevent corrosion, galling, and seizure between metal parts. Most often applied to shafts and bores during assembly. Unless otherwise specified, high viscosity regular grade lithium-graphite based anti-seize lubricant should be used. Grease Can be used to pre-fill (pack) bearings, boots, and seals before assembly, ease installation of components during assembly, or fill cavities between moving parts through grease fittings after assembly.
Special Tools You can order these special tools from your Toro Distributor. Some tools may also be available from a local tool supplier. Hydraulic Pressure Testing Kit Toro Part No. TOR47009 Use this kit to take various pressure readings for diagnostic tests. Quick disconnect fittings are provided to attach directly to the mating fittings on the machine test ports without the tools. A high-pressure hose is given for remote readings.
150 LPM (40 GPM) Hydraulic Tester Toro Part No. AT40002 Use this tester to test the hydraulic circuits and components for flow and pressure capacities. The tester flow measurement maximum is 151 LPM (40 GPM). This tester includes the following: Load Valve – Turn the valve to restrict the flow to create a simulated working load in the circuit. Pressure Gauge – A glycerine filled pressure gauge 0 to 34,500 kPa (0 to 5,000 psi) to provide operating circuit pressure.
Hydraulic Test Fitting Kit Toro Part No. TOR4079 This kit includes a variety of O-ring face seal fittings to let you connect the test gauges into the system.
High Flow Hydraulic Filter Kit Toro Part Number: TOR6011 The high flow hydraulic filter kit is designed with large flow (150 L/minute or 40 gallons/minute) and high pressure (34,500 kPa or 5,000 psi) capabilities. This kit provides for bi-directional filtration which prevents filtered unwanted material from entering into the circuit regardless of the flow direction.
Multimeter Obtain this tool locally The meter can test the electrical components and circuits for current, resistance, or voltage. Note: Use a digital multimeter when testing the electrical circuits. The high impedance (internal resistance) of a digital meter in the voltage mode ensures that the excess current is not allowed through the meter. This excess current can damage the circuits that are not designed to carry it. Battery Terminal Protector Toro Part No.
Specifications and Maintenance: Special Tools Page 2–16 Groundsmaster® 4300-D 16226SL Rev D
Chapter 3 Diesel Engine Table of Contents Specifications ....................................................................................................................................... 3–2 Engine................................................................................................................................................ 3–2 General Information ..............................................................................................................................
Specifications Engine Item Description Make/Designation Yanmar 3TNV86CT: 4-cycle, 3 cylinder common-rail water cooled diesel with EGR, turbocharged, and diesel-particulate filter (DPF). EPA Tier 4 Final compliant. Bore 86 mm (3.38 inches) Stroke 90 mm (3.54 inches) Total displacement 1568 cm3 (95.
General Information This chapter gives information about specifications and repair of the Yanmar diesel engine used in the Groundsmaster 4300-D machine. The general maintenance procedures are described in the Operator’s Manual. Detailed information on engine troubleshooting, testing, disassembly, and assembly is identified in the Yanmar Engine Service Manual and Troubleshooting Manual. Additionally, some engine repair procedures are described in this manual.
Engine Electronic Control Unit (ECU) (continued) IMPORTANT Do not plug or unplug the engine ECU for 30 seconds after the machine key switch is turned off. The engine ECU may remain energized even though the key switch is in the OFF position. If you must disconnect the engine ECU for any reason, ensure that the key switch is in the OFF position with the key removed before disconnecting the engine ECU.
Yanmar Engine g188100 Figure 8 The engine used on your Groundsmaster 4300-D machine is a Yanmar TNV Series, turbocharged, diesel engine that complies with EPA Tier 4F emission regulations.
Regeneration (continued) built up soot and turning it into ash. The different types of regeneration used are listed in order based on the amount of particulate matter in the soot filter (least to most). Note: The user interface and InfoCenter displays for DPF regeneration changed with machine software 120-6375J. Use the InfoCenter About screen to verify the software installed on the machine.
Regeneration (continued) Types of regeneration that are performed manually (while the machine is stationary) Type Conditions Description Parked Occurs when exhaust back pressure in the DPF increases due to continued soot buildup. May be caused by prolonged operation at low engine speed, low engine load, or the use of incorrect fuel or engine oil. Manually initiate a parked regeneration as soon as possible.
Soot Accumulation If the types of regeneration that are performed automatically (while the machine is operating) are bypassed or not allowed to complete before shutting off the engine, soot will continue to accumulate in the soot filter. When enough soot accumulates, the engine ECU will generate an engine fault to prompt a parked or recovery regeneration. In addition to an engine fault appearing on the InfoCenter, the engine output power will be reduced.
Shutting Off the Engine IMPORTANT The engine used on the Groundsmaster 4300-D machine is turbo-charged. Before shutting off the engine after mowing or full-load operation, allow the engine to run at low-idle speed for 5 minutes. This allows the turbocharger and internal engine components to adequately cool-down. Failure to allow this cool-down period may lead to premature turbocharger and engine failure.
Service and Repairs Air Cleaner System g188092 Figure 9 1. Clamp 7. Air cleaner bracket 13. Air cleaner mounting band 2. Air cleaner outlet hose 8. Flange-head screw (2 each) 14. Spring 3. Hose clamp (2 each) 9. Air cleaner stand 15. Bolt 4. Hose clamp 10. Bolt (2 each) 16. Adapter 5. Air cleaner assembly 11. Yanmar engine 17. Service indicator 6. Flange nut (4 each) 12. Nut 18.
Removing the Air Cleaner System Note: Refer to the Operator's Manual for maintenance procedures and intervals of the air cleaner. 1. Park the machine on a level surface, lower the cutting decks, shut off the engine, set the parking brake, and remove the key from the key switch. 2. Unlatch the hood and raise it. 3. Remove the air cleaner components as shown in Figure 9. 4. Examine the air cleaner assembly (item 5 in Figure 9) for wear or damage that could cause possible air leaks. 5.
Installing the Air Cleaner System (continued) 1. Assemble the air cleaner system as shown in Figure 9. A. If the service indicator and adapter were removed from the air cleaner assembly, apply thread sealant to the threads of the adapter before installing the adapter and service indicator to the housing (Figure 10). Install the adapter so that the grooves in the adapter hex and adapter filter element are installed toward service indicator. Torque the service indicator to 1.4 to 1.6 N∙m (12 to 15 in-lb). B.
Exhaust System g188095 Figure 11 1. Tailpipe guard 5. Flange nut (2 each) 9. Flange-head screw (2 each) Tailpipe bracket 10. Flange-head screw (2 each) 2. Washer-head screw (2 each) 6. 3. Exhaust tube 7. Jam nut (2 each) 11. Tailpipe bracket 4. Muffler clamp 8. Exhaust clamp 12.
The engine that powers your Groundsmaster 4300-D machine is a Yanmar diesel engine model 3TNV86CT that complies with EPA Tier 4F emission regulations. The engine is equipped with an exhaust system that includes a diesel oxidation catalyst (DOC) and a diesel-particulate filter (DPF). These exhaust components require service or component replacement at regular intervals; refer to the Operator’s Manual.
Radiator g188098 Figure 12 1. Screen 10. Washer-head screw (6 each) 19. Hose clamp (4 each) 28. Reservoir bracket 2. Pop rivet (2 each) 11. Mounting bracket (2 each) 20. Lower radiator hose 29. Button-head screw (5 each) 3. Detent ball pin 12. Foam seal (2 each) 21. Upper radiator hose 30. Reservoir cap 4. Draw latch 13. Foam seal (2 each) 22. Draincock 31. Pipe plug 5. Foam seal (2 each) 14. O-ring (2 each) 23. Radiator and oil cooler assembly 32. Reservoir hose 6.
Removing the Radiator 1. Park the machine on a level surface, lower the cutting decks, shut off the engine, set the parking brake, and remove the key from the key switch. 2. Remove the screen (item 1 in Figure 12) from the machine. 3. Unlatch the hood and raise it. DANGER If the radiator or engine is hot, pressurized hot coolant can escape and cause burns. Do not open the radiator cap or drain the radiator when the coolant is hot. WARNING Ethylene-glycol antifreeze is poisonous.
Removing the Radiator (continued) g189544 Figure 13 1. Radiator 3. Hydraulic tube 2. Straight hydraulic fitting (2 each) 4. Hydraulic tube 8. Read the General Precautions for Removing and Installing the Hydraulic System Components (page 4–87). 9. Clean the hydraulic tube ends and oil cooler fittings to prevent hydraulic system contamination. 10. Disconnect the hydraulic tubes from the straight hydraulic fittings (Figure 13). 11. Cover or plug the hydraulic tubes to prevent contamination. 12.
Installing the Radiator 1. If the 2 straight hydraulic fittings (Item 2 in Figure 13) were removed from the oil cooler, lubricate and install new O-rings onto the fittings. Install the fittings into the port openings and tighten the fittings; refer to Installing the Hydraulic Fittings (SAE Straight Thread O-Ring Fitting into the Component Port) (page 4–11). 2. Carefully position the radiator and oil cooler assembly to the radiator frame. Position the fan shroud to the radiator. 3.
Fuel System g188096 Figure 14 1. Hose clamp (2 each) Fuel tank cap 17. Fuel supply hose 25. 2. Fuel return hose 10. Fuel tank 18. Recess bumper 26. Fuel/water separator 3. Hose clamp (6 each) 11. Washer-head screw (2 each) 19. Flat washer 27. 90° elbow fitting (2 each) 4. Fuel supply hose 12. Clamp (2 each) 20. Bolt 28. Flange-head screw (3 each) 5. Flange-head screw (2 each) 13. Draincock 21. Sender cover 29. Carriage screw (2 each) 6. Fuel pump 14.
DANGER Diesel fuel is highly flammable and explosive. A fire or an explosion from the fuel can burn you, burn other people, and damage property. • Use caution whenever you store or handle diesel fuel. • Do not smoke while filling the fuel tank. • Do not fill the fuel tank while the engine is running, while the engine is hot, or when the machine is in an enclosed area. • Always fill the fuel tank outside and wipe up any spilled diesel fuel before starting the engine.
Removing the Fuel Tank (continued) IMPORTANT To prevent damage to the fuel hoses, numerous cable ties are used to secure the hoses to the machine components. Record the location of all cable ties that are removed from the machine during the fuel tank removal so that they can be properly replaced during the tank installation. 8. Loosen the hose clamps and carefully disconnect the fuel supply and return (items 17 and 2 in Figure 14) hoses from the fittings on the top of the fuel sender. 9.
Installing the Fuel Tank 1. Install the fuel tank to the frame (Figure 14). Secure the fuel hoses with the cable ties as recorded during the fuel tank removal. g188097 Figure 15 1. Fuel sender 2. Fuel supply fitting 3. Fuel return fitting 2. If the fuel sender was removed from the fuel tank, ensure that the fuel fittings on the sender are orientated at 90° from right side of the tank as shown in Figure 15.
Engine g189543 Figure 16 1. Bolt (14 each) 7. Spacer (4 each) 13. Bolt (2 each) 2. Lock washer (14 each) 8. Snubbing washer (4 each) 14. Flange nut (10 each) 3. Bolt (4 each) 9. 4. Right rear engine mount 5. 6. Flange nut (10 each) 15. Flange-head screw (8 each) 10. Yanmar engine 16. Right front engine mount Left rear engine mount 11. Driveshaft assembly 17. Lift tab Left front engine mount 12.
Removing the Engine 1. Park the machine on a level surface, lower the cutting decks, shut off the engine, set the parking brake, and remove the key from the key switch. 2. Unlatch the hood and raise it. 3. Disconnect both the battery cables at the battery. Disconnect the negative battery cable and then the positive battery cable; refer to Servicing the Battery (page 5–95). DANGER If the radiator or engine is hot, pressurized hot coolant can escape and cause burns.
Removing the Engine (continued) B. For assembly purposes, label the fuel hoses. Disconnect the fuel supply and return hoses from the fuel filter on the engine (Figure 17). C. Cover or plug the fuel hoses and fuel filter fittings openings to prevent contamination. Position the disconnected hoses away from the engine. 8. Remove the hydraulic pump driveshaft; refer to Hydraulic Pump Driveshaft (page 4–98). g189542 Figure 18 1. Negative battery cable 3. Bolt 2. Engine wire harness 4.
Removing the Engine (continued) IMPORTANT To prevent damage to the electrical wire harness, numerous cable ties are used to secure the wire harness to the machine components. Record the location of all cable ties that are removed from the machine during the engine removal so that they can be properly replaced during the engine installation. 9. For assembly purposes, note the location of the cable ties used to secure the wire harness to the machine.
Removing the Engine (continued) 12. Carefully raise the engine from the machine moving it toward the front of the machine and away from the radiator assembly. 13. If necessary, remove the engine mount brackets from the engine. Installing the Engine IMPORTANT Ensure that all parts are removed from the engine during maintenance or overhaul are correctly installed on the engine. 1. If the engine mount brackets were removed from the engine, secure the brackets to the engine with the lock washers and bolts.
Installing the Engine (continued) C. The engine wire harness power cable to the battery clamp through the cord grip and tighten the cord grip. D. The negative battery cable, engine wire harness ground cable and frame to engine ground cable at the engine block (Figure 18). g190801 Figure 20 1. Hydraulic pump driveshaft 4. Glow relay 2. EGR relay 5. Main power relay 3. Start relay E. The engine wire harness connectors to the main power, glow, start, and EGR relays (Figure 20). F.
Installing the Engine (continued) 13. Ensure that all the wires, fuel lines, hydraulic hoses, and cables are clear of moving parts and secured to their original locations. 14. Check the engine-oil level and adjust as necessary. 15. Check the hydraulic-fluid level in the hydraulic reservoir and add correct quantity of fluid if necessary; refer to the Operator’s Manual. 16. Prime the fuel system; refer to Priming the Fuel System (page 3–20). 17.
Diesel Engine: Service and Repairs Page 3–30 Groundsmaster® 4300-D 16226SL Rev D
Chapter 4 Hydraulic System Table of Contents Specifications ....................................................................................................................................... 4–3 Hydraulic System ............................................................................................................................... 4–3 General Information ..............................................................................................................................
Testing the lift Circuit–Relief Valve (PRV) Pressure.......................................................................... 4–78 Testing the Lift Circuit–Lift Cylinder Internal Leakage ....................................................................... 4–81 Testing the Lift Circuit–Gear Pump (P4) Flow................................................................................... 4–84 Service and Repairs ..............................................................................................
Specifications Hydraulic System Item Description Piston (traction) pump Maximum pump displacement (per revolution) Gear pump Section P1 displacement (per revolution) Section P2 displacement (per revolution) Section P3 displacement (per revolution) Section P4 displacement (per revolution) Sauer-Danfoss, LPV closed circuit axial piston design 35 cm³ (2.14 in³) Casappa 4-section, positive displacement gear type pump 16.84 cm³ (1.03 in³) 16.84 cm³ (1.03 in³) 6.1 cm³ (0.37 in³) 3.9 cm³ (0.
General Information The Operator's Manual provides information regarding the operation, general maintenance procedures, and maintenance intervals for your machine. Refer to the Operator's Manual for additional information when servicing the machine. Checking the Hydraulic Fluid g186172 Figure 21 1. Hydraulic reservoir cap g186201 Figure 22 1. 2. Piston (traction) pump Bypass valve The hydraulic system on your machine is designed to operate on anti-wear hydraulic fluid.
Checking the Hydraulic Fluid (continued) IMPORTANT Check the hydraulic-fluid level daily. Pushing or Towing the Traction Unit In case of emergency, the machine can be pushed for a very short distance. However, Toro does not recommend this as a standard procedure. 1. Ensure that the engine is not running. 2. Find the bypass valve on the piston (traction) pump (Figure 22). Loosen the valve (rotate them counterclockwise) 1 to 2 turns.
Releasing Pressure from the Hydraulic System Release all the pressure in the hydraulic system before you work on the hydraulic system. System pressure in the cutting circuit is released when the cutting decks are disengaged. Releasing the Hydraulic Pressure from the Traction Circuit Note: If you park the machine on an incline or slope, the pressure in the traction circuit does not release. 1. Park the machine on a level surface. 2. Lower the cutting decks. 3.
Traction Circuit Component Failure The traction circuit of the Groundsmaster 4300-D machines is a closed loop system that includes the piston (traction) pump and 4 wheel motors. If a component failure occurs in the traction circuit (e.g., traction (piston) pump or wheel motor), unwanted material and contamination from the damaged component will circulate throughout the traction circuit.
Hydraulic Hoses The hydraulic hoses are subject to extreme conditions such as pressure differentials during operation and exposure to weather, sun, chemicals, very warm storage conditions, in addition to mishandling during operation and maintenance. These conditions can cause damage to the hose or deterioration to the hose material. Some hoses are more susceptible to these conditions than others.
Installing the Hydraulic Hose and Tube (O-Ring Face Seal Fitting) 1. Ensure that all the threads, the sealing surfaces of the hose/tube, and the fitting are free of burrs, nicks, scratches, or unwanted material. g033770 Figure 23 1. Tube or hose 3. O-ring 2. Swivel nut 4. Fitting body g033771 Figure 24 2. To help prevent a hydraulic leak, replace the face seal O-ring when you open the connection. Ensure that the O-ring is installed and correctly seated in the groove of the fitting.
Installing the Hydraulic Hose and Tube (O-Ring Face Seal Fitting) (continued) B. Put a mark on the swivel nut and body of the fitting. Hold the hose/tube in alignment with a wrench to prevent the hose/tube from turning. C. Use a second wrench to tighten the nut to the correct Flats From Wrench Resistance (FFWR); refer to the Flats From Wrench Resistance Table (page 4–10). Note: The markings on the nut and body of the fitting show that the connection is correctly tightened.
Installing the Hydraulic Fittings (SAE Straight Thread O-Ring Fitting into the Component Port) Installing the Non-Adjustable Fittings g033772 Figure 25 1. Fitting 2. O-ring 1. Ensure that all the threads, the sealing surfaces of fitting, and the component port are free of burrs, nicks, scratches, or unwanted material. 2. To help prevent a hydraulic leak, replace the O-ring when you open the connection. 3. Lightly lubricate the O-ring with clean hydraulic fluid.
