Home

10178SL - Toro Media

1. zl na Si 39neuu u2s oineapAu 1361 v 3 LON OL 000i YE os YE os eel 000z oz osz Scot G IO3INVIA Osz SZ9E JOULNOD Rom Dad 2 LO Laz O0SE EW d SLL 00s Z eel 0002 a zna E Nid Ne ee IW IW SW di 1 ZW s lz s 55 i D za a w Vm snd EOL eL 1103813 MON TU OE NOUS 1 su sr v r TE l gerl ve Wai Wd suva 7 et INSNOdNO gt a in 31VH MOTs 3UnSSS3Ud INSH32V1dSIG gt LYVHD 34nSS3Hd QNV 31VY MOTA 1N383D2V1dSIdQ JIC Ws x Wu LNid i Uu ae LAY E ET IMa MON aa uv3u WW ld T 1 19 G IOJINVIA TOYLNOD 147 c dwnd N a NOLLOVU D H id NOLSId p n T Els ae E e uu e 59 1d0d E T Sh nne d y 5 E oh m oH Sd S is dB CB La m cu dcs k I Na 2 140d uvis 3 NOUS E 18918 99 GIOAINVW ii ex x x XVYLSSOYD z m NI n 3ATVA 9 e 7 t3 3 amp j SSVdA8 dWnd YVAD 1NOMJ 1431 uv38 avad LHOL 1481 n 1N033
2. 831N3 1N0 J i fee E Figure 10 Groundsmaster 4300 D Page 4 10 Hydraulic System Traction Circuit The hydraulic traction circuit consists of a variable dis placement piston pump P 5 connected in a closed loop parallel circuit to four 4 orbital roller vane wheel mo tors The traction pump input shaft is rotated by a drive shaft that is driven from the engine flywheel Forward traction circuit pressure can be measured ata test port located in the hydraulic tube that connects the front wheel motors Reverse traction circuit pressure can be measured attest ports in the AWD control man ifold Forward Direction Fig 10 Pushing the top ofthe traction pedal angles the traction pump swash plate to create a flow of oil This oil flow is directed to the wheel motors via hydraulic hoses and tubes to drive the wheels in the forward direction Trac tion pump flow is directed to the front wheel motors and then to the opposite rear wheel motors to maximize trac tion To reduce tire scuffing when turning traction sys tem pressure is equalized in the AWD control manifold with an orifice and a bi directional relief valve Check valves in the AWD manifold allow the rear wheel motors to over run during tightturns Forward traction pressure is limited to 3625 PSI 250 bar by the forward trac
3. Figure 96 1 Grease fitting 6 Retaining ring 11 O ring 2 Shaft 7 Back up washer 12 Grease fitting 3 Dust seal 8 O ring 13 Lock nut 4 Head 9 Piston 14 Barrel 5 Head seal 10 Piston seal NOTE The lift cylinders used on Groundsmaster 4300 D machines are very similar Service procedures for all lift cylinders are the same Hydraulic System Page 4 106 Groundsmaster 4300 D Disassembly Fig 96 1 Remove oilfromliftcylinderinto a drain pan by slowly pumping the cylinder shaft Plug both ports and clean the outside of the cylinder IMPORTANT Prevent damage when clamping the lift cylinder into a vise clamp on the clevis end of the barrel ONLY 2 Mountlift cylinder securely in a vise by clamping on the clevis end of the barrel Use of a vise with soft jaws is recommended 3 Using a spanner wrench rotate head clockwise until the edge ofthe retaining ring item 6 appears in the bar rel opening Insert a screwdriver under the beveled edge of the retaining ring to start the retaining ring through the opening Rotate the head counter clock wise to remove retaining ring from barrel and head 4 Remove plugs from ports Extract shaft head and piston by carefully twisting and pulling on the shaft IMPORTANT Do not clamp vise jaws against the shaft surface Clamp on the clevis ONLY 5 Mountshaftsecurely ina vise by clamping on the cle vis of the shaft Remove lock