Installing the Non-Adjustable Fittings (continued) Fitting Installation Torque Table (continued) Fitting Dash Size Fitting Port Side Thread Size (inch(es)—threads per inch) Installation Torque Into Steel Port Installation Torque Into Aluminum Port 10 7/8—14 135 to 164 N∙m (99 to 121 ft-lb) 82 to 100 N∙m (60 to 74 ft-lb) 12 1–1/16—12 182 to 222 N∙m (134 to 164 ft-lb) 110 to 134 N∙m (81 to 99 ft-lb) 14 1–3/16—12 217 to 265 N∙m (160 to 196 ft-lb) 131 to 160 N∙m (96 to 118 ft-lb) 16 1–5/16—12
Installing an Adjustable Fitting g033773 Figure 26 1. Locknut 2. Back-up washer 3. O-ring g033774 Figure 27 1. Ensure that all the threads, the sealing surfaces of fitting, and the component port are free of burrs, nicks, scratches, or unwanted material. 2. To help prevent a hydraulic leak, replace the O-ring when you open the connection. 3. Lightly lubricate the O-ring with clean hydraulic fluid. Ensure that the threads of the fitting are clean with no lubricant applied. 4.
Installing an Adjustable Fitting (continued) 7. Hold the fitting in the correct alignment with a wrench and use a torque wrench and tighten the fitting to the recommended torque value within the specified range of torque values; refer to the Fitting Installation Torque Table (page 4–11). This tightening procedure requires a drive-adapter wrench (e.g., crowfoot wrench). Note: It may be necessary to use a drive-adapter wrench (e.g.
Hydraulic Schematics g186183 Figure 28 Groundsmaster® 4300-D 16226SL Rev D Page 4–15 Hydraulic System: Hydraulic Schematics
Hydraulic Flow Diagrams g186202 Figure 29 Hydraulic System: Hydraulic Flow Diagrams Page 4–16 Groundsmaster® 4300-D 16226SL Rev D
Traction Circuits The hydraulic traction circuit consists of a variable displacement piston pump (P5) connected in a closed loop, parallel circuit to 4 orbital roller vane wheel motors. The traction pump input shaft is rotated by a driveshaft that is driven from the engine flywheel. The forward traction circuit pressure can be measured at the test port located in the hydraulic tube that connects the front wheel motors.
Reverse Direction (continued) The fluid flowing from the wheel motors returns to the traction pump and is continuously pumped through the closed loop traction circuit as long as the traction pedal is pressed. The charge circuit and flushing valve function the same in reverse as they do in the forward direction.
Reverse Direction (continued) g186193 Figure 30 Groundsmaster® 4300-D 16226SL Rev D Page 4–19 Hydraulic System: Hydraulic Flow Diagrams
Mow Circuit A 4-section gear pump is coupled to the piston (traction) pump. The gear pump sections (P1) and (P2) supply hydraulic flow for the mow circuit. These gear pumps take their suction from the hydraulic reservoir. The deck control manifold contains 2 independent control circuits for the front and rear cutting decks. Each circuit is supplied by its own pump section.
PTO Engaged (continued) creates a pressure increase at the logic cartridge that shifts the logic cartridge and allows fluid return from the deck motors. The maximum mow circuit pressure is limited at each deck manifold circuit by the proportional relief valve (PRV1/PRV2). The deck relief valve pressure is 17,500 kPa (2,500 psi) for the rear cutting unit circuit and 24,100 kPa (3,500 psi) for the front cutting unit circuit.
Mow Circuit Cutting Deck Blade Braking g186190 Figure 32 g186191 Figure 33 Hydraulic System: Hydraulic Flow Diagrams Page 4–22 Groundsmaster® 4300-D 16226SL Rev D
Mow Circuit Cutting Deck Blade Braking (continued) g186192 Figure 34 When the operator turns the PTO switch OFF (or if the decks are raised), the deck control manifold proportional relief valves (PRV1 and PRV2) are de-energized. The valves will shift to direct fluid away from the deck motors and toward the oil cooler and filter. Hydraulic pressure is reduced to the cutting deck motors which slows the cutting blades and also allows the deck control manifold relief valves (RV1 and RV2) to shift.
Mow Circuit Cutting Deck Blade Braking (continued) g186186 Figure 35 Hydraulic System: Hydraulic Flow Diagrams Page 4–24 Groundsmaster® 4300-D 16226SL Rev D
Lift Cylinder Circuit: Raise the Cutting Decks A 4-section gear pump is coupled to the piston (traction) pump. The 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. The lift control manifold includes 3 electrically operated valves.
Raise the Cutting Decks (continued) g186184 Figure 36 Hydraulic System: Hydraulic Flow Diagrams Page 4–26 Groundsmaster® 4300-D 16226SL Rev D
Lift Cylinder Circuit: Lower the Cutting Decks g186185 Figure 37 A 4-section gear pump is coupled to the piston (traction) pump. The 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. The lift control manifold includes 3 electrically operated valves.
Lower the Cutting Decks (continued) directed to the barrel end of all lift cylinders to extend the cylinders and lower the cutting decks. The 4 fixed orifices in the lift control manifold (C2, C4, C6, and C8) control the lowering speed of the cutting decks by providing a restriction for the return flow from the lift cylinders.
Counterbalance/Float (continued) g186200 Figure 38 Groundsmaster® 4300-D 16226SL Rev D Page 4–29 Hydraulic System: Hydraulic Flow Diagrams
Steering Circuit A 4-section gear pump is coupled to the piston (traction) pump. The gear pump section P3 supplies hydraulic flow to the steering control valve and for the traction charge circuit. The steering control valve receives the pump supply first, ensuring pressure and volume is always available for steering control, no matter the charge circuit demand. The gear pump takes its suction from the hydraulic reservoir.
Special Tools You can order these special tools from your Toro Distributor. Some tools are also available from a local tool supplier. Hydraulic Pressure Testing Kit g031764 Figure 39 Toro Part No. TOR47009 Use this kit to take various pressure readings for diagnostic tests. Quick disconnect fittings are provided to attach directly to the mating fittings on the machine test ports without the tools. A high-pressure hose is given for remote readings.
15 GPM Hydraulic Tester Kit (Pressure and Flow) (continued) 3. Pressure Gauge: A glycerine filled pressure gauge 0 to 34,500 kPa (0 to 5,000 psi) to provide operating circuit pressure. 4. Flow Meter: This meter measures the actual fluid flow in the operating circuit with a gauge rated at 5 to 55 L/minute (1 to 15 gallons/minute). 5. Outlet Hose: A hose from the outlet side of the hydraulic tester that connects to the hydraulic system circuit. 6.
Hydraulic Hose Kit g035152 Figure 42 Toro Part No. TOR6007 This kit includes the fittings and hoses that are used to connect the 40 GPM hydraulic tester (AT40002) or high flow hydraulic filter kit (TOR6011) to the machine hydraulic traction system components. O-Ring Kit g033395 Figure 43 Toro Part No. 117-2727 This kit includes O-rings in a variety of sizes for the face seal and port seal hydraulic connections.
High Flow Hydraulic Filter Kit g035050 Figure 44 Toro Part No. TOR6011 The high flow hydraulic filter kit is designed with large flow (150 L/minute or 40 gallons/minute) and high pressure (34,500 kPa or 5,000 psi) capabilities. This kit provides for bi-directional filtration which prevents filtered unwanted material from entering into the circuit regardless of flow direction.
Hydraulic Test Fitting Kit (continued) This kit includes a variety of O-ring face seal fittings to let you connect the test gauges into the system. The kit includes: tees, unions, reducers, plugs, caps, and male test fittings. Spindle Plug g194566 Figure 46 Toro Part No. 94-2703 This spindle plug can be used to prevent contaminant entry into the cutting deck spindle assembly when the hydraulic motor is removed from the spindle. Wheel Hub Puller g185941 Figure 47 Toro Part No.
Measuring Container Figure 48 Toro Part No. TOR4077 Use this container to test hydraulic motor efficiency (motors with case drain lines only). Limit the outlet flow from the motor and measure the leakage from the case drain line to measure the efficiency of a hydraulic motor while the hydraulic system pressurizes the motor. The table gives the gallons per minute (gpm) conversion for the measured milliliter or ounce motor case drain leakage. GPM mL/15 seconds oz/15 seconds 0.1 95 3.2 0.2 189 6.
Remote Starter Switch (continued) g186163 Figure 50 g193733 Figure 51 1. 2. B+ terminal Starter solenoid 3. Starter motor After flushing the hydraulic system or replacing a hydraulic component (e.g., gear pump, piston pump, or wheel motor), it is necessary to prime the hydraulic pumps. A remote starter switch (Figure 49) can be used for priming the hydraulic pumps. You can get this switch locally.
Remote Starter Switch (continued) connectors. Connecting the wire to switch terminals 1 and 2 will allow the momentary switch contacts to be used for the remote starter switch (Figure 50). Note: For information on using the remote starter switch to prime the hydraulic pumps; refer to Priming the Hydraulic Pumps (page 4–88).
Troubleshooting The following chart contains suggestions that can be used to solve performance issues specific to the hydraulic system. The suggestions are not all-inclusive. There can be more than 1 cause for a machine malfunction. Review the hydraulic schematic found in Appendix A—Foldout Drawings and information on the hydraulic system operation in the Hydraulic Flow Diagrams (page 4–16). This information will be useful during the hydraulic troubleshooting process.
Traction Circuit Problems Problem Possible Causes The traction response is sluggish. • The piston (traction) pump bypass valve is open or damaged. • The brake is dragging or binding. • The piston (traction) pump check valve, relief valve, and/or flushing valve is leaking. • The charge pressure is low. • The hydraulic fluid is very cold. • The piston (traction) pump or wheel motor(s) is worn or damaged. • The flushing valve in piston (traction) pump is not seating or is damaged.
Traction Circuit Problems (continued) Problem Possible Causes The wheel motor does not hold load in the NEUTRAL position. • The charge pressure is low. Note: The machine may not be completely stationary if parked on an incline without the parking brake engaged. • The check valves in the piston (traction) pump are damaged. • The valve plate(s) in the piston (traction) pump is worn or damaged. • The wheel motor is worn or damaged.
Lift/Lower Circuit Problems Problem Possible Causes • The cutting deck has excessive unwanted elements. One cutting deck raises slowly or not at all. • The lift arm or lift cylinder is binding. • The flow control orifice in lift control manifold for the affected cutting deck is plugged, stuck, or damaged. • The lift cylinder leaks internally. One or more cutting deck raises, but does not stay up. • The lift circuit hydraulic lines or fittings are leaking.
Steering Circuit Problems Problem Possible Causes The steering is inoperative or sluggish. • The steering components (e.g., tie rods, steering cylinder ends) are worn or binding. • The steering cylinder is binding. • The fluid level in the hydraulic reservoir is low (other hydraulic systems are affected as well). • The steering relief valve (R10) in the steering control valve is stuck or damaged. • The steering cylinder leaks internally. • The steering control valve is worn or damaged.
Testing the Hydraulic System The most effective procedure to isolate the problems in the hydraulic system is to use hydraulic test equipment, such as pressure gauges and flow meters in the circuits during different operational checks; refer to Special Tools (page 4–31). WARNING Opening the hydraulic system without releasing pressure from the system will cause the hydraulic fluid to escape, causing possible injury.
IMPORTANT Use 2 people to perform all the tests, with 1 person in the seat and the other to read and record the test results. 1. Clean the machine fully before you disconnect or disassemble the hydraulic components. Note: Cleanliness is required whenever you work on the hydraulic equipment. Contamination causes too much wear on hydraulic components. 2. When you perform tests on the hydraulic system, wear eye protection. 3.
Testing the Traction Circuit–Charge Pressure g189668 Figure 52 Test Procedure The charge pressure test is the first in a series of tests recommended to determine traction circuit performance. A charge pressure drop of more than 20% indicates an internal leak in the piston pump/hydrostat. Continued unit operation can generate excessive heat, cause damage to seals and other components in the hydraulic system, and affect overall machine performance. Special Equipment Required: Pressure gauge 1.
Test Procedure (continued) 3. Read all Warning, Cautions, and precautions listed at the beginning of this section. 4. Raise and support the operator seat to get access to the hydraulic pump assembly. 5. Ensure that the traction pedal is in the NEUTRAL position, the steering wheel is stationary and parking brake is set. g189669 Figure 53 1. Traction pump 4. Oil filter/filter adapter 2. Test port 5. Hydraulic tube 3. Hydraulic tube g217039 Figure 54 1. Test port 2. Wheel motor (left front) 6.
Test Procedure (continued) 8. Attach a heavy chain to the rear of the machine frame and an immovable object to prevent the machine from moving during testing. 9. Block the wheels with chocks to prevent the wheel rotation during testing. 10. Start the engine and press the engine speed switch to full speed (3,005 to 3,055 rpm) position. Use the InfoCenter to check that the engine speed is correct. 11. Record the reading on the charge circuit pressure gauge.
Testing the Traction Circuit–Wheel Motor Efficiency g192619 Figure 55 The wheel motor efficiency is the second in a series of tests recommended to determine the traction circuit performance. Hydraulic fluid flow of 5.7 L/minute (1.5 gallons/minute) or more through a single stationary front wheel motor under load indicates an internal leak in the wheel motor. Hydraulic fluid flow of 4.5 L/minute (1.
wheel motor is less efficient. Eventually, enough fluid bypass will cause the wheel motor to stall under heavy load conditions. Continued operation can generate excessive heat, cause damage to the seals and other components in the hydraulic system, and affect overall machine performance. There are moments during wheel motor operation (geroller position) when fluid flow through the motor is less restricted.
3. Ensure that the traction pedal is correctly adjusted for the NEUTRAL position; refer to the Operator’s Manual. 4. Attach a heavy chain to the rear of the machine frame and an immovable object to prevent the machine from moving during testing. Testing the Front Wheel Motors Hydraulic fluid flows through both front wheel motors (in parallel) before passing through the rear wheel motors (in series). To accurately test the front wheel motors, the rear wheel motors must be removed from the traction circuit.
Testing the Front Wheel Motors (continued) rotate both the front wheels 180° and then test again. Use the average of the 3 flow meter readings to judge the front wheel motor performance. Testing of wheel motor leakage in the 3 different wheel positions will provide the most accurate test results. 9. The total internal leakage for the front wheel motors combined will be shown on the flow meter. Leakage for the front wheel motors combined should be less than 11.3 L/minute (3 gallons/minute).
Testing the Rear Wheel Motors g212732 Figure 57 1. 2. Upper hydraulic fitting Right rear wheel motor g217163 Figure 58 1. Left rear wheel motor 2. Lower hydraulic fitting Hydraulic fluid flows through both front wheel motors (in parallel) before passing through the rear wheel motors (in series). To accurately test the rear wheel motors, the front wheel motors must be allowed to rotate. 1.
Testing the Rear Wheel Motors (continued) CAUTION The rear wheel motors will try to move the machine forward. Use extreme caution when performing the test. 7. Slowly press the traction pedal in the forward direction until 6,900 kPa (1,000 psi) is displayed on the tester pressure gauge. Ensure that the rear wheels are not rotating and record the flow meter reading. 8. Release the traction pedal, shut off the engine, rotate both the front wheels 90° and then test again.
Testing the Traction Circuit–Piston Pump/Hydrostat Flow and Relief Pressure g192623 Figure 59 The hydrostat flow test is the third in a series of tests recommended to determine the traction circuit performance. This test compares fluid flow at No Load with fluid flow Under Load. A drop in flow under load of more than 12% indicates an internal leak or malfunctioning relief valve in the piston pump/hydrostat. The final traction circuit test is verifying the hydrostat relief valve operation.
Test Procedure 1. Warm oil after test equipment is connected to prevent technician from working on a hot machine—applicable to tests when possible (any test that requires an open un-pluged/capped line (case drain tests) would not apply and oil should be warmed before disconnecting the lines).
Test Procedure (continued) IMPORTANT Ensure that the fluid flow indicator arrow on the flow meter is showing that the fluid will flow from the pump, through the tester, and into the disconnected hydraulic hose. 7. Install a tester with the pressure gauge and flow meter in series between the traction pump fitting and the disconnected hose. 8. Use the hydraulic hose kit to connect tester to the machine; refer to Special Tools (page 4–31). Ensure that the fitting and hose connections are properly tightened.
Test Procedure (continued) 14. If the relief pressure can not be met or is greater than specified, the traction relief valve is damaged and should be replaced. 15. The under load test flow reading (step 12C) should not drop more than 12% when compared to the no load test flow reading (step 11B). A difference of more than 12% may indicate the piston pump/hydrostat is worn and should be repaired or replaced. 16. After you complete the testing, disconnect the tester and connect the hose to the pump fitting.
Testing the Mow Circuit–Circuit Pressure g212310 Figure 61 The cutting unit circuit pressure is the first in a series of tests recommended to check the cutting unit circuit performance. The results from this test will help determine which component(s) are the cause of cutting unit performance issues. Special Equipment Required: Pressure gauge with extension hose.
Test Procedure g212309 Figure 62 1. Test fitting (port G2) 2. Deck control manifold 3. Test fitting (port G1) 1. Ensure that the hydraulic fluid is at normal operating temperature by operating the machine for at least 10 minutes. 2. Park the machine on a level surface with the PTO switch off, lower the cutting decks, shut off the engine, set the mow speed limiter to the MOW position, and set the parking brake. 3. Read all Warning, Cautions, and precautions listed at the beginning of this section. 4.
Test Procedure (continued) 9. If the pressure readings are within specifications and cutting deck performance is still in question, test the cutting deck motors individually; refer to Testing the Mow Circuit–Deck Motor Efficiency/Case Drain (page 4–62). 10. If the pressure specifications are not met, consider the following: A. The proportional relief valve (PRV1 or PRV2) is damaged; refer to Testing the Mow Circuit–Relief Valve (PRV1) and (PRV2) Pressure (page 4–65)). B.
Testing the Mow Circuit–Deck Motor Efficiency/Case Drain g189653 Figure 63 The deck motor efficiency/case drain test is the second in a series of tests recommended to check the cutting unit circuit performance. Over a period of time, a deck motor can wear internally. This test measures case drain volume while restricting flow across the motor ports. Case drain volume under load of more than 9% of total motor flow indicates the gears and wear plates in the motor have worn.
Test Procedure 1. Ensure that the hydraulic fluid is at normal operating temperature by operating the machine for at least 10 minutes. 2. Determine which of the deck motor is suspect and begin testing with that motor. 3. Park the machine on a level surface with the PTO switch off, lower the cutting decks, shut off the engine, mow speed limiter is in the MOW position, and set the parking brake.
Test Procedure (continued) 7. For the deck motor that is to be tested, clean the junction of the hydraulic return hose and deck motor fitting at the motor outlet (Figure 64). 8. Disconnect the return hose from the motor, install a tester with the pressure gauge and flow meter in series with the motor and disconnected return hose. Ensure that the flow control valve on tester is fully open. Note: Use a graduated container, the special tool TOR4077, to measure the case drain leakage (Figure 63). 9.
Testing the Mow Circuit–Relief Valve (PRV1) and (PRV2) Pressure g192624 Figure 65 Test the performance of the deck control manifold proportional relief valves (PRV1) and (PRV2) to ensure that the maximum amount of fluid is available to the cutting deck motors up to the set relief pressure. This test also ensures that pump (P1) or (P2) are capable of generating enough pressure to open properly functioning proportional relief valves.
Test Procedure 1. Park the machine on a level surface with the PTO switch off, lower the cutting decks, shut off the engine, mow speed limiter is in the MOW position, and set the parking brake. CAUTION Before opening the hydraulic system, operate all the hydraulic controls to release system pressure and avoid injury from the pressurized hydraulic fluid; refer to Releasing Pressure from the Hydraulic System (page 4–6). g217169 Figure 66 1. 2.
Test Procedure (continued) 3. To test the front cutting unit circuit relief valve PRV2, clean and disconnect the inlet hose to the #4 (front left) cutting deck motor (Figure 66). 4. To test the rear cutting unit circuit relief valve PRV1, clean and disconnect the inlet hose to the #2 (rear left) cutting deck motor (Figure 67). IMPORTANT Ensure that the fluid flow indicator arrow on the flow meter is showing that the fluid will flow from the disconnected hose, through the tester, and into the deck motor. 5.
Test Procedure (continued) pump (P1) (rear cutting deck circuit) for wear, damage, or inefficiency; refer to Testing the Mow Circuit–Gear Pump (P1) and (P2) Flow (page 4–69). 14. After you complete the testing, shut off the engine, and then release hydraulic system pressure; refer to Releasing Pressure from the Hydraulic System (page 4–6). Disconnect the tester from the machine and connect the hydraulic hose to the deck motor fitting. 15.
Testing the Mow Circuit–Gear Pump (P1) and (P2) Flow g192620 Figure 68 The gear pump (P1) and (P2) flow test is the last in a series of tests recommended to determine cutting unit circuit performance. The gear pump P1 supplies hydraulic flow to the rear cutting decks, while gear pump P2 provides hydraulic flow to the front cutting decks. This test compares fluid flow at No Load with fluid flow Under Load.
Test Procedure 1. Park the machine on a level surface with the PTO switch off, lower the cutting decks, shut off the engine, mow speed limiter is in the MOW position, and set the parking brake. CAUTION Before opening the hydraulic system, operate all the hydraulic controls to release system pressure and avoid injury from the pressurized hydraulic fluid; refer to Releasing Pressure from the Hydraulic System (page 4–6). 2. Read all Warning, Cautions, and precautions listed at the beginning of this section.
Test Procedure (continued) 7. Ensure that the hydraulic fluid is at normal operating temperature by operating the machine for at least 10 minutes. 8. Start the engine and run it at low-idle speed. Check for hydraulic-fluid leaks from the test connections and correct before continuing the test. 9. With the engine running, press the engine speed switch to full speed (3,005 to 3,055 rpm) position. Do not engage the cutting decks. Use the InfoCenter to check that the engine speed is correct. 10.
Testing the Steering Circuit–Steering Control Valve, Relief Valve (R10) Pressure, and Steering Cylinder g189907 Figure 70 Unit steering performance will be affected by incorrect rear tire pressure, binding in the hydraulic steering cylinder, extra weight on the vehicle, and/or binding of the steering forks. Ensure that these conditions are checked and functioning properly before proceeding with any steering system hydraulic testing.
Test Procedure 1. Ensure that the hydraulic fluid is at normal operating temperature by operating the machine for at least 10 minutes. 2. Drive the machine slowly in a figure eight on a flat level surface. A. There should be no shaking or vibration in the steering wheel or rear wheels. B. The steering wheel movements should be followed immediately by a corresponding rear wheel movement without the steering wheel continuing to turn. 3. Stop unit with the engine running.
Test Procedure (continued) D. The system pressure should be approximately 6,900 kPa (1,000 psi) as the relief valve lifts. E. Return the steering wheel to the NEUTRAL position, shut off the engine, and record the test results. 6. If the specification is not met, repair or replace the steering control valve; refer to Servicing the Steering Control Valve (page 4–154). 7.
Testing the Steering Circuit–Gear Pump (P3) Flow g192621 Figure 71 The gear pump (P3) is designed to satisfy the steering cylinder needs (at full speed). The gear pump (P3) flow test compares fluid flow at No Load with fluid flow Under Load. A drop in flow under load of more than 15% indicates the gears and wear plates in the pump have worn. Continued operation with a worn pump can generate excessive heat and cause damage to the seals and other components in the hydraulic system.
Test Procedure (continued) 3. Lift and support the operator seat to get access to the hydraulic pump assembly. Figure 72 1. 2. Gear pump (P3) Hydraulic tube 4. Clean both ends of the hydraulic tube that connects the charge filter outlet with the traction pump (Figure 72). Disconnect both ends of the hydraulic tube and remove it from the machine. Plug both ends of the removed hydraulic tube to prevent system contamination.
Test Procedure (continued) 11. Verify the pump flow Under Load as follows: CAUTION Do not close the tester valve fully when performing this test. In this test, the hydraulic tester is positioned in an unprotected part of the steering circuit. Pump damage can occur if the fluid flow is fully restricted by fully closing the tester flow control valve. A. Monitor the tester pressure gauge carefully while you slowly close the flow control valve until you get 5,500 kPa (800 psi). B.
Testing the lift Circuit–Relief Valve (PRV) Pressure g189662 Figure 73 Perform the lift relief valve (PRV) pressure test to ensure that the lift circuit relief pressure is correct.
Test Procedure 1. Ensure that the hydraulic fluid is at normal operating temperature by operating the machine for at least 10 minutes. 2. Park the machine on a level surface with the PTO switch off, lower the cutting decks, shut off the engine, mow speed limiter is in the MOW position, and set the parking brake. 3. Read all Warning, Cautions, and precautions listed at the beginning of this section. g217321 Figure 74 1. 2. PRV solenoid Test port (G4) 3. Lift control manifold 4.
Test Procedure (continued) 10. If the measured pressure is incorrect, remove the pressure reducing valve (PRV) from the lift control manifold and clean or replace the valve; refer to Servicing the Lift Control Manifold (page 4–142). 11. Also, if the lift circuit pressure is low, check for the restriction in gear pump inlet line. The Internal lift cylinder leakage would also cause low lift circuit pressure; refer to Testing the Lift Circuit–Lift Cylinder Internal Leakage (page 4–81).
Testing the Lift Circuit–Lift Cylinder Internal Leakage Figure 75 Perform a lift cylinder internal leakage test if you identify a cutting deck raise and lower problem. This test determines if the lift cylinder being tested is damaged. The lift cylinders must be tested individually. Note: The raise/lower circuit operation can be affected by the lift cylinder binding, extra weight on the cutting deck, and/or binding of the lift components.
Test Procedure Note: When performing the lift cylinder internal leakage test, the cutting decks should be attached to the lift arms. g189903 Figure 76 1. #5 lift cylinder 2. Cylinder rod end fitting 3. Hydraulic hose 1. Park the machine on a level surface with the PTO switch off, position the cutting decks in the turn-around position, shut off the engine, and set the parking brake. 2. For the lift cylinder that is to be tested, use a jack to raise the lift arm slightly.
Test Procedure (continued) 8. If the lift cylinder allows the cutting deck to lower too quickly, replace or repair the lift cylinder; refer to Lift Cylinder (page 4–144) and Servicing the Lift Cylinder (page 4–147). 9. Once the lift cylinder condition is determined, use a jack to raise lift arm slightly which removes the load from the lift cylinder. 10. Support the lift arm with jack stands to prevent it from lowering. 11. Remove the cap from the cylinder fitting and the plug from the hydraulic hose. 12.
Testing the Lift Circuit–Gear Pump (P4) Flow g192622 Figure 77 The gear pump (P4) is designed to satisfy the lift cylinder needs (at full speed). The gear pump (P4) flow test compares fluid flow at No Load with fluid flow Under Load. A drop in flow under load of more than 15% indicates the gears and wear plates in the pump have worn. Continued operation with a worn pump can generate excessive heat and cause damage to the seals and other components in the hydraulic system.
Test Procedure 1. Park the machine on a level surface with the PTO switch off, lower the cutting decks, shut off the engine, mow speed limiter is in the MOW position, and set the parking brake. CAUTION Before opening the hydraulic system, operate all the hydraulic controls to release system pressure and avoid injury from the pressurized hydraulic fluid; refer to Releasing Pressure from the Hydraulic System (page 4–6). 2. Read all Warning, Cautions, and precautions listed at the beginning of this section.
Test Procedure (continued) 8. Verify the pump flow at No Load as follows: Record the tester pressure and flow readings at no load. Unrestricted pump output should be approximately 11.9 L/minute (3.2 gallons/minute). 9. Verify the pump flow Under Load as follows: CAUTION Do not close the tester valve fully when performing this test. In this test, the hydraulic tester is positioned before the manifold relief valve.
Service and Repairs General Precautions for Removing and Installing the Hydraulic System Components Before Repairing or Replacing the Components 1. Before removing any parts from the hydraulic system, park the machine on a level surface, lower the cutting decks, shut off the engine, set the parking brake, and remove the key from the key switch. 2. Clean the machine before you disconnect, remove, or disassemble the hydraulic components.
After Repairing or Replacing the Components (continued) 4. Remove all the caps or plugs from the hydraulic tubes, hydraulic fittings, and components before connecting them again. 5. Use proper tightening procedures when installing the hydraulic hoses and fittings; refer to Installing the Hydraulic Hose and Tube (O-Ring Face Seal Fitting) (page 4–9) and Installing the Hydraulic Fittings (SAE Straight Thread O-Ring Fitting into the Component Port) (page 4–11). 6.
Priming the Hydraulic Pumps (continued) (traction) pump have sufficient fluid during initial start-up and running. The pumps can be primed by using a remote starter switch (refer to Special Tools (page 4–31)) to crank the engine which allows the pumps to prime. Use the following procedure to prime the hydraulic pumps: 1. Ensure that the key switch is in the OFF position and the key is removed from the key switch. 2.
Flushing the Hydraulic System (continued) IMPORTANT If a component failure occurs in the traction circuit; refer to the Traction Circuit Component Failure (page 4–7) for information regarding the importance of removing contamination from the traction circuit. 1. Ensure that the hydraulic fluid is at normal operating temperature by operating the machine for at least 20 minutes.
Flushing the Hydraulic System (continued) 12. Move the PTO switch to the ON position to engage the cutting decks and let them run for several minutes. Move the PTO switch to the OFF position. 13. Shut off the engine and check for hydraulic-fluid leaks. Note: Check the hydraulic-fluid level in the hydraulic tank and add correct quantity of fluid if necessary; refer to the Operator’s Manual. 14. Operate the machine for 2 hours under normal operating conditions. 15. Check the condition of hydraulic fluid.
Filtering the Closed-Loop Traction Circuit (continued) IMPORTANT Before lifting the machine with a jack, review and follow Jacking Instructions (page 1–6). 2. Lift and support the machine so that all the wheels are off the ground. Note: If the wheel motor was replaced, install a high-flow filter to the inlet of the new motor instead of to the traction pump fitting. This will prevent system contamination from entering and damaging the new wheel motor. 3.
Filtering the Closed-Loop Traction Circuit (continued) 8. With the engine running at high-idle speed (3,005 to 3,055 rpm) and traction pedal moved to the forward direction, periodically apply brakes to increase pressure in the traction circuit. While monitoring the filter indicator, continue this process for 5 more minutes. IMPORTANT If you are using a filter that is not the Toro high flow filter that is bi-directional, do not press the traction pedal in the reverse direction.
Charging the Hydraulic System Note: When initially starting the hydraulic system with new or rebuilt components such as pumps, wheel motors, or lift cylinders, it is important that the hydraulic system is charged properly. Remove the air from the system and its components to reduce the chance of damage. IMPORTANT Change the hydraulic-fluid filters when you repair or replace the hydraulic components. 1. Park the machine on a level surface and shut off the engine. 2.
Charging the Hydraulic System (continued) C. The suction line that is blocked. D. The charge relief valve in the traction pump that is damaged. E. The gear pump that is damaged. 11. After the lift cylinder moves normally, proceed to step 12. 12. Turn the steering wheel in both directions so that the steering cylinders move in and out several times. 13. Operate the traction pedal in the forward and reverse directions. The drive wheels should rotate in the proper direction.
Hydraulic Tank g186182 Figure 81 Bolt 17. O-ring 10. Hydraulic hose 18. Hydraulic tank Clamp (2 each) 11. O-ring 19. Clamp (2 each) Hydraulic hose 12. 90° hydraulic fitting 20. Washer-head screw (2 each) 5. Gear pump 13. O-ring 21. Screen filter 6. Flange nut (3 each) 14. Hydraulic hose 22. Hydraulic tank cap 7. Recess bumper 15. O-ring 8. Flat washer 16. Adapter 1. O-ring 2. Tank strainer 3. 4. Hydraulic System: Service and Repairs 9.
Removing the Hydraulic Tank 1. Park the machine on a level surface, lower the cutting decks, shut off the engine, set the parking brake, and remove the key from the key switch. 2. Clean the hydraulic hose ends and fittings on the hydraulic tank to prevent contaminants from entering into the hydraulic system. 3. For assembly purposes, label all the hydraulic hoses and fittings. 4.
Hydraulic Pump Driveshaft g193011 Figure 82 1. Bolt (6 each) 6. Flange nut (4 each) 11. Guard hoop 2. Back-up ring 7. Piston (traction) pump 12. Driveshaft assembly 3. Flywheel adapter plate 8. Flange nut (2 each) 13. Flange-head screw (8 each) 4. Flange nut (6 each) 9. Flange-head screw (2 each) 5. Bolt (2 each) 10. Flange-head screw (2 each) Removing the Hydraulic Pump Driveshaft 1.
Removing the Hydraulic Pump Driveshaft (continued) 6. If necessary, remove the 6 bolts (item 1 in Figure 82), 6 flange nuts, and a back-up ring that secure the driveshaft assembly to the flywheel adapter plate. Servicing the Driveshaft Cross and Bearing g193292 Figure 83 1. Grease fitting 4. Cross and bearing kit 2. Snap ring (4 each) 5. End yoke 3. Shaft yoke 1. Remove the snap rings that secure the bearings in the yokes.
Installing the Hydraulic Pump Driveshaft 1. Apply anti-seize lubricant to the traction pump input shaft. 2. If removed, secure the driveshaft assembly to the flywheel adapter plate with the back-up ring, 6 bolts, and 6 flange nuts. 3. Position the driveshaft assembly to the engine and pump input shaft. 4. Apply loctite (or equivalent) to the threads of the flange-head screws (item 13 in Figure 82).
Hydraulic Pump Assembly g193007 Figure 84 1. Driveshaft assembly 14. Hydraulic hose 27. O-ring (2 each) 2. Bolt (2 each) 15. Hydraulic hose 28. Straight connector fitting 3. Guard hoop 16. O-ring 29. O-ring 4. Flange-head screw (2 each) 17. Straight fitting 30. Manifold 5. Traction neutral switch 18. O-ring (2 each) 31. Hose clamp (2 each) 6. O-ring (2 each) 19. O-ring (2 each) 32. Hydraulic hose 7. Straight fitting (2 each) 20. Straight fitting 33.
Removing the Hydraulic Pump Assembly CAUTION Before opening the hydraulic system, operate all the hydraulic controls to release system pressure and avoid injury from the pressurized hydraulic fluid; refer to Releasing Pressure from the Hydraulic System (page 4–6). g193008 Figure 85 1. Piston (traction) pump 2. Gear pump 3. Traction cable bracket g193009 Figure 86 1. Pump lever 8. Traction cable bracket 2. Ball joint 9. Traction cable 3. Flat washer 10. Flange nut 4. 5.
Removing the Hydraulic Pump Assembly (continued) 1. Park the machine on a level surface, set the parking brake, lower the cutting decks, and shut off the engine. Remove the key from the key switch. 2. Read the General Precautions for Removing and Installing the Hydraulic System Components (page 4–87). 3. Clean the traction and gear pump assembly and all hydraulic connections to prevent hydraulic system contamination. 4. For assembly purposes, label all the hydraulic connections. 5.
Removing the Hydraulic Pump Assembly (continued) g193010 Figure 87 1. Traction pump 6. Pump support bracket 2. O-ring 7. Locknut (2 each) 3. Flat washer (2 each) 8. Flat washer (2 each) 4. Lock washer (2 each) 9. Gear pump 5. Socket-head screw (2 each) 14. Separate the traction and gear pumps (Figure 87) as follows: A. Remove the 2 socket-head screws, 2 lock washers, and 2 flat washers that secure the gear pump to the traction pump. B. Remove the gear pump from the traction pump.
Installing the Hydraulic Pump Assembly (continued) IMPORTANT Ensure that you do not damage the machine components while installing the pump assembly. 3. Carefully lower the pump assembly into the machine frame. 4. Secure the pump assembly to the machine frame with the 2 flange-head screws (item 38 in Figure 84) and 2 flange nuts. 5. Secure the pump support bracket to the inside of the frame bracket with the 2 carriage screws (item 22 in Figure 84) and 2 flange nuts. 6.
Servicing the Piston (Traction) Pump g193295 Figure 88 1. Seal 13. Trunnion cover 25. Plug 37. O-ring 2. O-ring (2 each) 14. Screw (4 each) 26. Spring 38. End cap 3. Bearing (2 each) 15. Cylinder block kit 27. Loop flushing spool 39. Needle bearing 4. Traction pump housing 16. Valve plate 28. O-ring 40. End cap gasket 5. Plug (2 each) 17. Slotted pin 29. Bypass valve 41. Spring 6. O-ring (2 each) 18. Neutral return pivot 30. Seal kit 42. Thrust plate 7.