4. Ps Wa bond 1102813 MON 1NOtJ la D k bbe cUm en LINY MON uvas G IOJINVIA TOYLNOD 44 YAGNITAD SNIu3als co 3ATVA TOYLNOD ONIYSALS dWnNd NOLLOVW L NOLSId EE err e 831N3 1N0233 89 Gioginvw XVulSSOu D FORWARD Na AATWA SSVdA8 Figure 18 D Groundsmaster 4300 18 Page 4 Hydraulic System Lift Circuit Lower Cutting Decks A four section gear pump is coupled to the piston trac tion pump Gear pump section P 4 supplies hydraulic flow to the liftcontrol manifold and liftcylinders The gear pump takes its suction from the hydraulic reservoir The lift control manifold includes three 3 electrically operated valves Solenoid valve S 1 is used to directoil flow to extend the liftcylinders when energized or retract them when de energi
5. Groundsmaster 4300 D Electrical Schematic Sheet 2 of 2 All relays and solenoids are shown as de energized All ground wires are black Page 8 5 PI4 P28 PRV P22 TO SEAT HARNESS JOI BATTERY 12 VDC PI8 TO SEAT HARNESS 2 P50 F3 LOGIC PWR P4I FUEL PUMP PIT TO SEAT HARNESS Pe PRESSURE TRANSDUCER P0 START P53 RELAY MOW TRANSPORT ENGINE INTERCONNECT P39 HEADLIGHT RH SWITCH P55 PARK ING BRAKE PII P09 P40 HEADLIGHT LH P04 P20 STARTER B P52 NEUTRAL SWITCH P08 PIO PRVI PRV2 REAR FRONT REEL REEL ENGAGE ENGAGE Groundsmaster 4300 D Main Wire Hamess Drawing Page 8 6 zi EY Q 8 t zee E gt amp S56 ey m s amp Qe c S5 78 Ld 2 2 S2u Z er ze w a Boe S ovo Z gt gt lt a vo S d a SaS ur RO ene ea tS F3 LOGI
6. 47 Indicator Lights 23 Hydraulic Solenoid Valve Coil 48 Hour Meter ec isn cia rk Beene a 24 Groundsmaster 4300 D Page5 1 Electrical System E b System This page is intentionally blank Electrical System Page5 2 Groundsmaster 4300 D General Information Operator s Manual The Operator s Manual provides information regarding the operation general maintenance and maintenance intervals for your Groundsmaster 4300 D machine Re fer to that publication for additional information when servicing the machine Toro Electronic Controller TEC Groundsmaster 4300 D machines use a Toro Electron ic Controller TEC to manage machine electrical func tions The controller is a microprocessor controlled device thatsenses the condition of various switches in puts and then directs electrical power to control ap propriate machine functions outputs based on the inputs The status of inputs to the controllers as well as outputs from the controllers can be monitored with the Diagnostic Display see Special Tools in this chapter CAN bus Communications The TEC controllerusedon the Groundsmaster4300 D communicates with other electrical components on a CAN bus communication system The CAN bus sys tem reduces the number of electrical components and connections used on the machine and allows the num ber of wires in the wire harness to be reduced CAN ident
7. x I 3 P a and Maintenance Standard Torque for Dry Zinc Plated and Steel Fasteners Inch Series Grade 1 5 amp 8 with Thin Height Nuts SAE Grade 1 Bolts Screws Studs amp Sems with Regular Height Nuts SAE J 995 Grade 2 or Stronger Nuts Thread Size co Ui uw w B B w N m oO Ui a1 eo a1 eo N pen M Ui I I I I I I I I I I I wo co o Ui gt uw Ui gt w N N 6 32 UNC 147 23 6 40 UNF 8 32 UNC 282 30 8 36 UNF 10 24 UNC 339 56 10 32 UNF 1 4 20 UNC 48 7 599 79 1 4 28 UNF 5347 734 113 5 16 18 UNC 115 15 105 15 1186 169 5 16 24 UNF 138 17 128 17 1446 192 3 8 16 UNC 3 8 24 UNF 7 16 14UNC 27 3 7 16 20 UNF 29 3 1 2 13 UNC 30 3 1 2 20 UNF 32 4 5 8 11 UNC 119 16 5 8 18 UNF 75 10 129 20 3 4 10 UNC 93 12 140 20 190 27 3 4 16 UNF 115 15 165 25 224 34 7 8 9 UNC 140 20 225 25 305 34 cea au mer bud scc 3 aw M o w w N N N a o M gt N I I I I I I wo wo gt gt w w 13 2 65 10 88 12 95 15 7 8 14 UNF 155 25 260 30 353 41 NOTE Reduce torque values listed in the table above by 25 for lubricated fasteners Lubricated fasteners are defined as threads coated with a lubricant such as engine oil or thread sealant such as Loctite NOTE Torque values may have to be reduced when installing fasteners into threaded aluminum or brass The specific