Servicing the Gear Pump g193293 Figure 89 1. Front cover 2. Dowel pin (16 each) 3. 4. 9. Splined connecting shaft (3 each) 17. Body (P4 section) 10. Drive gear 18. Washer (4 each) Back-up ring (8 each) 11. Body (P2 section) 19. Stud bolt (2 each) Pressure seal (8 each) 12. Driven gear (2 each) 20. Nut (2 each) 5. Thrust plate (8 each) 13. Square section seal (8 each) 21. Bolt (2 each) 6. Driveshaft 14. Drive gear 22. Rear cover 7. Body (P1 section) 15.
Disassembling the Gear Pump Note: The gear pump must be replaced as a complete assembly. Individual gears, housings, and thrust plates are not available separately. Disassemble the gear pump for cleaning, inspection, and seal replacement only. IMPORTANT Keep bodies, gears, flanges, and thrust plates for each pump section together; do not mix the parts between the pump sections. 1. Plug the pump ports and clean the outer surface of the pump with cleaning solvent. Ensure that the work area is clean.
Disassembling the Gear Pump (continued) timing. The pump efficiency may be affected if the teeth are not installed in the same position during assembly. Keep the parts for each pump section together; do not mix the parts between sections. 8. Clean all the parts. Check all the components for burrs, scoring, nicks, and other damage. 9. Replace the entire pump assembly if the parts are excessively worn or scored. Assembling the Gear Pump 1.
Front Wheel Motors g185925 Figure 91 1. Locknut (4 each per wheel shield) 2. Wheel shield (right rear) 3. Flange-head screw (4 each per wheel shield) 4. Left brake assembly 17. Bolt (2 each) 10. Bolt (4 each per brake assembly) 18. Jam nut (2 each) 11. Left spring clip 19. Right spring clip Locknut (4 each per wheel motor) 12. Brake drum (2 each) 20. Flange nut (2 each) 5. Left wheel motor 13. Locknut (2 each) 21. Right brake assembly 6. Square key (2 each) 14.
Removing the Front Wheel Motor CAUTION Before opening the hydraulic system, operate all the hydraulic controls to release system pressure and avoid injury from the pressurized hydraulic fluid; refer to Releasing Pressure from the Hydraulic System (page 4–6). 1. Park the machine on a level surface, lower the cutting decks, shut off the engine, set the parking brake, and remove the key from the key switch. 2. Block the rear wheels with chocks to prevent the machine from moving. 3.
Removing the Front Wheel Motor (continued) 17. Support the wheel motor to prevent it from falling during removal. Remove the 4 locknuts (item 4 in Figure 91) from the 4 bolts that secure the motor and brake bracket to the frame. 18. Remove the 4 bolts (item 8 in Figure 91), brake assembly with the brake adapter, and spring clip from the wheel motor and frame. 19. Remove the wheel motor from the machine. 20.
Installing the Front Wheel Motor (continued) 11. Install the front wheel to the machine; refer to Installing the Wheel (page 6–6). 12. Lower the machine to the ground. 13. Torque the locknut (item 13 in Figure 91) to 427 to 521 N∙m (315 to 385 ft-lb). 14. Operate the machine functions slowly until air is out of system; refer to Charging the Hydraulic System (page 4–94). 15.
Servicing the Front Wheel Motor g186198 Figure 92 1. Bolt (7 each) 8. Valve 15. Bearing race (2 each) 2. End cap 9. Dowel pin (4 each) 16. Thrust bearing 3. O-ring (3 each) 10. Balancing ring 17. Output shaft 4. Geroler assembly 11. Bearing 18. Drive 5. Valve plate 12. Grease seal 19. Back-up ring (2 each) 6. Thrust bearing 13. Housing 20. O-ring 7. Bearing 14. Shaft seal 21.
Servicing the Front Wheel Motor (continued) IMPORTANT If a wheel motor fails; refer to the Traction Circuit Component Failure (page 4–7) for information regarding the importance of removing contamination from the traction circuit.
Rear Wheel Motors g186194 Figure 93 1. Wheel motor (left) 6. Wheel hub 11. Motor housing 2. Hydraulic tube (2 each per motor) 7. Locknut 12. Rear axle 3. O-ring (2 each per motor) 8. Woodruff key 13. Tie rod 4. 45° hydraulic fitting (2 each per motor) 9. Bolt (4 each per motor) 14. Steering cylinder 5. O-ring (2 each per motor) Hydraulic System: Service and Repairs 10.
Removing the Rear Wheel Motor CAUTION Before opening the hydraulic system, operate all the hydraulic controls to release system pressure and avoid injury from the pressurized hydraulic fluid; refer to Releasing Pressure from the Hydraulic System (page 4–6). 1. Park the machine on a level surface, lower the cutting decks, shut off the engine, set the parking brake, and remove the key from the key switch. 2. Block the front wheels with chocks to prevent the machine from moving. 3.
Installing the Rear Wheel Motor IMPORTANT Because of the internal differences in the wheel motors, do not interchange the wheel motors on the machine (e.g., do not put the right motor on the left side of the machine). If necessary, use the Parts Catalog and Part Number on the wheel motor to identify the right and left motors, there is also a yellow dot on the left motor. 1. If the hydraulic fittings were removed from the wheel motor, lubricate and install new O-rings to the fittings.
Servicing the Rear Wheel Motor g186199 Figure 94 1. Dirt and water seal 9. Thrust bearing 2. 3. Outer bearing 10. Coupling shaft 18. Manifold Housing 11. Thrust bearing 19. Stator 17. Commutator ring 4. Back-up ring 12. Drive link 20. Vane (7 each) 5. Back-up washer 13. Bolt (7 each) 21. Wear plate 6. 7. Shaft seal Inner bearing 14. 15. End cover Body seal (5 each) 22. 23. Rotor Commutator ring 8. Thrust washer 16.
Servicing the Rear Wheel Motor (continued) IMPORTANT If a wheel motor fails; refer to the Traction Circuit Component Failure (page 4–7) for information regarding the importance of removing contamination from the traction circuit.
CrossTrax™ AWD Control Manifold Assembly g186174 Figure 95 1. Hydraulic hose (4 each) 6. Hydraulic tube 11. O-ring (2 each) 2. Straight fitting (7 each) 7. O-ring (7 each) 12. Frame bracket 3. AWD control manifold 8. O-ring (7 each) 13. Bolt (3 each) 4. Hydraulic tube 9. Dust cap (2 each) 14. Lock washer (3 each) 5. Hydraulic tube 10. Diagnostic fitting (2 each) 15. Spacer (3 each) Removing the CrossTrax AWD Control Manifold Assembly 1.
Removing the CrossTrax AWD Control Manifold Assembly (continued) 5. Disconnect the hydraulic hoses and tubes from the fittings in the AWD control manifold assembly. Allow the lines to drain into a suitable container. Remove and discard the O-rings from the fittings. 6. Install clean caps or plugs on the hydraulic lines and fittings to prevent system contamination. 7. Support the AWD control manifold assembly to prevent it from falling. 8.
Servicing the CrossTrax AWD Control Manifold Assembly g186173 Figure 96 1. Seal kit (2 each) 5. O-ring 2. Check valve (2 each) 6. #8 zero-leak plug 9. 3. O-ring (3 each) 7. 4. #6 zero-leak plug (3 each) 8. Orifice (0.040) 10. AWD control manifold #4 zero-leak plug (2 each) 11. Bi-directional relief valve O-ring (2 each) 12. Seal kit For the control manifold service procedures; refer to Servicing the Deck Control Manifold Assembly (page 4–127).
Deck Control Manifold Assembly g186179 Figure 97 1. 6. Deck control manifold Hydraulic tube 11. Flange-head screw (3 each) 2. O-ring (2 each) 7. O-ring (6 each) 12. Hydraulic tube 3. Diagnostic fitting (2 each) 8. Hydraulic hose (2 each) 13. Hydraulic tube 4. Dust cap (2 each) 9. O-ring 5. Hydraulic tube 10. Hydraulic tube Note: For testing the solenoid valve coils; refer to Testing the Hydraulic Solenoid Valve Coils (page 5–75).
Removing the Deck Control Manifold Assembly CAUTION Before opening the hydraulic system, operate all the hydraulic controls to release system pressure and avoid injury from the pressurized hydraulic fluid; refer to Releasing Pressure from the Hydraulic System (page 4–6). 1. Park the machine on a level surface, lower the cutting decks, shut off the engine, set the parking brake, and remove the key from the key switch. 2.
Installing the Deck Control Manifold Assembly g186180 Figure 98 1. Deck control manifold 5. O-ring 2. Straight fitting (6 each) 6. O-ring (6 each) 3. Straight fitting 7. O-ring (6 each) 4. O-ring 1.
Servicing the Deck Control Manifold Assembly g186178 Figure 99 1. #8 zero-leak plug (8 each) 5. Relief valve (RV1/RV2) (2 each) 2. O-ring (8 each) 6. Pilot piston (2 each) 10. Nut (2 each) 3. O-ring (2 each) 7. Logic element (LC1/LC2) (2 each) 11. Deck control manifold 4. #4 zero-leak plug (2 each) 8. Proportional relief valve (PRV1/PRV2) (2 each) Groundsmaster® 4300-D 16226SL Rev D Page 4–127 9.
Note: The ports on the deck control manifold are marked for easy identification of the components. Example: P1 is the pump P1 connection port and PRV2 is the location for the proportional relief valve PRV2; refer to the Hydraulic Schematic in Appendix A—Foldout Drawings to identify the function of the hydraulic lines and cartridge valves at each manifold port. Note: The deck control manifold uses several zero-leak plugs.
Servicing the Deck Control Manifold Assembly (continued) CAUTION Sudden movement of the internal valve spools can release the stored fluid suddenly. 6. Use clean-mineral spirits and clean the cartridge valve. Put the valve in the clean-mineral spirits to flush out contamination. IMPORTANT Particles as fine as talcum powder can affect the operation of high-pressure hydraulic valves.
Cutting Deck Motor g186175 Figure 100 9. Hydraulic hose 17. Hydraulic hose 1. #4 hydraulic deck motor 2. O-ring 10. 90° hydraulic fitting 18. Hydraulic hose 3. 90° hydraulic fitting 11. Hydraulic hose 19. Hydraulic hose 4. O-ring 12. Hydraulic hose 20. #3 hydraulic deck motor 5. Hydraulic hose 13. 45° hydraulic fitting 21. Hydraulic fitting 6. O-ring 14. Hydraulic hose 22. Hydraulic hose 7. 45° hydraulic fitting 15. #1 hydraulic deck motor 23.
Removing the Cutting Deck Motor g186181 Figure 101 1. Park the machine on a level surface, lower the cutting decks, shut off the engine, set the parking brake, and remove the key from the key switch. 2. Read the General Precautions for Removing and Installing the Hydraulic System Components (page 4–87). 3. For assembly purposes, label all the hydraulic connections. Clean the hydraulic connections before loosening the hydraulic lines from the deck motor.
Removing the Cutting Deck Motor (continued) 4. Disconnect the hydraulic hoses from the fittings in the deck motor. Allow the lines to drain into a suitable container. Remove and discard the O-rings from the fittings. 5. Install clean caps or plugs on the hydraulic hoses and fittings to prevent system contamination. 6. Remove the 2 socket-head screws and 2 flat washers that secure the hydraulic motor to the cutting deck (Figure 102), and remove the hydraulic motor and O-ring from the deck. 7.
Installing the Cutting Deck Motor (continued) 5. Lubricate and install new O-rings to the fittings on the deck motor. Use the labels that you attached during the removal process to correctly connect the hydraulic hoses to the motor fittings; refer to Installing the Hydraulic Hose and Tube (O-Ring Face Seal Fitting) (page 4–9). 6. Check the hydraulic-fluid level in the hydraulic tank and add correct quantity of fluid if necessary; refer to the Operator’s Manual. 7.
Servicing the Cutting Deck Motor g186195 Figure 104 1. Dust seal 8. Rear wear plate 15. O-ring 2. Flange washer 9. Anti-cavitation valve 16. Idler gear 3. Front flange 10. Washer (4 each) 17. Front wear plate 4. Pressure seal 11. Bolt (4 each) 18. Shaft seal 5. Drive gear 12. Relief valve 19. Retaining ring 6. Dowel pin 13. Rear cover 7. Body 14.
Disassembling the Cutting Deck Motor 1. Install clean plugs in the motor ports and clean the outer surface of the motor. After cleaning, remove the plugs and drain the hydraulic fluid out of the motor. g186196 Figure 105 1. Marker line g186197 Figure 106 1. Dust seal 3. Flange washer 2. Retaining ring 4. Shaft seal 2. Use a marker to make a diagonal line across the front flange, body, and rear cover for assembly purposes (Figure 105).
Disassembling the Cutting Deck Motor (continued) 8. Remove and discard the O-rings from the body. Locate and retrieve the dowel pins. IMPORTANT Before removing the wear plates, note the position of the open and closed side of the wear plates. Also identify the wear plates (front and rear) with a marker for proper assembly. IMPORTANT Mark the relative positions of the gear teeth and wear plates so that you can assemble them in the same position.
Inspecting the Cutting Deck Motor (continued) g193306 Figure 107 1. Gear shaft spline 3. Gear shaft 2. Gear teeth 4. Gear face edge 3. Inspect the drive gears and idler gears for the following (Figure 107): A. Gear shafts must be free of rough surfaces and excessive wear at the bushing points and sealing areas. Replace the gears if you find any scoring, rough surfaces, or wear on the gear shafts. B. Gear teeth must be free from excessive scoring and wear.
Assembling the Cutting Deck Motor (continued) 4. Install the pressure seals, flat side outward, into the grooves in the wear plates. Follow by carefully placing the back-up gaskets, flat side outward, between the pressure seals and the grooves in the wear plate. 5. Apply a light coating of petroleum jelly to the exposed side of the front flange. 6. Lubricate the drive gear shaft with clean hydraulic fluid. 7.
Lift Control Manifold g186188 Figure 108 1. Hydraulic hose 7. Flange-head screw (2 each) 13. Hydraulic hose 2. O-ring 8. Hydraulic hose 14. O-ring 9. O-ring 15. Hydraulic tube Hydraulic hose 16. Hydraulic tube 17. Hydraulic hose 3. Lift control manifold 4. O-ring 5. Diagnostic fitting 11. Hydraulic hose 6. Dust cap 12. Hydraulic hose 10. Note: For testing the solenoid valve coils; refer to Testing the Hydraulic Solenoid Valve Coils (page 5–75).
Removing the Lift Control Manifold (continued) 4. For assembly purposes, label all the hydraulic connections. Clean the hydraulic connections before loosening the hydraulic lines. CAUTION Before opening the hydraulic system, operate all the hydraulic controls to release system pressure and avoid injury from the pressurized hydraulic fluid; refer to Releasing Pressure from the Hydraulic System (page 4–6).
Removing the Lift Control Manifold (continued) 7. For assembly purposes, label all the solenoid coil wire harness leads. Disconnect the wire harness leads from the solenoid coils on the manifold. 8. Remove the 2 flange-head screws that secure the manifold to the machine frame. 9. Remove the lift control manifold from the machine. IMPORTANT A flow control orifice is placed below several hydraulic fittings on the lift control manifold (Figure 109). The lift control manifold uses 2 different orifice sizes.
Servicing the Lift Control Manifold g186187 Figure 110 1. Nut 4. Proportional relief valve (PRV) 7. Solenoid valve (S1) 2. Solenoid coil 5. Logic cartridge (LC) 8. Solenoid valve (S2) 3. Nut 6. Lift control manifold 9. Solenoid coil Note: The ports on the lift control manifold are marked for easy identification of the components.
Servicing the Lift Control Manifold (continued) WARNING Ensure that the cutting decks are fully lowered and supported before loosening the hydraulic lines, cartridge valves, or plugs from the lift control manifold. If the decks are not fully lowered as the manifold components are loosened, the decks may drop unexpectedly.
Lift Cylinder g193308 Figure 111 1. 6. Cylinder slide pin Hydraulic hose 11. Flat washer 2. Thrust washer (2 each) 7. O-ring (2 each) 12. Flange-head screw 3. Retaining ring (2 each) 8. Hydraulic hose 13. #1 lift arm 4. O-ring (2 each) 5. 90° hydraulic fitting (2 each) 9. Pivot shaft 10. Lift cylinder g186181 Figure 112 Note: The procedure for lift cylinder removal and installation is the same for all Groundsmaster 4300-D lift cylinders.
Removing the Lift Cylinder g193309 Figure 113 1. Flange nut 3. Carriage screw 2. R-clamp 4. #4 lift cylinder 1. Park the machine on a level surface, lower the cutting decks, shut off the engine, set the parking brake, and remove the key from the key switch. 2. Read the General Precautions for Removing and Installing the Hydraulic System Components (page 4–87). 3.
Installing the Lift Cylinder 1. If the hydraulic fittings were removed from the lift cylinder, lubricate new O-rings with clean hydraulic fluid, position the O-rings to the fittings, and install the fittings into the lift cylinder ports; refer to Installing the Hydraulic Fittings (SAE Straight Thread O-Ring Fitting into the Component Port) (page 4–11). Ensure that the fittings are orientated correctly. 2. Position the lift cylinder to the frame.
Servicing the Lift Cylinder g193307 Figure 114 1. Grease fitting 5. Back-up washer 2. 3. Barrel Piston 6. 7. Head Retaining ring 4. O-ring 8. Shaft Grease fitting 13. Piston seal 10. 11. Dust seal Head seal 14. Locknut 12. O-ring 9. Note: The lift cylinders used on the Groundsmaster 4300-D machines are very similar. The service procedures for all lift cylinders are the same. Disassembling the Lift Cylinder 1.
Disassembling the Lift Cylinder (continued) 3. Use a spanner wrench, rotate the head clockwise until the edge of the retaining ring (item 7 in Figure 114) appears in the barrel opening. Insert a screwdriver under the beveled edge of the retaining ring to start the retaining ring through the opening. Rotate the head counterclockwise to remove the retaining ring from the barrel and head. 4. Remove the plugs from the ports. Carefully twist and pull the shaft and remove the shaft with head and piston.
Assembling the Lift Cylinder (continued) C. Install the piston onto the shaft and secure the piston with the locknut. Torque the locknut to 54 N∙m (40 ft-lb). D. Remove the shaft from the vise. IMPORTANT When you clamp the lift cylinder in a vise, clamp the clevis end of the barrel only to prevent damage. 4. Mount the barrel in a vise by clamping on the clevis end of the barrel.