8. Page 4 109 7 Position steering column brace item 13 to machine and secure with four 4 screws and flange nuts 8 Slide rubber bellows to bottom of steering column 9 Place rubber bushings and spacers into holes of shroud Fig 98 Position shroud in place and secure with removed fasteners 10 Check oil level in hydraulic reservoir and add correct oil if necessary 11 Follow Hydraulic System Start up procedures see Hydraulic System Start up in this section Washer 2 used 5 Locknut 2 used Screw 2 used 6 Cover plate Washer head screw 7 Bushing 2 used Platform shroud 8 Spacer 2 used Pus Figure 99 Hydraulic System Steering Control Valve Service 20 to 24 ft lb 27 to 33 N m Big em 1 Figure 100 1 Screw 5 used 10 Spool 19 Check ball 2 O ring 5 used 11 Sleeve 20 Housing 3 End cover 12 Cross pin 21 Dust seal ring 4 O ring 13 Spring set 22 Relief valve 5 Outer gearwheel 14 Ring 23 Spring 6 Inner gearwheel 15 Thrust washer 24 O ring 7 Distributor plate 16 Bearing 25 Plug 8 O ring 17 Shaft seal 26 Plug 9 Cardan shaft 18 Ball stop NOTE For repair of the steering control valve see the Sauer Danfoss Steering Unit Type OSPM Service Manual atthe end of this chapter Hydraulic System Page 4 110 Groundsmaster 4300 D Hydraulic System This page is intentionally blank Groundsmaster 4300 D Page 4 111 Hy
9. Figure 20 D Groundsmaster 4300 20 Page 4 Hydraulic System Steering Circuit A four section gear pump is coupled to the piston trac tion pump Gear pump section P3 supplies hydraulic flow to the steering control valve and for the traction charge circuit The gear pump takes its suction from the hydraulic reservoir Steering circuit pressure is limited to 1000 PSI 70 bar by a relief valve R10 located in the steering control valve With the steering wheel in the neutral position and the engine running hydraulic flow enters the steering con trol valve at the P port and goes through the steering control spool valve bypassing the rotary meter V1 and steering cylinder Flow leaves the control valve through the T portto the transmission oil filter and traction charge circuit Left Turn Fig 20 When a left turn is made with the engine running the turning of the steering wheel positions the steering con trol spool valve so that flow is directed through the bot tom ofthe spool Flow entering the steering control valve atthe P port goes through the spool and is routed to two places First most of the flow through the valve is by passed out the T port back to the transmission oil filter and traction charge circuit Second the remainder ofthe flow is directed through the rotary meter V1 and outthe L port Pressure contracts the steering cylinder piston for a leftturn The rotary meter ensures that the oil flow
10. B Temperature correct each cell reading For each 10 F 5 59C above 80 F 26 7 C add 0 004 to the specific gravity reading For each 10 F 5 5 C be low 80 F 26 79C subtract 0 004 from the specific gravity reading Example Cell Temperature 100 F Cell Gravity 1 245 100 F minus 80 F equals 20 F 37 79C minus 26 7 C equals 11 0 C 20 F multiply by 0 004 10 F equals 0 008 11 C multiply by 0 004 5 5 C equals 0 008 ADD conversion above 0 008 Correction to 80 F 26 7 C 1 253 C If the difference between the highest and lowest cell specific gravity is 0 050 or greater or the lowest cell specific gravity is less than 1 225 charge the bat tery Charge atthe recommended rate and