Steering Control Valve g185938 Figure 115 1. Steering wheel cover 6. Flange nut (6 each) 11. Flange-head screw (2 each) 2. Locknut 7. Steering control valve 12. Column brace 3. Flat washer 8. O-ring (4 each) 13. Socket-head screw (4 each) 4. Steering wheel 9. Straight hydraulic fitting (4 each) 14. Steering column assembly 5. Socket-head screw (4 each) Hydraulic System: Service and Repairs 10.
Removing the Steering Control Valve g185930 Figure 116 1. Platform shroud 5. Cover plate 2. Washer-head screw (6 each) 6. Bushing (2 each) 3. Washer (2 each) 7. Spacer (2 each) 4. Screw (2 each) 8. Flange nut (2 each) 1. Park the machine on a level surface, lower the cutting decks, shut off the engine, set the parking brake, and remove the key from the key switch. 2. Remove the fasteners that secure the shroud to the front of the machine (Figure 116).
Removing the Steering Control Valve (continued) g193311 Figure 117 10. Disconnect the hydraulic lines from the steering control valve. Allow the lines to drain into a suitable container. 11. Install clean caps or plugs on the hydraulic lines and fittings to prevent contamination. 12. Loosen and remove the remaining 2 socket-head screws and 2 flange nuts that secure the steering column to the machine. 13. Remove the steering column and steering control valve assembly from the machine. 14.
Removing the Steering Control Valve (continued) 16. If necessary, remove the hydraulic fittings from the steering control valve. 17. Remove and discard the O-rings from the fittings. Installing the Steering Control Valve 1.
Servicing the Steering Control Valve g193310 Figure 118 10. Plug 19. Bearing O-ring (5 each) 11. Plug 20. Ring End cover 12. O-ring 21. Cross pin 4. O-ring 13. Spring 22. Sleeve 5. Outer gearwheel 14. Relief valve 23. Spool 6. Inner gearwheel 15. Dust seal ring 24. Spring set 7. Distributor plate 16. Housing 25. Thrust washer 26. Shaft seal 1. Screw (5 each) 2. 3. 8. O-ring 17. Check ball 9. Cardan shaft 18.
Steering Cylinder g195114 Figure 119 1. Grease fitting 5. O-ring (2 each) 9. Ball joint 13. Slotted hex nut 2. Hydraulic hose 6. Hydraulic hose 10. Rear axle 14. Right drag link 3. O-ring (2 each) 7. 90° grease fitting 11. Jam nut (2 each) 15. Steering cylinder 4. 90° hydraulic fitting (2 each) 8. Retaining ring 12. Cotter pin 16. Ball joint Removing the Steering Cylinder 1.
Removing the Steering Cylinder (continued) CAUTION Before opening the hydraulic system, operate all the hydraulic controls to release system pressure and avoid injury from the pressurized hydraulic fluid; refer to Releasing Pressure from the Hydraulic System (page 4–6). 3. For assembly purposes, label all the hydraulic hoses and tubes that are connected to the fittings on the steering cylinder. 4. Clean the hydraulic hose ends before you disconnect the hoses from the steering cylinder. 5.
Installing the Steering Cylinder (continued) 2. If removed, press the ball joint (item 9 in Figure 119) into the barrel and secure the ball joint with the retaining ring. 3. If the ball joint was removed from the cylinder shaft, fully retract the cylinder shaft and thread the ball joint into the shaft so that the distance from the cylinder front head to the center of the ball joint is as measured during removal process. Tighten the jam nut. 4. Clean the tapers on the ball joints and axle assembly. 5.
Servicing the Steering Cylinder g193734 Figure 121 1. Dust seal 7. Roll pin 13. Rear head seal 2. Front head seal 8. Rear shaft (1.250 inches) 14. Piston 3. Barrel 9. Rear head O-ring/backup ring 15. Piston seal 4. Front shaft (1 inch) 10. Rear head (1.250 inches) 16. Front head O-ring/backup ring 5. Wear ring 11. External collar (2 each) 17. Front head (1 inch) 6. O-ring 12. Dust seal Disassembling the Steering Cylinder 1.
Disassembling the Steering Cylinder (continued) 5. Hold the end of the front shaft and use a twisting and pulling motion to carefully extract the rear shaft, piston, front shaft, and front head assembly from the barrel. 6. Remove the cylinder from the vise. IMPORTANT When removing the roll pin from the front and rear shafts, ensure that the shaft surfaces are not damaged. 7. Remove and discard the roll pin (item 7 in Figure 121) that secures the front shaft to the rear shaft.
Assembling the Steering Cylinder (continued) IMPORTANT When installing the roll pin into the front and rear shafts, ensure that the shaft surfaces are not damaged. 4. Slide the rear shaft into the front shaft and align the roll pin holes in the shafts. Install new roll pin to secure the shafts. IMPORTANT When clamping the cylinder’s barrel in a vise; clamp on the clevis only to prevent damage. Do not close the vise on the barrel. 5.
Oil Cooler Assembly g188098 Figure 122 1. Screen 10. Washer-head screw (6 each) 19. Hose clamp (4 each) 28. Reservoir bracket 2. Pop rivet (2 each) 11. Mounting bracket (2 each) 20. Lower radiator hose 29. Button-head screw (5 each) 3. Detent ball pin 12. Foam seal (2 each) 21. Upper radiator hose 30. Reservoir cap 4. Draw latch 13. Foam seal (2 each) 22. Draincock 31. Pipe plug 5. Foam seal (2 each) 14. O-ring (2 each) 23. Radiator and oil cooler assembly 32.
Hydraulic System: Service and Repairs Page 4–162 Groundsmaster® 4300-D 16226SL Rev D
Chapter 5 Electrical System Table of Contents General Information .............................................................................................................................. 5–3 Electrical Schematic and Wire Harness Drawings/Diagrams ............................................................. 5–3 Toro Electronic Controller (TEC) ........................................................................................................ 5–3 CAN-bus Communications............................
Seat Switch ...................................................................................................................................... 5–62 Traction Neutral Switch .................................................................................................................... 5–64 Parking Brake Switch ....................................................................................................................... 5–66 Mow/Transport Switch................................................
General Information The Operator’s Manual provides information regarding the operation, general maintenance, and maintenance intervals for your machine. Refer to the Operator’s Manual for additional information when servicing the machine. Electrical Schematic and Wire Harness Drawings/Diagrams Refer to the Electrical Schematic and Wire Harness Drawings/Diagrams in Appendix A (page A–1).
CAN-bus Communications (continued) IMPORTANT The terminator resistors at the ends of the bus cables are required for proper electrical system operation. Yanmar Engine Electronic Control Unit (ECU) g188094 Figure 123 1. Diesel-particulate filter (DPF) 2. Electronic Control Unit (ECU) The Groundsmaster 4300-D machines use an electronic control unit (ECU) for engine management and to communicate with the TEC and InfoCenter display on the machine.
Special Tools You can order these special tools from your Authorized Toro Distributor. Some tools are also available from a local supplier. Multimeter g033636 Figure 124 The meter can test the electrical components and circuits for current, resistance, or voltage. You can get the digital multimeter locally. Note: Use a digital multimeter when testing the electrical circuits.
Battery Hydrometer g033640 Figure 126 Use the battery hydrometer when measuring the specific gravity of the battery electrolyte. You can get this tool locally. Dielectric Gel g033639 Figure 127 Toro Part No. 107-0342 Use the dielectric gel to prevent corrosion of unsealed connection terminals.
InfoCenter Display g190807 Figure 128 1. InfoCenter display 2. Control arm The InfoCenter display used on your Groundsmaster is a LCD device that is located on the control arm (Figure 128). The InfoCenter provides information to the operator during the operation of the machine, provides the electrical system diagnostic assistance for the technicians, and allows inputs for the adjustable machine settings (Figure 129).
g190799 Figure 129 Electrical System: InfoCenter Display Page 5–8 Groundsmaster® 4300-D 16226SL Rev D
Splash Screen g189679 Figure 130 1. Battery voltage 2. Fuel gauge 6. Down button 3. 4. Hour meter Glow plugs energized 7. Menu/back button 5. Left/right button g189680 Figure 131 1. Engine RPM 4. Menu/back button 2. Left/right button 5. Battery voltage 3. Down button 6.
Splash Screen (continued) • Hour meter (displayed for first 5 seconds) • Glow plug indicator (displayed only while glow plugs are energized) • Engine RPM (displayed after 5 seconds) After the splash screen has been displayed for 10 seconds, the main information screen will appear on the InfoCenter. Main Information Screen g189675 Figure 132 1. Engine coolant temperature 6. Menu/back button 2. Fuel gauge 7. Parking brake (engaged) 3. PTO on 8. Traction system (neutral) 4.
Main Information Screen (continued) g189676 Figure 133 1. Navigation pane 2. Left/right button 3. Menu/back button The InfoCenter main information screen (Figure 132) is displayed after the initial splash screen has been displayed for 10 seconds. The main information screen is the default screen as it will be displayed during normal machine operation.
Operator Advisory Screen g187150 Figure 134 1. Fault indicator 3. Advisory description 2. Advisory qualifier 4. Advisory number/code If the Toro Electronic Controller (TEC) inputs are not in the correct position to allow certain machine operations, or are malfunctioning, the fault indicator will illuminate and an advisory screen will appear on the InfoCenter display (Figure 134). Each advisory screen has 3 elements: the advisory number/code, advisory description, and advisory qualifier.
Main Menu Screen g189676 Figure 135 1. Navigation pane 2. Left/right button 3. Menu/back button g187148 Figure 136 1. 2. Main menu Left/right button 3. Down button 4. 5. Menu/back button Menu items The main menu screen (Figure 136) is accessed from the InfoCenter main information screen. Press the menu/back button once to expose the navigation pane (Figure 135), then press the menu/back button again (as indicated by in the navigation pane).
Main Menu Screen (continued) at the bottom of the screen) to Press the down button (as indicated by the highlight the desired menu screen, then press the left/right button (as indicated at the bottom of the screen) to enter the highlighted menu screen. by the To return to the main information screen from the main menu screen, press the menu/back button (as indicated by the at the bottom of the screen). Faults Screen Machine Faults g189674 Figure 137 1. 2. Fault menu Left/right button 3.
Machine Faults (continued) The faults screen (Figure 137 and Figure 138) will list all machine electrical faults that have occurred since the faults were last cleared from the InfoCenter. The faults will be identified by a number code and when the fault occurred. The faults that might occur on the machine are listed in the Machine Faults (page 5–30).
Engine Faults g187359 Figure 139 Yanmar Diesel Engines – If an engine fault occurs during machine operation, the fault indicator will illuminate and the fault will be displayed on the InfoCenter to notify the operator (Figure 139). The engine fault will continue to appear until the offending condition is corrected. Once the offending condition has been corrected, the engine fault will be retained in the engine electronic control unit (ECU) and can only be viewed using the engine diagnostic tool.
Service Screen g189677 Figure 140 1. Service screen (hours) 4. Menu/back button 2. Left/right button 5. Service items 3. Down button The service screen (Figure 140) contains operational information of the machine including hours and counts.
Service Screen (continued) DPF Regeneration (PIN required) allows an operator or technician to initiate a stationary regeneration for the exhaust system DPF (diesel-particulate filter) on the machines with Yanmar diesel engines. If the engine ECU identifies that a stationary DPF regeneration is necessary, an advisory will occur on the InfoCenter display.
Diagnostics Screen The diagnostics screen (Figure 141) lists a variety of machine operations and the current state of the Toro Electronic Controller (TEC) inputs, qualifiers, and outputs required to allow the operation to proceed. The diagnostics screen should be used to troubleshoot machine operation issues, and check that necessary components and circuit wiring are functioning correctly (refer to Troubleshooting (page 5–24)).
Diagnostics Screen (continued) g189672 Figure 141 1. Diagnostics menu 4. Menu/back button 2. Left/right button 5. Diagnostics items 3. Down button Engine identifies the requirements necessary to allow the TEC to start and run the engine. Note: The components for engine operation (i.e., glow plugs, starter) are controlled by the Yanmar engine ECU.
Settings Screen g187358 Figure 142 1. Settings menu 4. Menu/back button 2. Left/right button 5. Settings items 3. Down button g189678 Figure 143 1. Settings menu 4. Menu/back button 2. Left/right button 5. Settings items 3. Down button The settings screen (Figure 142 and Figure 143) allows the operator or technician to customize the InfoCenter display, modify a variety of machine functions, and provides access to unlock various protected menus and settings.
Settings Screen (continued) at the bottom of the Units: Use the left/right button (as indicated by the screen) to select between metric or English units of measure. Allow the desired selection to remain in view for 5 seconds. at the bottom of the Language: Use the left/right button (as indicated by the screen) to select from numerous language options. Allow the desired selection to remain in view for 5 seconds.
Settings Screen (continued) after the correct passcode (PIN) has been entered (refer to the Protected Menus in the Settings Screen (page 5–21)). Counterbalance: Controls the amount of counterbalance applied to the cutting decks. Auto Idle: (Yanmar diesel engines only) When the engine is running and the machine is in neutral, the engine will automatically return to the low idle setting after the set time delay.
Troubleshooting CAUTION Remove all the jewelry, especially rings and watches, before doing any electrical troubleshooting or testing. Disconnect the battery cables unless the test requires battery voltage. For the effective troubleshooting and repairs, you must have a good understanding of the electrical circuits and components that are used on this machine; refer to the Electrical Schematic and Wire Harness Drawings/Diagrams in Appendix A (page A–1).
Operator Advisories (continued) Advisories Table (continued) Advisory Number Groundsmaster® 4300-D 16226SL Rev D Advisory Description Possible Reason for Advisory 178 Low fuel Fuel level in the fuel tank is low 179 Ash cleaning warning Excessive ash accumulated in DPF Advisory Qualifiers Qualifiers Description 160 Engine is running 162 Version check restriction 163 Sit down or set parking brake 164 Machine not in neutral 171 Raise switch closed 172 Lower switch closed 173 Operator n
Using the InfoCenter Display for Troubleshooting g189681 Figure 145 1. Diagnostics menu 4. Menu/back button 2. Left/right button 5. Diagnostics items 3. Down button g189682 Figure 146 1. Diagnostics items 3. Down button 2. Left/right button 4. Menu/back button The diagnostics screen of the InfoCenter display can be very helpful when troubleshooting machine operation issues (refer to Diagnostics Screen (page 5–19)).
Using the InfoCenter Display for Troubleshooting (continued) • PTO The components necessary to engage the cutting decks. • Engine The components necessary to start and run the engine. If a machine operation is malfunctioning, the following procedure can help identify the cause of the component or circuit wiring causing the malfunction. 1. Park the machine on a level surface, lower the cutting decks, set the parking brake, and shut off the engine. 2.
Using the InfoCenter Display for Troubleshooting (continued) g189684 Figure 148 1. 2. 3. 4. Qualifier items Left/right button Down button Menu/back button 5. Manually operate each input item listed (Figure 147). The input condition on the InfoCenter display should alternate ON and OFF as the input is switched open and closed.
Using the InfoCenter Display for Troubleshooting (continued) In the PTO operation example, the following qualifiers must be in the desired condition ( ) before any operation Outputs can be energized: • Joystick lower off • Mow/transport switch in LOW (mow) range • Operator must be in seat (seat switch) • Engine temperature is ok • Engine must be running Engine RPM above 800 as reported by engine ECU and do not alternate when the qualifier condition is changed, the If qualifier or the circuit wiring for the
Machine Faults The Machine Fault Table (page 5–31) identifies the fault codes that are generated by the Toro Electronic Controller (TEC) to identify an electrical system fault (malfunction) that occurred during the operation of the machine. Use the InfoCenter display to view faults that have occurred since the faults were last cleared from the InfoCenter; refer to Faults Screen (page 5–14). The Yanmar engine ECU can also generate electrical faults.
Using Machine Faults (continued) Machine Fault Table Fault Code 1 Fault Description Excessive engine coolant temperature (above 105°C) caused PTO to disengage Service Suggestions Check the radiator and screen for debris buildup Check the engine cooling fan and drive belt Check the engine coolant level 2 Excessive engine coolant temperature (above 115°C) caused engine to stop Check the radiator and screen for debris buildup Check the engine cooling fan and drive belt Check the engine coolant level 3 O
Using Machine Faults (continued) Machine Fault Table (continued) Fault Code Electrical System: Troubleshooting Fault Description Service Suggestions 37 TEC output current to energize glow relay is excessive Check the glow relay and circuit wiring 53 TEC output current for hydraulic solenoid coil SV1 is excessive Check the lift control manifold solenoid coil SV1 and circuit wiring 54 TEC output current for hydraulic solenoid coil SV2 is excessive Check the lift control manifold solenoid coil SV2
Engine Faults g187359 Figure 149 The engine faults are generated by the Yanmar engine ECU to identify an electrical system malfunction (fault) pertaining to the engine during operation. When an engine fault occurs, the fault indicator will flash and the InfoCenter will display information about the fault. The number of flashes and/or the flashing pattern vary depending on the type or source of the fault, enabling quick-fix. Depending on the severity of the fault, a Stop icon may display as well.
Starting Problems Problem Possible Causes All the electrical power is dead, including the InfoCenter display. • The battery is discharged or damaged. • The battery cables are loose or corroded. • The fuse F1-1 (15 A) or F1-2 (10 A) is damaged. • The ground connection is loose or corroded. • The key switch or circuit wiring is damaged. • The fusible link harness at the engine starter motor is damaged. The starter solenoid clicks, but the starter does not crank.
Starting Problems (continued) Problem Possible Causes The engine starts, but stops when the key switch is released from the START position. • The circuit wiring is damaged. Nothing happens when you attempt to start the engine. The InfoCenter display operates with the key switch in the RUN position. • The traction pedal is not in the NEUTRAL position. Note: An operator advisory is displayed on the InfoCenter if the interlock switches for engine start are not functioning.
General Run and Transport Problems Problem Possible Causes The engine continues to run, but should not, when the key switch is turned to the OFF position. • The key switch or circuit wiring is damaged. • The main power relay or circuit wiring is damaged. • The engine or fuel system is malfunctioning; refer to Chapter 3: Diesel Engine (page 3–1). The engine continues to run, but should not, when the traction pedal is engaged with no operator in the seat. • The seat switch or circuit wiring is damaged.
Cutting Deck Operating Problems Problem Possible Causes The cutting decks remain engaged, but should not, with no operator in the seat. • The seat switch or circuit wiring is damaged. • The TEC is damaged. The cutting decks run, but should not, when raised. The cutting decks shut off with the PTO switch. • A hydraulic problem in the cutting deck circuit exists; refer to Troubleshooting (page 4–39). The cutting decks run, but should not, when raised.
Cutting Deck Lift/Lower Problems Problem Possible Causes None of the cutting decks will lower. • The seat switch or circuit wiring is damaged. • The mow speed limiter is in the TRANSPORT position. • The lower/mow switch on the joystick or circuit wiring is damaged. • The mow/transport switch or circuit wiring is damaged. • The lift control manifold PRV solenoid coil or circuit wiring is damaged. • The lift control manifold S1 solenoid coil or circuit wiring is damaged.
Electrical System Quick Checks Testing the Battery (Open Circuit Test) Use a multimeter to measure the voltage between the battery terminals; refer to Battery Test Table (page 5–39). Set the multimeter to the DC volts settings. The battery must be at a temperature of 16°C to 38°C (60°F to 100°F). Ensure that the key switch is in the OFF position and all the accessories are turned off.
Testing the Charging System (continued) Battery Voltage Table At least 0.50 V over the initial battery voltage. Initial battery voltage = 12.30 V Battery voltage after 3 minutes charge = 12.85 V Difference = +0.55 V Testing the Glow Plug System This is a fast, simple test that helps to determine the integrity and operation of the Groundsmaster glow plug system. Perform this test when you find hard starting (cold engine) on a diesel engine equipped with a glow plug system.
Adjustments Traction Neutral Switch g190164 Figure 150 1. Pump plate 4. Jam nut (2 each) 2. Traction pump 5. Lock washer (2 each) 3. Traction neutral switch 6. Pump lever g190165 Figure 151 1. Traction pump 2. Traction neutral switch 3. Pump lever 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 pump plate on the traction pump (Figure 150).
Adjusting the Traction Neutral Switch (continued) Note: To prevent the traction neutral switch damage, ensure that the pump lever does not contact the switch. 2. When the traction pedal is in the NEUTRAL position, the gap between the head of the neutral switch and the pump lever should be 3.05 to 3.55 mm (0.12 to 0.14 inch) (Figure 151). 3. If gap is incorrect, loosen the jam nuts that secure the neutral switch to the pump plate.
Parking Brake Switch g190163 Figure 152 1. Parking brake detent 4. Jam nut (2 each) 2. Brake pedal 5. Parking brake switch 3. Lock washer (2 each) The parking brake switch is a normally open proximity switch. The parking brake switch is attached to the bottom of the brake pedal (Figure 152). When the parking brake is not set, the parking brake detent is positioned near the target end of the parking brake switch so that the switch is closed.
Mow/Transport Switch g190162 Figure 153 1. Mow speed limiter 2. Gap 3. 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 (Figure 153). The sensing plate for the mow/transport switch is the mow speed limiter. Adjusting the Mow/Transport Switch 1. The gap between the mow/transport switch and the mow speed limiter should be 1.4 to 2.
Testing the Electrical Components For accurate resistance and/or continuity checks, electrically disconnect the component being tested from the circuit (e.g., unplug the key switch connector before doing a continuity check of the switch). Note: Use the InfoCenter display to test the TEC inputs and outputs before further troubleshooting of an electrical problem on your Groundsmaster. Note: For engine component testing information; refer to the Yanmar Engine Service Manual or Troubleshooting Manual.
fail, current to the protected circuit stops; refer to the Electrical Schematic in Appendix A—Foldout Drawings for additional circuit information. Testing the Fusible Link Harness 1. Ensure that the key switch is in the OFF position, disconnect the negative battery cable from the battery terminal, and then disconnect the positive cable from the battery; refer to Servicing the Battery (page 5–95). 2. Locate and unplug the fusible link connector P1 from the platform wire harness. 3.
Fuses g191008 Figure 156 1. Fuse block 2. TEC (Toro Electronic Controller) g191006 Figure 157 1. 2. Starter motor 10 A fuse 3. 2 A fuse The fuse block is located behind the control arm access cover (Figure 156). In addition to the fuses in the fuse block, there are 2 additional fuses included in the engine wire harness. These fuses plug into the in-line fuse holders near the starter motor (Figure 157). The fuses have the following functions: 2 A fuse: Protects the TEC logic power circuit.
Identification and Function g190996 Figure 158 Refer to Figure 158 to identify each individual fuse and its correct amperage. The fuses have the following functions. F1-1 (15 A): Protects starter circuit power supply. F1-2 (10 A): Protects main power supply. F1-3 (10 A): Protects power supply for headlights. F1-4 (10 A): Protects power supply for power point. F2-1 (7.5 A): Protects power supply for TEC outputs. F2-2 (7.5 A): Protects power supply for TEC outputs. F2-3 (7.
Toro Electronic Controller (TEC) g191008 Figure 159 1. Fuse block 2. TEC (Toro Electronic Controller) g190804 Figure 160 The Groundsmaster 4300-D machine uses a Toro Electronic Controller (TEC) to monitor the condition of various switches (inputs) and then direct power output to allow certain machine functions.
Toro Electronic Controller (TEC) (continued) arm access cover next to the fuse block (Figure 159). Use the InfoCenter display when checking the inputs and outputs of the TEC used on your machine. The logic power is provided to the controller as long as the battery cables are connected to the battery. Circuit protection for this logic power to the controller is provided by 2 A fuse.
Toro Electronic Controller (TEC) (continued) g321413 Figure 161 1. 2. TEC controller Machine harness connector 3. Socket head screw If the wire harness connector is removed from the TEC controller for any reason, tighten the harness connector screw from 2.8 to 3.2 N·m (25 to 28 in-lb).
Key Switch g190808 Figure 162 1. Key switch 2. Control arm g190999 Figure 163 The key switch is located on the control arm and has 3 positions: OFF, RUN, and START (Figure 163). The Toro Electronic Controller (TEC) monitors the operation of the key switch. Testing the Key Switch 1. Park the machine on a level surface, lower the cutting decks, set the parking brake, and shut off the engine. Remove the key from the key switch. 2.
Testing the Key Switch (continued) Circuit Logic Table Switch Position Circuits OFF None RUN B+C+F, D+E START A+B+C 8. Replace the key switch if testing determines that it is damaged. 9. If the key switch testing is correct and a circuit problem still exists, check the wire harness; refer to the Electrical Schematic and Wire Harness Drawings/Diagrams in Appendix A (page A–1). 10. After you complete the testing, connect the platform wire harness connector to the key switch. 11.
PTO Switch g191000 Figure 164 1. PTO switch 2. Control arm g191001 Figure 165 The PTO switch is located on the control arm (Figure 164) and allows the cutting decks to operate when the front of the switch is pressed. An indicator light on the switch identifies when the PTO switch is engaged. The TEC monitors the position of the PTO switch (up or down).
Testing the PTO Switch (continued) multimeter (ohms setting), test the switch functions to determine if continuity exists between the various terminals for each switch position. Check the continuity between the switch terminals. Circuit Logic Table Switch Position Normal Circuits Other Circuits ON 2+3 5+6 OFF 2+1 5+4 8. Replace the PTO switch if testing determines that the switch is damaged. 9.
Engine Speed Switch g190806 Figure 166 1. 2. Control arm Engine speed switch g037935 Figure 167 The engine speed switch is used as an input for the TEC to signal the engine ECU via the CAN-bus to increase or decrease the engine speed. When the switch is pressed and held in the forward position, the engine speed will increase. Conversely, when the rear of the switch is pressed, the engine speed will decrease. The engine speed switch is located on the control arm (Figure 166).
Testing the Engine Speed Switch (continued) Circuit Logic Table Switch Position Normal Circuits Other Circuits DECREASE 2+1 5+4 OFF None None INCREASE 2+3 5+6 Note: The engine speed switch terminals 4, 5, and 6 are not used on the Groundsmaster 4300-D machines. 8. Replace the engine speed switch if testing determines that the switch is damaged. 9.
Lower/Raise Joystick Switches g190998 Figure 168 1. Joystick 2. Control arm g191007 Figure 169 1. Joystick 5. Normally Closed terminal (not used) 2. 3. 4. Switch lever Common terminal Normally Open (NO) terminal 6. 7. Raise switch Lower switch The cutting deck lower and raise switches are located on the joystick assembly that is located on the control arm (Figure 168). When the joystick is pushed forward, the rear switch is used to lower the cutting decks.
Testing the Lower/Raise Joystick Switches (continued) 3. If the InfoCenter verifies that the joystick switches and circuit wiring are functioning correctly, no further switch testing is necessary. 4. If the InfoCenter determines that the joystick switches and circuit wiring are not functioning correctly, proceed with the test. 5. Remove the control arm covers to get access to the joystick switches; refer to Disassembling the Control Arm (page 6–24). 6. Ensure that the key switch is in the OFF position.
Headlight Switch g190997 Figure 170 1. 2. Control arm Headlight switch g037935 Figure 171 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 the Headlight Switch 1. Park the machine on a level surface, lower the cutting decks, set the parking brake, and shut off the engine. 2. Remove the left control arm cover to get access to the headlight switch; refer to Disassembling the Control Arm (page 6–24). 3.
Testing the Headlight Switch (continued) 6. If the switch testing is correct and a circuit problem still exists, check the wire harness; refer to the Electrical Schematic and Wire Harness Drawings/Diagrams in Appendix A (page A–1). 7. After you complete the testing, connect the wire harness connector to the headlight switch. 8. Secure the left control arm cover to the machine; refer to Assembling the Control Arm (page 6–24).
Seat Switch g190802 Figure 172 1. Platform wire harness 2. Seat switch connector g190803 Figure 173 1. Operator seat 3. Washer-head screw (2 each) 2. Seat switch harness 4. Seat switch The seat switch is normally open and closes when the operator is on the seat. If the traction system or PTO switch is engaged when the operator raises out of the seat, an operator advisory will be displayed on the InfoCenter.
Testing the Seat Switch (continued) 2. Before you disconnect the seat switch for testing, ensure that you test the switch and its circuit wiring as a TEC electrical input with the InfoCenter display; refer to Using the InfoCenter Display for Troubleshooting (page 5–26). 3. If the InfoCenter verifies that the seat switch and circuit wiring are functioning correctly, no further switch testing is necessary. 4.
Traction Neutral Switch g190822 Figure 174 1. Pump plate 5. Jam nut (2 each) 2. Traction pump 6. Lock washer (2 each) 3. Switch LED location 7. Pump lever 4. 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 pump plate on the traction pump (Figure 174). The sensing plate for the traction neutral switch is the pump lever that is secured to the traction pump.
Testing the Traction Neutral Switch (continued) B. Ensure that the key switch is in the OFF position and disconnect the traction neutral switch connector from the platform wire harness. C. Use a multimeter (ohms setting), check that the platform wire harness connector terminal for black wire is closed (continuity) to the ground. D.
Parking Brake Switch g190820 Figure 175 1. Brake pedal 4. Parking brake switch 2. Lock washer (2 each) 5. Switch LED location 3. Jam nut (2 each) 6. Parking brake detent The parking brake switch is a normally open proximity switch. The parking brake switch is attached to the bottom of the brake pedal (Figure 175). The machine is equipped with an interlock switch on the parking brake.
Testing the Parking Brake Switch (continued) 7. With the key switch still in the RUN position (do not start the engine), set the parking brake and check the LED on the cable end of the parking brake switch. The LED should not be illuminated when the parking brake is set. 8. If the parking brake switch LED did not function correctly, do the following: A. Ensure that the parking brake switch is properly adjusted; refer to Adjusting the Parking Brake Switch (page 5–43).
Mow/Transport Switch g190819 Figure 176 1. Mow speed limiter 2. Mow/transport switch 3. Switch LED location 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 (Figure 176). The sensing plate for the mow/transport switch is the mow speed limiter. The Toro Electronic Controller (TEC) monitors the operation of the mow/transport switch.
Testing the Mow/Transport Switch (continued) D. Turn key switch to the RUN position (do not start the engine) and check with a multimeter that the platform wire harness connector terminal for pink wire has system voltage (12 VDC) present. E. If the black wire is closed to the ground, the pink wire has system voltage present, and the switch LED did not function, replace the mow/transport switch. Adjust the switch after installation; refer to Adjusting the Mow/Transport Switch (page 5–44). 8.
Relays with 4 Terminals g190796 Figure 177 1. Hydraulic pump driveshaft 2. Glow relay 3. Main power relay g034744 Figure 178 The Groundsmaster 4300-D machine uses 2 identical electrical relays that have 4 terminals. A tag near the wire harness relay connector can be used to identify each relay. The main power relay is used to provide current to the TEC, headlights, power point, and optional electric equipment. When the key switch is in the RUN or START position, the main power relay is energized.
The main power and glow relay are attached to a frame bracket under the hood next to the hydraulic pump driveshaft (Figure 177). Testing the Relays with 4 Terminals 1. Park the machine on a level surface, lower the cutting decks, shut off the engine, set the parking brake, and remove the key from the key switch. 2.
Relays with 5 Terminals g190797 Figure 179 1. Hydraulic pump driveshaft 2. EGR relay 3. Start relay g034753 Figure 180 1. Coil terminal 3. Normally open term 2. Normally closed term 4. Common terminal The Groundsmaster 4300-D machine uses 2 identical electrical relays that have 5 terminals. A tag near the wire harness relay connector can be used to identify each relay. The start relay is used in the engine starting circuit.
Testing the Relays with 5 Terminals 1. Park the machine on a level surface, lower the cutting decks, shut off the engine, set the parking brake, and remove the key from the key switch. 2. Ensure that the machine operation does not occur unexpectedly, disconnect the negative (-) cable from the battery and then disconnect the positive (+) cable from the battery; refer to Servicing the Battery (page 5–95). 3. Locate the relay that is to be tested. 4.
Hydraulic Solenoid Valve Coils g191004 Figure 181 1. 2. 3. Deck control manifold PRV1 solenoid PRV2 solenoid g189663 Figure 182 1. 2. 3. 4.
The Groundsmaster 4300-D hydraulic control manifolds use several hydraulic solenoid valve coils for system control. The deck control manifold includes 2 solenoid valves (Figure 181) and the lift control manifold includes 3 solenoid valves (Figure 182). When the solenoid coils are energized, the hydraulic valve shift occurs to control the hydraulic fluid flow. The correct resistance of a coil can be identified by measuring the height and diameter of the coil (Figure 183).
Testing the Hydraulic Solenoid Valve Coils (continued) 7. If the solenoid coil testing is correct and a circuit problem still exists, check the platform wire harness; refer to the Electrical Schematic and Wire Harness Drawings/Diagrams in Appendix A (page A–1). 8. After testing the coils, connect the wire harness electrical connector to the solenoid valve coil. 9. Lower and secure the operator seat if the deck control manifold was accessed.
Fuel Sender g191005 Figure 184 1. Fuel sender cap 2. Fuel sender 6. Screw (5 each) 3. 4. Fuel tank Fuel sender gasket 7. 8. Fuel return hose Fuel supply hose 5. Sender cover The fuel sender is a variable resistance device that is located in the fuel tank (Figure 184). The resistance of the fuel sender increases as the fuel level in the fuel tank decreases. The TEC uses the fuel sender as an input to generate an output for the InfoCenter fuel gauge. Testing the Fuel Sender 1.
Testing the Fuel Sender (continued) 4. To test the circuit wiring and InfoCenter fuel gauge, use a jumper wire to connect the 2 terminals in the wire harness connector. Ensure that the jumper wire connections are secure. g188097 Figure 185 1. Fuel sender 2. Fuel supply fitting 3. Fuel return fitting 5. Turn the key switch to the RUN position. The InfoCenter display should indicate a full fuel tank if the circuit wiring and InfoCenter are working correctly.
Testing the Fuel Sender (continued) g191009 Figure 186 1. Sender full position 2. Sender empty position 9. Use a multimeter to check the resistance of the fuel sender across the 2 sender terminals (Figure 186). A. The resistance with the float in the full position (completely up) should be 5 to 8 ohms. B. The resistance with the float in the empty position (completely down) should be 89 to 95 ohms. 10. Replace the fuel sender if testing determines that it is damaged. 11.
Fuel Pump The fuel pump is attached to the air cleaner stand adapter below the fuel/water separator (Figure 187). Electrical current is available for the fuel pump when the key switch is in either the RUN or START position. The Toro Electronic Controller (TEC) energizes the fuel pump. IMPORTANT When testing the fuel pump, ensure that the pump is not operated without fuel. DANGER Diesel fuel is highly flammable. • Use caution whenever you handle diesel fuel. • Do not smoke while testing the fuel pump.
Testing the Fuel Pump Capacity (continued) 5. Place the disconnected end of the pump discharge hose into a large, graduated cylinder sufficient enough to collect 0.9 L (32 fl oz). IMPORTANT When testing the fuel pump output, do not turn the key switch to the START position. 6. Turn the key switch to the ON position and collect the fuel in the graduated cylinder. Allow the pump to run for 30 seconds and then turn the switch to the OFF position.
CAN-bus Terminator Resistor g035036 Figure 188 1. 2. CAN-bus terminator resistor Keyway The system communication between the electrical components on the Groundsmaster 4300-D machine is accomplished on a CAN-bus communication system. The 2 specially designed, twisted cables form the bus for the network are used on the machine. These wires provide the data pathways between the machine components. The 120 ohm CAN-bus terminator resistor plugs into the platform wire harness in the control arm.
Resistor Assembly g034715 Figure 189 1. 2. End of the resistor body Resistor assembly g190821 Figure 190 1. 2. Engine ECU 75 ohm resistor A 75 ohm resistor (Figure 190) is necessary for proper key switch operation on all Groundsmaster 4300-D machines. The resistor plugs into the engine wire harness near the engine ECU; refer to the Engine Wire Harness Drawing/Diagram in Appendix A—Foldout Drawings.
Diode Assemblies g034714 Figure 191 1. End of the diode body 3. Male terminal 2. Diode assembly 4. Female terminal g190805 Figure 192 1. Diode (2 each) 2. Engine ECU The electrical system of the Groundsmaster 4300-D machine includes 2 identical diodes. The maximum current allowed through any of the diodes is 6 A. The diode assemblies can be identified by a black color, diode symbol, and Toro Part Number on the end of the diode assembly body (Figure 191).
Testing the Diode Assembly (continued) 3. The diode (Figure 191) can be tested by using a digital multimeter (diode test or ohms setting) and the Diode Test Table (page 5–85). 4. Replace the diode assembly if testing determines that the diode is damaged. 5. After you complete the testing, ensure that the diode is fully installed into the wire harness connector and secured to the harness with cable tie.