time giv en in Battery Charging in this section or until specific gravity of all cells is 1 225 or greater with the difference in specific gravity between the highestand lowest cell less than 0 050 If these charging condi tions can not be met replace the battery 2 Perform a high discharge test with an adjustable load tester This is one ofthe mostreliable means oftesting a battery as itsimulates the cold cranking test A commercial bat tery load tester is required to perform this test A CAUTION Follow the battery load tester manufacturer s instructions when using a battery load tester A Check the voltage across the battery terminals prior to testing the battery If the voltage is less than 12 4 VDC charge the batte
11. Hydraulic System 5 Hydraulic Reservoir 105 to 115 ft lb 143 to 155 N m 26 to 32 ft lb 36 to 43 N m Figure 64 1 Suction strainer 10 Flat washer 19 Oil filter 2 Tank cap 11 Bumper 20 Filter head 3 Hydraulic reservoir 12 Washer head screw 2 used 21 Hydraulic hose 4 Adapter 13 Clamp 2 used 22 O ring 5 Manifold 14 Flange nut 23 90 hydraulic fitting 6 O ring 15 Flange head screw 2 used 24 O ring 7 Hydraulic hose 16 O ring 25 Screen filter 8 O ring 17 Hose clamp 2 used 26 Hydraulic fitting 9 Capscrew 18 Hydraulic hose Hydraulic System Page 4 64 Groundsmaster 4300 D Removal Fig 64 1 Park the machine on a level surface engage parking brake lower cutting decks and stop engine Remove key from the ignition switch 2 Thoroughly clean hydraulic hose ends and fittings on hydraulic reservoir to prevent hydraulic system conta mination Label hydraulic hoses to assist in installation 3 Disconnect hydraulic hose item 7 from adapter fit ting on bottom of reservoir to allow draining of reservoir Drain reservoir into a suitable container 4 Disconnect remaining hydraulic hoses from reser voir Allow hydraulic lines to drain into a suitable contain er Plug or cap openings of reservoir and lines to prevent contamination 5 Remove hydraulic reservoir using Figure 64 as a guide 6 Remove suction strainer from reservoir Discard O ring 7 Ifhydrauli
12. 1 6 Chapter 2 Product Records and Maintenance ProductRecords cece cece cece ees 2 1 Maintenance lt 2 mco ke thas 2 1 Equivalents and Conversions 2 2 Torque Specifications 2 3 Chapter 3 Kubota Diesel Engine General Information 3 1 Specifications 3 2 Adjustments Z ice et ER eer eR 3 3 Service and Repairs 3 4 KUBOTA WORKSHOP MANUAL DIESEL ENGINE 05 E3B SERIES Chapter 4 Hydraulic System Specifications 12 ul ether n Ee as 4 2 General Information 4 3 Hydraulic Schematic 4 9 Hydraulic Flow Diagrams 4 10 Special TOMS ys 7i s DR es wes be erat 4 22 Troubleshooting 4 26 TeSHflgs sordo Bet Edu ELLE ES 4 32 Service and Repairs 4 60 SAUER DANFOSS LPV CLOSED CIRCUIT AXIAL PISTON PUMPS REPAIR MANUAL SAUER DANFOSS LPV CLOSED CIRCUIT AXIAL PISTON PUMPS SERVICE INSTRUCTIONS PARKER TORQMOTOR SERVICE PROCEDURE TC TB TE TJ TF TG TH AND TL SERIES SAUER DANFOSS STEERING UNIT TYPE OSPM SERVICE MANUAL Groundsmaster 4300 D Chapter 5 Electrical System General Information Special Tools Troubleshooting Electrical System Quick Checks Adjustments Component Testing Service and Repairs Chapter 6 Chassis Spe