Pressure Transducer g212730 Figure 193 1. Traction pump 2. Hydraulic tube 3. Pressure transducer g212731 Figure 194 1. 2. Machine wire harness connector 1.5 V dry cell battery 3. Multimeter probe Electrical System: Testing the Electrical Components Page 5–86 4. 5.
The hydraulic pressure transducer is installed on the forward traction hydraulic tube located in between the front wheels (Figure 193). The transducer senses the counterbalance pressure between the hydraulic motors and the hydraulic pump. The TEC monitors the counterbalance pressure range using inputs from the pressure transducer and controls the energizing of the hydraulic solenoid valves used to drive the cutting deck motors. Testing the Pressure Transducer 1.
Fan Speed Switch (Machines with Two−Post ROPS Extension Operator Fan Kit) g242793 Figure 195 1. Fan speed switch 2. Control knob 3. Control panel g242792 Figure 196 Back of Switch The fan speed switch is attached to the overhead control panel (Figure 195). The switch is used to select the fan speed (OFF, LOW, MEDIUMOR HIGH). Testing 1. Park the machine on a level surface, lower the cutting decks, and shut off the engine. Remove the key from the key switch. 2.
Testing (continued) Switch Position Closed Circuits OFF L+H LOW B+C+L MEDIUM B+C+M HIGH B+C+H 5. Replace the fan speed switch if testing determines that the switch is damaged. 6. If the fan speed switch testing is correct and a circuit problem still exists, check the wire harness; refer to Appendix A (page A–1) - Foldout Drawings. 7. After you complete the testing, connect the machine wire harness to the switch and install the sunshade.
Resistor Module (Machines with Two−Post ROPS Extension Operator Fan Kit) g242796 Figure 197 1. Operator’s fan 2. Fan mount bracket 3. Resistor module g250221 Figure 198 1. Pin 1 (Violet wire) 4. Pin 4 (Not used) 2. Pin 2 (Brown wire) 5. Motor pin 3. Pin 3 (Orange wire) 6. Resistor module The resistor module is attached to the rear of the fan mounting bracket (Figure 197). The resistor module is used for operation of the operator’s fan.
Testing 1. Park the machine on a level surface, lower the cutting decks, and shut off the engine. Remove the key from the key switch. 2. To access the resistor, remove the sunshade from the top of the ROPS extension. 3. Disconnect the wire harness connectors from the resistor module terminals. 4. Use a multimeter to check that the resistance values of the resistor module as below (Figure 198).
Service and Repairs Note: For engine component repair information, refer to the Yanmar Engine Service Manual or Troubleshooting Manual. Hydraulic Solenoid Valve Coils g191011 Figure 199 1. 2. 3. 4. Deck control manifold Solenoid coil PRV1 Nut Solenoid coil PRV2 g191010 Figure 200 1. 2. 3. Nut Solenoid coil PRV Lift control manifold 4. 5. 6.
Removing the Hydraulic Solenoid Valve Coils 1. Park the machine on a level surface, lower the cutting decks, set the parking brake, shut off the engine, and remove the key from the key switch. 2. Locate the solenoid valve coil that you replace. A. Tilt the operator seat up to get access to the deck control manifold. Refer to Figure 199 for the location of solenoid coils on the deck control manifold. B. The lift control manifold is attached to a frame bracket under the operator floor plate.
Battery Care (continued) WARNING The gases are explosive; also, they can cause nausea. • Wear safety goggles and rubber gloves when working with electrolyte. Charge the battery in a well ventilated place so that the gasses produced while charging can dissipate. • Keep open flames and electrical sparks away from the battery; do not smoke. • Disconnect the charger from the electrical outlet before connecting or disconnecting charger leads to or from the battery posts.
Servicing the Battery The battery is the heart of the electrical system. With the regular and correct service, the battery life can be extended. Additionally, the battery and electrical component failure can be prevented. CAUTION Battery-electrolyte is corrosive and can burn skin and eyes and damage clothing. While working with the batteries, use extreme caution to avoid splashing or spilling of the electrolyte. Always wear the safety goggles and a face shield while working with batteries.
Removing and Installing the Battery (continued) IMPORTANT Be careful when removing the battery cables and ensure that you do not damage the terminal posts or cable connectors. 1. Unlatch, raise the hood and support it. 2. Loosen and remove the negative (-) cable from the battery. After you disconnect the negative cable from the battery, loosen and remove the positive cable (+) from the battery. 3. Loosen the flange nut that secures the battery retainer. 4. Carefully remove the battery from the machine. 5.
Inspecting, Maintaining, and Testing the Battery (continued) IMPORTANT Ensure that the area around the cells is clean before opening the battery caps. A. Use a hydrometer to measure the specific gravity of each cell. Pull the electrolyte in and out of the hydrometer barrel before taking a reading to warm-up the hydrometer. At the same time, take the temperature of the cell. B. Temperature correct each cell reading. For each 5.5°C (10°F) above 27°C (80°F) add 0.004 to the specific gravity reading.
Inspecting, Maintaining, and Testing the Battery (continued) E. If you charge the battery, apply a 150 A load for 15 seconds to remove the surface charge. Wait for 10 minutes before proceeding with load test. F. Apply a test load of 270 A (1/2 the cranking performance rating of the battery) for 15 seconds. G. After test load has been applied for 15 seconds, take a test voltage reading and then remove the load. Record the test voltage reading. H.
Charging the Battery (continued) 2. Determine the charging time and rate using the manufacturer's battery charger instructions or the following Battery Charge Level Table (page 5–99). Battery Charge Level Table Battery Reserve Capacity (Minutes) 75% 50% 25% 0% 80 or less 3.8 hrs 7.5 hrs 11.3 hrs 15 hrs @ @ @ @ 3 A 3 A 3 A 3 A 5.3 hrs 10.5 hrs 15.8 hrs 21 hrs @ @ @ @ 4 A 4 A 4 A 4 A 5.5 hrs 11 hrs 16.5 hrs 22 hrs @ @ @ @ 5 A 5 A 5 A 5 A 5.8 hrs 11.5 hrs 17.
Charging the Battery (continued) Note: The battery is fully charged when the cells are gassing freely at a low charging rate and there is less than a 0.003 change in specific gravity for 3 consecutive readings.
Chapter 6 Chassis Table of Contents Specifications ....................................................................................................................................... 6–2 Chassis .............................................................................................................................................. 6–2 General Information ..............................................................................................................................
Specifications Chassis Item Description Front tire pressure (26.5×14.0-12, 4 ply, tubeless) 83 to 103 kPa (12 to 15 psi) Rear tire pressure (20×12.0-10, 4 ply, tubeless) 83 to 103 kPa (12 to 15 psi) Wheel lug nut torque 95 to 122 N∙m (70 to 90 ft-lb) Steering control valve mounting screws Steering wheel mounting nut Chassis: Specifications 9.5 to 13.
General Information The Operator’s Manual provides information regarding the operation, general maintenance, and maintenance intervals for your Groundsmaster 4300-D machine. Refer to the Operator’s Manual for additional information when servicing the machine.
Special Tools You can order the special tools from your Toro Distributor. Wheel Hub Puller g185941 Figure 202 The wheel hub puller allows you to safely remove the wheel hub from the wheel motor shaft. Toro Part No.
Service and Repairs Wheels g185942 Figure 203 1. Rear wheel 5. Brake assembly (left) 2. Wheel-lug nut (5 each per wheel) 6. Wheel stud (5 each per hub) 10. Locknut 3. 4. Locknut Front wheel motor (left) 7. 8. Front wheel hub Brake drum 11. 12. Rear wheel hub Rear wheel motor (left) Groundsmaster® 4300-D 16226SL Rev D Page 6–5 9.
Removing the Wheel 1. Park the machine on a level surface, lower the cutting decks, shut off the engine, set the parking brake, and remove the key from the key switch. 2. Block the wheels that are not removed with chocks to prevent the machine from moving. 3. Loosen, but do not remove the 5 wheel-lug nuts that attach the wheel to the machine. IMPORTANT Before lifting the machine with a jack, review and follow Jacking Instructions (page 1–6). 4.
Steering Column g185938 Figure 204 1. Steering wheel cover 6. Flange nut (6 each) 11. Flange-head screw (2 each) 2. Locknut 7. Steering control valve 12. Column brace 3. Flat washer 8. O-ring (4 each) 13. Socket-head screw (4 each) 4. Steering wheel 9. Straight hydraulic fitting (4 each) 14. Steering column assembly 5. Socket-head screw (4 each) Groundsmaster® 4300-D 16226SL Rev D 10.
Removing the Steering Column g185930 Figure 205 1. Platform shroud 5. Cover plate 2. Washer-head screw (6 each) 6. Bushing (2 each) 3. Washer (2 each) 7. Spacer (2 each) 4. Screw (2 each) 8. Flange nut (2 each) g185937 Figure 206 Chassis: Service and Repairs 9. Pin 1. Steering column 2. 3. Pin Lock washer (2 each) 10. 11. Pedal block Pedal cover 4. Release pin 12. Pedal 5. Cylinder shaft 13. Spring 6. Jam nut 14. Universal joint 7. Cylinder 15. Pin 8.
Removing the Steering Column (continued) 1. Park the machine on a level surface, set the parking brake, lower the cutting decks, shut off the engine, and remove the key from the key switch. 2. Remove the steering wheel cover (item 1 in Figure 204) from the steering wheel by carefully prying up on one of the cover spokes. 3. Remove the locknut (item 2 in Figure 204) and flat washer that secure the steering wheel to the steering column. 4.
Installing the Steering Column 1. Assemble the steering column (Figure 206). After assembly, ensure that the release pin on the end of the cylinder shaft is positioned against the pedal. The jam nut on the cylinder shaft can be used to adjust the location of the release pin. 2. Apply anti-seize lubricant to the input shaft of the steering control valve (item 7 in Figure 204). 3. Slide the steering column assembly (item 14 in Figure 204) onto the steering control valve.
Servicing the Brakes g185925 Figure 207 1. Locknut (2 each per wheel shield) 10. Bolt (4 each per brake assembly) 19. Brake return spring (2 each) 2. Wheel shield (right rear) 11. Left spring clip 20. Bolt (2 each) 3. Flange-head screw (2 each per wheel shield) 12. Front wheel (left) 21. Jam nut (2 each) 4. Locknut (4 each per wheel motor) 13. Wheel-lug nut (5 each per wheel) 22. Right spring clip 5. Left wheel motor 14. Brake drum (2 each) 23. Flange nut (2 each) 6.
Disassembling the Brake 1. Park the machine on a level surface, lower the cutting decks, shut off the engine, and remove the key from the key switch. g185919 Figure 208 1. Hold down pin (2 each) 8. Hold down spring (2 each) 2. Backing plate 9. 3. Rivet (4 each) 10. 4. Clevis pin 11. Brake actuator 5. Retaining ring 12. Brake actuator lever Hold down cup (2 each) Shoe spring (actuator) 6. Brake shoe (2 each) 13. Back-up plate 7. Shoe spring 14. Boot g185920 Figure 209 1. 2.
Disassembling the Brake (continued) Note: The clevis pin (item 25 in Figure 207) that secures the brake cable to the brake actuator lever is secured with the brake return spring. 5. Remove the brake return spring (item 19 in Figure 207) and clevis pin that attach the brake cable to the brake actuator lever. 6. Remove the brake drum (item 14 in Figure 207) from the brake assembly. IMPORTANT Do not hit the wheel hub, wheel-hub puller, or wheel motor with a hammer while removing or installing the wheel hub.
Assembling the Brake 1. Use a wire brush to remove rust and unwanted material from all the brake parts before the installation. Clean all the parts. 2. Visually examine the brake shoes and contact surfaces of the brake drum for excessive wear. Replace the parts that are worn and damaged. 3. If the brake backing plate was removed from the machine, secure the backing plate to the brake adapter with the 4 bolts (item 10 in Figure 207). 4.
Assembling the Brake (continued) CAUTION After servicing the brakes, always check the brakes for proper operation in a wide open, level area that is free of other persons and obstructions. 15. Check for the operation of the brake, before you return the machine to operation. Burnish Brake Pads After brake pads replacement, burnish (break-in) the brakes before use. 1. Bring the machine to full speed and apply the brakes to rapidly stop the machine without skidding or locking up the wheels. 2.
Rear Axle Motor Housings g185931 Figure 210 1. Steering cylinder 8. Left drag link 15. Lock washer (4 each per 22. motor) 2. Flange-head screw (2 each) 9. Woodruff key 16. Rear wheel motor (left) 23. Right drag link 3. Spindle cap (2 each) 10. Rear wheel (left) 17. Motor housing (2 each) 24. Motor housing shaft 4. Retaining ring (2 each) 11. Wheel-lug nut (5 each per wheel) 18. Cotter pin (3 each) 25. Ball joint 5. Flange bushing (4 each) 12. Locknut 19.
Removing the Rear Axle Motor Housings 1. Park the machine on a level surface, lower the cutting decks, shut off the engine, set the parking brake, and remove the key from the key switch. 2. Block the front wheels with chocks to prevent the machine from moving. 3. Remove the rear wheel assembly; refer to Removing the Wheel (page 6–6). 4. Remove the cotter pin and slotted hex nut that secure the tie rod end (item 22 in Figure 210) to the drag link.
Installing the Rear Axle Motor Housings (continued) 6. Slide the wheel motor assembly (with the wheel hub and hydraulic hoses attached) into the motor housing. Secure the wheel motor to the motor housing with the 4 bolts and 4 lock washers; torque the bolts to 109 to 135 N∙m (80 to 100 ft-lb). 7. Clean the tapered surfaces of both mating parts before installation, connect the tie rod end (item 22 in Figure 210) to the drag link with the slotted hex nut and cotter pin. 8.
Rear Axle g185932 Figure 211 1. Axle pivot pin 10. Retaining ring (2 each) Locknut 28. Rear axle 2. Roll pin 11. Flange bushing (4 each) 20. 19. Wheel hub 29. Jam nut (2 each) 3. 90° grease fitting 12. Grease fitting (5 each) 21. Woodruff key 30. Tie rod 4. Retaining ring 13. Thrust washer (2 each) 22. Bolt (4 each per motor) 31. Right drag link 5. Ball joint 14. Left drag link 23. Lock washer (4 each per motor) 32. Steering cylinder 6. Thrust washer (2 each) 15.
Removing the Rear Axle (continued) 2. Block the front wheels with chocks to prevent the machine from moving. 3. Remove the 2 rear wheel assemblies; refer to Removing the Wheel (page 6–6). 4. Remove the steering cylinder (with the hydraulic hoses attached) from the rear axle; refer to Removing the Steering Cylinder (page 4–155). 5. Remove both wheel motor housings from the rear axle; refer to Removing the Rear Axle Motor Housings (page 6–17). 6. Unlatch and open the radiator screen assembly.
Servicing the Rear Axle 1. Clean the rear axle pivot pin. Inspect the pin for wear and replace the pivot pin if it is worn or damaged. 2. Clean the rear axle bushings and inspect the axle bushings (item 7 in Figure 211) in the rear axle for wear or damage. If the bushings need replacement, do the following steps: Note: Do not damage the bore of the axle during bushing removal. A. Use a bushing removal tool to extract both the axle bushings from the axle pivot. B.
Installing the Rear Axle 1. Position the rear axle assembly to the frame. Install the thrust washer (item 6 in Figure 211) between each side of the axle and frame. Slide the pivot pin through the frame, thrust washers, and axle. Ensure that the roll pin on the pivot pin is positioned in the frame reliefs. 2. Install a thrust washer (item 36 in Figure 211) and jam nut onto the pivot pin. Torque the jam nut to 123 to 162 N∙m (90 to 120 ft-lb).
Control Arm g185923 Figure 214 1. Arm rest 12. Right control arm cover 23. Retainer bracket 2. Locknut 13. Swell latch (2 each) 24. Clevis pin 3. Engine speed switch 14. Access cover 25. Bolt 4. PTO switch 15. Washer-head screw (10 each) 26. Latch 5. InfoCenter display 16. Foam seal 27. Cotter pin 6. Control arm 17. Platform wire harness 28. Spacer 7. Key switch 18. Flange nut (3 each) 29. Flat washer 8. TEC (Toro Electronic Controller) 19. Spring 30.
Disassembling the Control Arm g185936 Figure 215 1. Foam seal 2. Platform wire harness 1. Park the machine on a level surface, lower the cutting decks, shut off the engine, set the parking brake, and remove the key from the key switch. 2. Disconnect the negative battery cable from the battery; refer to Servicing the Battery (page 5–95). 3. Loosen the 2 swell latches (item 13 in Figure 214) and remove the access cover from outside of the control arm. 4.
Operator Seat g185929 Figure 216 1. Seat 10. Seat belt 19. Seat suspension 2. Bolt 11. Lock washer (2 each) 20. Flange nut (4 each) 3. Left armrest 12. Bolt (2 each) 21. Manual tube 4. Flange nut 13. Seat adjuster w/latch 22. Housing cap 5. Screw 14. Flat washer (8 each) 23. R-clamp (2 each) 6. Flange-head screw (3 each) 15. Socket-head screw (4 each) 24. Seat adjuster 7. 8. Flat washer Spacer 16. 17. Seat switch harness Seat switch 25. Seat base 9.
IMPORTANT The operator seat, seat base, and control arm assembly are attached to the machine with the same fasteners. Support the seat base and control arm to prevent them from shifting when removing the seat. Damage to the control arm electrical components and platform wiring harness can occur if the seat base and control arm are not properly supported during seat removal. Removing the Operator Seat g185935 Figure 217 1. 2. Platform wire harness Flange-head screw (2 each) 3.
Removing the Operator Seat (continued) 2. Disconnect the negative battery cable from the battery; refer to Servicing the Battery (page 5–95). 3. Disconnect the seat switch wire harness connector from the platform wire harness (Figure 217). 4. Record the position of the control arm before removal. The control arm angle is adjustable for operator comfort. 5. Remove the 2 flange-head screws and 2 flat washers that secure the control arm assembly to the seat base (Figure 217 and Figure 218).
Mechanical Seat Suspension g187025 Figure 219 1. Rivet (2 each) 13. Roll pin 25. Lower shock bolt (2 each) 37. Flat washer 2. Cotter pin 14. Weight adjust spacer 26. Lower housing 38. Spring shaft 3. Roll pin 15. Weight adjust shaft 27. Shaft block (4 each) 39. Extension spring (2 each) 4. Up-stop bumper block 16. Weight adjuster 28. Scissor assembly 40. Spring bushing (2 each) 5. Flat washer 17. Weight adjust nut 29. Lower shock bushing (2 each) 41. Flat washer 6.
Removing the Mechanical Seat Suspension g185934 Figure 220 1. Seat adjuster w/latch 2. Seat adjuster 3. Flat washer (4 each) 4. 5. 8. Manual tube 9. Seat base cover 10. Seat frame Flange-head screw (4 each) 11. Bolt (4 each) Flange nut (8 each) 12. Seat suspension bracket (2 each) 6. R-clamp (2 each) 13. Seat suspension 7. Spacer (4 each) 1.
Installing the Mechanical Seat Suspension 1. Install all the seat suspension components that were removed (Figure 219 and Figure 220). If removed, use the seat adjuster mounting holes that were recorded during removal. IMPORTANT Do not damage the electrical harness when installing the seat suspension to the machine. 2. Position the seat base cover and 4 spacers (item 7 in Figure 220) to the seat frame. 3.
Front Lift Arms g185924 Figure 221 1. Roll pin (1 each per lift arm pivot shaft) 8. Left tipper bracket 15. Locknut (4 each) 2. Locknut (4 each) 3. Lift arm pivot shaft (3 each) 9. Bumper (4 each) 16. #1 lift arm Bolt (1 each per lift arm) 17. 4. Grease fitting (1 each per lift arm) Flange bushing (2 each per lift arm) 11. Flat washer (1 each per lift arm) 18. Right tipper bracket 5. Bolt (1 each per lift arm) 12. Bolt (4 each) 19. #5 lift arm 6. #4 lift arm 13.
Removing the Front Lift Arms 1. Park the machine on a level surface, lower the cutting decks, shut off the engine, set the parking brake, and remove the key from the key switch. 2. Remove the cutting deck from the front lift arm to be removed; refer to Removing the Cutting Deck Carrier Frame (page 7–24). g185927 Figure 222 1. Cylinder pin 4. Lift cylinder 2. Thrust washer (2 each) 5. #1 lift arm 3. Retaining ring (2 each) 3.
Installing the Front Lift Arms 1. If the lift arm pivot shaft (item 3 in Figure 221) was removed from the frame, apply anti-seize lubricant to the pivot shaft surface and insert the shaft into the frame. Align the holes in the frame with the pivot shaft. Secure the pivot shaft with new roll pin. 2. If the cutting deck pivot shaft (item 7 in Figure 221) was removed from the lift arm, insert the cutting deck pivot shaft in the lift arm and secure with the bolt. 3.
Rear Lift Arms g185933 Figure 223 1. Bridge plate 7. Bolt 2. Bulkhead bracket 8. Cutting deck pivot shaft (1 each per 14. lift arm) Locknut 3. Flat washer (2 each) 9. 4. Bolt (2 each) 5. 6. 13. Lift arm pivot shaft (2 each) #2 lift arm 15. Roll pin (1 each per pivot shaft) 10. Bolt (1 each per pivot shaft) 16. #3 lift arm Bolt 11. Grease fitting (1 each per lift arm) Thrust washer (2 each) 12.
Removing the Rear Lift Arms 1. Park the machine on a level surface, lower the cutting decks, shut off the engine, set the parking brake, and remove the key from the key switch. 2. Remove the cutting deck from the rear lift arm to be removed; refer to Removing the Cutting Deck Carrier Frame (page 7–24). g185928 Figure 224 1. 5. Lift cylinder Washer-head screw 2. Retaining ring (2 each) 6. R-clamp 3. Thrust washer (2 each) 7. #2 lift arm 4. Cylinder pin 3.
Removing the Rear Lift Arms (continued) 7. If necessary, remove the bolt that secures the cutting deck pivot shaft (item 8 in Figure 223) in the lift arm. Remove the cutting deck pivot shaft from the lift arm. 8. If necessary, remove the roll pin and lift arm pivot shaft (item 13 in Figure 223) from the frame. Discard the roll pin. Installing the Rear Lift Arms 1.
Hood g185926 Figure 225 1. Hood 8. Clevis pin (2 each) 15. Latch 2. Washer-head screw (10 each) 9. Side hood frame tube (2 each) 16. Locknut (4 each) 3. Flange nut (10 each) 10. Rubber latch (2 each) 17. Flat washer (4 each) 4. Rear hood frame tube 11. Flange-head screw (2 each) 18. Washer-head screw (4 each) 5. Rubber bumper (2 each) 12. Hex nut 19. Catch latch (2 each) 6. Flange-head screw (10 each) 13. Spacer 20. Hood saddle 7. Bow tie pin (2 each) 14.
Removing the Hood 1. Park the machine on a level surface, lower the cutting decks, shut off the engine, and remove the key from the key switch. 2. Unlatch the hood. 3. Remove the bow tie pins (item 7 in Figure 225) and clevis pins to allow hood removal. 4. Lift the hood assembly from the machine. 5. Remove the hood components as necessary (Figure 225). Installing the Hood 1. Install all the hood components that were removed (Figure 225). 2. Position the hood assembly to the machine. 3.
Chapter 7 Cutting Deck Table of Contents Specifications ....................................................................................................................................... 7–2 Cutting Deck ...................................................................................................................................... 7–2 General Information ..............................................................................................................................
Specifications Cutting Deck g186523 Figure 226 Mounting: All the cutting decks are supported by independent lift arms and are interchangeable to any cutting deck positions. The Groundsmaster 4300-D machine uses 5 cutting decks. Construction: The deck chamber and frame are welded steel construction reinforced with the channels and plates. Height-of-cut range: 19 to 101 mm (0.75 to 4 inches) adjustable in 6.4 mm (0.5 inch) increments.
General Information CAUTION Do not install or work on the cutting decks or lift arms with the engine running. Always shut off the engine and remove the key from the key switch before working on the cutting decks or lift arms. Cutting Deck Operator's Manual The Cutting Deck Operator’s Manual provides information regarding the operation, general maintenance, and maintenance intervals for the cutting deck on your machine.
Troubleshooting There are a number of factors that can contribute to unsatisfactory quality of cut, some of which may be turf conditions. The turf conditions such as the excessive thatch, sponginess, 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. Remember that the effective or actual height-of-cut depends on the cutting deck weight and turf conditions.
Special Tools You can order these special tools from your Toro Distributor. Rear Roller Bearing and Seal Installation Tools g195109 Figure 227 1. Inner seal tool 2. Bearing/outerseal tool 3. Bearing installation washer These tools are used to assemble the cutting deck rear roller.
Adjustments CAUTION Do not install or work on the cutting decks or lift arms with the engine running. Always shut off the engine and remove the key from the key switch before working on the cutting decks or lift arms. Refer to the Cutting Deck Operator’s Manual for adjustment procedures of the cutting decks on the Groundsmaster 4300-D machine. Blade Stopping Time The blades of the cutting decks should come to a complete stop in less than 5 seconds after you disengage the PTO switch.
Service and Repairs CAUTION Do not install or work on the cutting decks or lift arms with the engine running. Always shut off the engine and remove the key from the key switch before working on the cutting decks or lift arms. Blade Spindle Assembly g195110 Figure 229 1. Hydraulic deck motor 2. Cutting deck 3. Stud (6 each) 4. Blade bolt 8. Groundsmaster® 4300-D 16226SL Rev D 5. Anti-scalp cup 9. 6. Cutting blade 10. Flange nut (6 each) 7. Spindle assembly 11.
Removing the Blade Spindle 1. Park the machine on a level surface, lower the cutting decks, shut off the engine, set the parking brake, and remove the key from the key switch. g195111 Figure 230 1. Hydraulic deck motor 2. Socket-head screw (2 each) 2. Remove the 2 socket-head screws and 2 flat washers that secure the hydraulic deck motor to the cutting deck (Figure 230), and remove the hydraulic deck motor and O-ring from the deck. 3.
Installing the Blade Spindle (continued) IMPORTANT A pneumatic grease gun can produce high pressure inside the spindle housing that can damage the spindle seals. Thus, do not use a pneumatic grease gun for greasing of the spindle housings. 7. Attach a hand pump grease gun to 1 of the grease fittings on the housing and fill the housing cavity with grease until grease starts to come out of the lower seal. 8.
Servicing the Blade Spindle g195112 Figure 231 Spindle nut 7. Bearing 2. Spindle plug 8. Spindle housing 3. Oil seal (2 each) 9. Shaft spacer 1. 4. Bearing 10. Spindle shaft 5. Spacer set (2 piece) 11. Grease fitting (2 each) 6. Spacer ring 12. Large snap ring g189007 Figure 232 1. Bearing 4. Inner bearing spacer 2. Spacer ring 5. Outer bearing spacer 3.
Disassembling the Blade Spindle 1. Remove the blade spindle from the cutting deck; refer to Removing the Blade Spindle (page 7–8). 2. Loosen and remove the spindle nut from the top of the spindle shaft. 3. Use an arbor press to remove the spindle shaft from the spindle housing. Note: Ensure that the spindle shaft spacer remains on the spindle shaft while removing the shaft. 4. Carefully remove the oil seals from the spindle housing, note the direction of the seal lips. 5.
Assembling the Blade Spindle (continued) g033719 Figure 233 1. Bearing cups 4. Arbor press 2. Large snap ring 5. Support 3. Large spacer 6. Arbor press base g195113 Figure 234 1. Upper seal installation 2. Bottom seal installation 3. Use an arbor press to push the bearing cups into the top and bottom of the spindle housing. Note: The top bearing cup must contact the outer bearing spacer that was previously installed, and the bottom bearing cup must contact the large snap ring.
Assembling the Blade Spindle (continued) Note: The bottom seal must have the lip facing out (down) (Figure 234). This seal installation allows grease to purge from the spindle during the lubrication process. IMPORTANT If you are replacing the bearings, ensure to that you use the spacer ring that is included with the new bearing set (Figure 232). 6. Slide the spacer ring and inner bearing spacer into the spindle housing, then install upper bearing cone and greased oil seal into top of the housing.
Rear Roller g195106 Figure 235 1. Deck frame 4. Roller shaft screw (2 each) 7. Skid bracket (2 each) 2. Flange-head screw (4 each) 5. Grease fitting (2 each) 8. Bolt (2 each) 3. Roller mount (2 each) 6.
Removing the Rear Roller g195107 Figure 236 1. Grease fitting 4. Roller mount 2. Roller shaft screw 5. Scraper plate 3. Roller scraper 6. Bolt 1. Park the machine on a level surface, lower the cutting decks, shut off the engine, set the parking brake, and remove the key from the key switch. 2. If the cutting deck is equipped with a roller scraper (Figure 236), remove the fasteners that secure the left and right scraper rod brackets to the roller mounts, and remove the scraper rod assembly. 3.
Installing the Rear Roller (continued) the roller should be 0.5 to 1.0 mm (0.020 to 0.040 inch). Torque the bolts to 41 N∙m (30 ft-lb). 6. Install and tighten the fasteners that secure each end of the roller to the roller mounts. Torque the roller shaft screws (item 4 in Figure 235) and bolts (item 8 in Figure 235) to 40 to 47 N∙m (29 to 35 ft-lb). 7. After you complete the assembly, raise and lower the cutting deck to check that the hydraulic hoses and fittings do not contact anything.
Servicing the Rear Roller g195108 Figure 237 1. 2. Roller tube Roller shaft 5. 6. Outer seal Bearing locknut 3. 4. Inner seal Bearing 7. Set screw g195710 Figure 238 1. 2. Roller tube Inner seal 3. Inner seal tool Disassembling the Rear Roller 1. Remove the bearing locknut from each end of the roller shaft. 2. Loosely secure the roller assembly in a bench vise and lightly tap one end of the roller shaft until the outer seals and bearing are removed from opposite end of the roller tube.
Disassembling the Rear Roller (continued) 5. Clean the roller shaft and all surfaces on the inside of the roller tube. Inspect components for wear or damage. Also, carefully inspect the seating surface and threads of the bearing locknuts. Replace all the components that were damaged. Assembling the Rear Roller 1. Install the inner seals into the roller tube and ensure that the seal lip (and garter spring) faces end of the tube.
Assembling the Rear Roller (continued) g195712 Figure 240 1. 2. Roller tube Inner seal 3. Bearing 4. 5. Outer seal Bearing/outer seal tool g195713 Figure 241 1. Roller tube 4. Bearing 2. 3. Roller shaft Inner seal 5. 6. Washer Bearing/outer seal tool C. Install the first outer seal into the roller tube and ensure that the seal lip (and garter spring) faces end of the tube.
Assembling the Rear Roller (continued) C. Apply a small quantity of grease around the lip of both outer seals. D. Carefully install the first outer seal into the roller tube and ensure that the seal lip (and garter spring) faces end of the tube. Use a bearing/outer seal tool (refer to Special Tools (page 7–5)) and a soft-faced hammer to lightly seat seal (Figure 242). Ensure that the shaft and bearings still freely rotate after the seal installation. E.
Assembling the Rear Roller (continued) Note: After the roller is installed to the cutting deck, lubricate the roller grease fittings, rotate the roller to properly distribute grease in bearings and clean excess grease from the roller ends. A properly assembled roller should rotate with less than 0.68 N∙m (5 in-lb) resistance.
Servicing the Front Roller g195715 Figure 243 1. Mounting bolt 4. Bearing spacer 2. Bearing 5. Spacer 3. Front roller 6. Deck frame Disassembling the Front Roller 1. Park the machine on a level surface, lower the cutting decks, shut off the engine, set the parking brake, and remove the key from the key switch. 2. Remove the front roller mounting bolt. 3. Remove the front roller assembly and spacer from the deck frame. 4.
Cutting Deck Carrier Frame g195716 Figure 244 1. Cutting deck assembly 7. Grease fitting 13. Pin (2 each per deck) 2. Bumper 8. #4 lift arm 14. Pivot bracket (2 each per deck) 3. Flange nut (4 each per deck) 9. Cutting deck pivot shaft 15. Bushing 4. Flange nut (2 each per deck) 10. Bushing (2 each per frame) 16. Flange nut 5. Thrust washer 11. Carrier frame 17. Bolt (4 each per deck) 6. Lynch pin 12. Bolt (2 each per deck) 18.
Removing the Cutting Deck Carrier Frame g186181 Figure 245 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. The cutting deck positions are identified in Figure 245. Remove the cutting deck from the lift arm pivot shaft as follows: 1. Park the machine on a level surface, lower the cutting decks, shut off the engine, set the parking brake, and remove the key from the key switch.
Appendix A Foldout Drawings Table of Contents Electrical Drawing Designations.........................................................................................................A–2 Hydraulic Schematic ..........................................................................................................................A–3 Electrical Schematic (Serial numbers below 403430000) ..................................................................A–4 Electrical Schematic (Serial numbers above 403430001) .
Electrical Drawing Designations Note: A splice used in a wire harness will be identified on the wire harness diagram by SP. The manufacturing number of the splice is also identified on the wire harness diagram (e.g., SP01 is splice number 1). Wire Color The following abbreviations are used for wire harness colors on the electrical schematics and wire harness drawings in this chapter.
Hydraulic Schematic g195998 , Drawing 3384-456 Rev A, Sheet 1 16226SL Rev D Page A–3
Electrical Schematic (Serial numbers below 403430000) g212621 Page A–4 16226SL Rev D Groundsmaster 4300-D (Serial numbers below 403430000), Drawing 125-8756 Rev A, Sheet 1
Electrical Schematic (Serial numbers above 403430001) CV g329264 Groundsmaster 4300-D (Serial numbers above 403430001), Drawing 122-1456 Rev A, Sheet 1 16226SL Rev D Page A–5
g326106 Page A–6 16226SL Rev D , Drawing Rev , Sheet
Wire Harness Drawing - Seat (sheet 1 of 2) g195999 Groundsmaster 4300-D, Drawing 115-8081 Rev C, Sheet 1 16226SL Rev D Page A–7
Wire Harness Drawing - Seat (sheet 2 of 2) g196000 Page A–8 16226SL Rev D Groundsmaster 4300-D, Drawing 115-8081 Rev C, Sheet 2
Wire Harness Drawing - Engine (sheet 1 of 2) g195994 Groundsmaster 4300-D, Drawing 122-0893 Rev A, Sheet 1 16226SL Rev D Page A–9
Wire Harness Drawing - Engine (sheet 2 of 2) g195995 Page A–10 16226SL Rev D Groundsmaster 4300-D, Drawing 122-0893 Rev A, Sheet 2
Wire Harness Drawing - Main (sheet 1 of 2) (Serial numbers below 403430000) g195996 Groundsmaster 4300-D (Serial numbers below 403430000), Drawing 120-6384 Rev D, Sheet 1 16226SL Rev D Page A–11
Wire Harness Drawing - Main (sheet 2 of 2) (Serial numbers below 403430000) g195997 Page A–12 16226SL Rev D Groundsmaster 4300-D (Serial numbers below 403430000), Drawing 120-6384 Rev D, Sheet 2
Wire Harness Drawing - Main (sheet 1 of 2) (Serial numbers 403430001 to 405699999) CV g329265 Groundsmaster 4300-D (Serial numbers 403430001 to 405699999), Drawing 122-1457 Rev A, Sheet 1 of 2 16226SL Rev D Page A–13
Wire Harness Drawing - Main (sheet 2 of 2) (Serial numbers 403430001 to 405699999) g329266 Page A–14 16226SL Rev D Groundsmaster 4300-D (Serial numbers 403430001 to 405699999), Drawing 122-1457 Rev A, Sheet 2 of 2
Wire Harness Drawing - Main (sheet 1 of 2) (Serial numbers above 405700001) CV g329267 Groundsmaster 4300-D (Serial numbers above 405700001), Drawing 122-1727 Rev A, Sheet 1 of 2 16226SL Rev D Page A–15
Wire Harness Drawing - Main (sheet 2 of 2) (Serial numbers above 405700001) g329268 Page A–16 16226SL Rev D Groundsmaster 4300-D (Serial numbers above 405700001), Drawing 122-1727 Rev A, Sheet 2 of 2
Wire Harness Diagram − Two−Post ROPS Extension (sheet 1 of 2) g250223 Groundsmaster 4300-D, Drawing 122-0892 Rev B, Sheet 1 16226SL Rev D Page A–17
Wire Harness Diagram − Two−Post ROPS Extension (sheet 2 of 2) g250224 Page A–18 16226SL Rev D Groundsmaster 4300-D, Drawing 122-0892 Rev B, Sheet 2