13. Class 8 8 Bolts Screws and Studs with Class 8 or Stronger Nuts 644 68 N cm 1085 113 N cm Class 10 9 Bolts Screws and Studs with Regular Height Nuts Class 10 or Stronger Nuts 133 14 in Ib 1503 158 N cm M6 X 1 0 M8 X 1 25 19 2 ft lb M10 X 1 5 38 4 ft lb M12X 1 75 66 7 ft lb M16 X 2 0 166 17 ft lb M20 X 2 5 325 33 ft lb NOTE Reduce torque values listed in the table above by 25 for lubricated fasteners Lubricated fasteners are defined as threads coated with a lubricant such as engine oil or thread sealant such as Loctite NOTE Torque values may have to be reduced when installing fasteners into threaded aluminum or brass The specific torque value should be determined based on the fastener size the aluminum or base material strength length of thread engagement etc Groundsmaster 4300 D 26 3N m 52 5N m 90 10 N m 225 23 N m 440 45 N m Page 2 5 28 3 ft lb 38 4N m NOTE The nominal torque values listed above are based on 75 of the minimum proof load specified in SAE J 1199 The tolerance is approximately 10 ofthe nominal torque value Product Records and Maintenance 78 8 in Ib 881 90 N cm v x I 5 3 P a and Maintenance Other Torque Specifications SAE Grade 8 Steel Set Screws Wheel Bolts and Lug Nuts Thread Size Square Head HexSocket 7o 20unr 65210m s82i4n m Grade 5 1 2 20UNF 80 10 ft lb 108 14 N m 5 16 18 UNC 215 435
14. If a component failure occurs in the closed loop traction circuit contamination from the failed part will remain in the circuit until removed When connecting hydraulic test gauges in order to test traction circuit components orafterreplacing a failed traction circuit component e g hydrostat or wheel motor the high flow hydraulic filter can be installed in the traction circuit The filter will en sure that contaminates are removed from the closed loop and thus do notcause additional componentdam age Figure 26 Toro Part Number TOR6011 NOTE Use of Hydraulic Hose Kit TOR6007 is recom mended when using the high flow hydraulic filter kit NOTE Replacementfilter elementis Toro partnumber TOR6012 Filter element cannister tightening torque is 25 ft Ib 34 N m Hydraulic TestFitting Kit This kit includes a variety of O ring face seal fittings to enable connection of test gauges to the system TORO TEST FITTING KIT TOR4079 TOOL NUMBER The kit includes tee s unions reducers plugs caps Swivel Ma Run Tee 2 oa and male test fittings Toro Part Number TOR4079 Figure 27 Spindle Plug The spindle plug can be used to prevent contaminant entry into the cutting deck spindle assembly when the hydraulic motor is removed from the spindle Toro Part Number 94 2703 D Figure 28 Hydraulic System Page 4 24 Groundsmaster 4300 D Wheel Hub Puller The wheel hub puller allows safe removal of
15. CROSSTRAX Ay M303 MANIFOLD PRESSURE GAUGE cn v PISTON TRACTION PUMP FROM STEERING CONTROL VALVE Figure 32 The traction circuit relief pressure test should be per formed to make sure that forward and reverse traction circuit relief pressures are correct Procedure for Traction Circuit Relief Valve R3 and R4 Pressure Test 1 Make sure hydraulic oil is at normal operating tem perature by operating the machine under load for approximately ten 10 minutes 2 Drive machine to an open area Park machine on a level surface with the cutting decks lowered and PTO switch off Make sure engine is off Apply the parking brake 3 Read Precautions For Hydraulic Testing in this sec tion Hydraulic System Page 4 34 Before opening hydraulic system operate all hy draulic controls to relieve system pressure and avoid injury from pressurized hydraulic oil See Relieving Hydraulic System Pressure in the Gen eral Information section of this chapter 4 Locate traction circuit test port for direction to be tested Forward testportis located on hydraulic tube be tween front wheels Fig 33 Reverse test ports are lo cated on AWD hydraulic manifold Fig 34 Thoroughly Clean test po
16. Each cutting deck is suspended from a carrier frame The cutting deck carrier frame is attached to the liftarm and allows the cutting deck to pivot on the lift arm pivot shaft Cutting deck positions are identified in Figure 19 To remove cutting decks from the lift arm pivot shaft 1 Park machine on a level surface lower cutting decks stop engine engage parking brake and remove key from the ignition switch 2 Remove lynch pin and thrust washer that secures carrier frame to lift arm pivot shaft 3 Slide cutting deck assembly off pivotshaftand away from machine 4 Disassemble carrier frame as needed using Fig 18 as a guide Installation Fig 18 1 Assemble carrier frame as needed using Fig 18 as a guide 2 Slide cutting deck assembly onto pivot shaft on lift arm 3 Secure cutting deck to pivot shaft with thrust washer and lynch pin 4 Lubricate carrier frame grease fittings GROUNDSMASTER 4300 D CUTTING DECK LOCATIONS Groundsmaster 4300 D Page 7 19 Figure 19 Cutting Decks This page is intentionally blank Cutting Decks Page 7 20 Groundsmaster 4300 D Chapter 8 TORO Foldout Drawings Table of Contents HYDRAULIC SCHEMATIC 3 ELECTRICAL SCHEMATIC 4 Sheet TOf 2 usata hamana aka k Qan a 4 Sheet2 0f 2 feisty Ret exte ees 5 WIRE HARNESS DRAWINGS 6 Main Wire Hamess Drawing 6 Main Wire Harness Di
17. Page 3 11 10 Carefully pull radiator assembly from the machine Plug radiator and hose openings to prevent contamina tion 11 Inspect all foam seals placed between radiator fan shroud and radiator frame Replace damaged foam seals Installation Fig 8 1 Remove plugs placed in radiator and hose openings during the removal procedure 2 Carefully position radiator assembly to the radiator support Position fan shroud to the radiator 3 Secure fan shroud and radiator to radiator frame with removed flange head screws and flange nuts Make sure that at least 0 250 6 4 mm clearance exists atall points between shroud opening and fan 4 Position coolant reservoir and brackets to the fan shroud Secure reservoir to fan shroud and radiator frame with two 2 flange head screws and flange nuts 5 Place spacers item 43 into holes in foam seal item 42 Position foam seal and air intake screen item 37 to radiator frame Secure intake screen to machine with five 5 flange head screws and flange nuts 6 Connect upper and lower radiator hoses to radiator and secure with clamps 7 Connect overflow hose to radiator fill opening and secure with hose clamp 8 Make sure radiator draincock is closed threaded out fully 9 To allow air to escape during radiator filling remove pipe plug item 8 from top of radiator Fill radiator with coolant Make sure to install plug once all airis bled from radiator 10 Aft
18. REAR CUTTING x INTERNAL 100 MESH SUCTION BYPASS STRAINER VALVE Qa v MY04 CROSSTRAX MANIFOLD sO B PISTON TRACTION PUMP FROM STEERING CONTROL VALVE Figure 43 Procedure for Piston Traction Pump Flow Test This test measures piston traction pump output flow During this test pump load is created at the flow meter using the adjustable load valve on the tester IMPORTANT Traction circuit flow for the Groundsmaster 4300 is approximately 30 GPM 113 5 LPM Use 40 GPM Hydraulic Tester AT40002 pressure and flow for this test see Special Tools in this chapter 1 Make sure hydraulic oil is at normal operating tem perature by operating the machine under load for approximately ten 10 minutes Make sure the hydrau lic tank is full Hydraulic System Page 4 42 2 Park machine on a level surface with the cutting decks lowered and off Shut off engine Make sure mow speed limiter is in the transport position to allow full movement of traction pedal 3 Read Precautions For Hydraulic Testing in this sec tion Before opening hydraulic system operate all hy draulic controls to relieve system pressure and avoid injury from pressurized hydraulic oil See Relieving H
19. inders 11 After testing is complete check oil level in hydraulic reservoir and adjust if necessary Figure 56 1 Liftcylinder 5 shown 3 Hydraulic hose 2 Cylinder rod end fitting Figure 57 1 Lift cylinder rod 3 Tape initial position 2 Lift cylinder head Figure 58 1 Tape after 2 hours 2 Cylinder rod movement Groundsmaster 4300 D Page 4 55 Hydraulic System Steering Relief Valve R10 Pressure Test TO DECK CONTROL MANIFOLD FRONT CUTTING UNITS TO LIFT CONTROL P MANIFOLD lt TO DECK CONTROL MANIFOLD REAR CUTTING UNITS DER X LANA PUMP P5 INTERNAL eran CASE STRAINER DRAIN TO TRACTION CHARGE CIRCUIT lt STEERING WHEEL TURNED FOR RIGHT TURN STEERING CONTROL VALVE PRESSURE GAUGE STEERING CYLINDER Figure 59 Hydraulic System Page 4 56 Groundsmaster 4300 D The steering relief valve R10 pressure test should be performed to make sure that the steering circuit relief pressure is correct Procedure for Steering Relief Valve Pressure Test 1 Make sure hydraulic oil is at normal operating tem perature by operating the machine under load for approximately ten 10 minutes 2 Park machine on a level surface with the cutting decks lowered and PTO switch off Make sure engine is off Ap
20. matic and Circuit Drawings in Chapter 8 Foldout Drawings 6 Make sure that traction neutral switch is connected to wire harness when testing is complete Figure 31 5 Jam nut 2 used 6 Lock washer 2 used 7 Switch LED location Traction pump Traction neutral switch Traction lever bracket Pump control arm BU NE Electrical System E b u Parking Brake Switch The parking brake switch is a normally open proximity switch The parking brake switch is attached to the bot tom of the brake pedal Fig 32 The parking brake switch is used as an input for the TEC controller When the parking brake is notapplied the parking brake detent is positioned near the target end of the parking brake switch so the switch is closed The parking brake detentis moved away from the switch when the parking brake is applied causing the switch to open Testing 1 Before disconnecting the parking brake switch for testing the switch and its circuit wiring should be tested as a TEC controller input with the Diagnostic Display see Diagnostic Display in the Troubleshooting section of this chapter If the Diagnostic Display verifies thatthe parking brake switch and circuit wiring are functioning correctly no further switch testing is necessary If how ever the Diagnostic Display determines that the parking brake switch and circuit wiring are not functioning cor rectly proceed with testing procedure 2 Turn ignition swi
21. Check hydrau lic oil level and adjust if necessary Hydraulic System Hydraulic Pump Drive Shaft Permatex Threadlocker 34 to 42 ft lb 46 to 56 N m Antiseize Lubricant Figure 65 1 Piston traction pump 5 Cap screw 2 used 8 Drive shaft assembly 2 Flange nut 2 used 6 Engine flywheel 9 Flange nut 4 used 3 Flange head screw 2 used 7 Cap screw 6 used 10 Flange head screw 2 used 4 Guard hoop Hydraulic System Page 4 66 Groundsmaster 4300 D Removal Fig 65 1 Park the machine on a level surface engage parking brake lower cutting decks and stop engine Remove key from the ignition switch 2 Remove two 2 flange head screws and flange nuts that secure drive shaft guard hoop item 4 to machine frame Remove guard 3 Remove two 2 cap screws item 5 and flange nuts item 9 thatsecure drive shaftyoke to piston pump input shaft 4 Remove six 6 cap screws item 7 thatsecure drive shaft flange to engine flywheel 5 Remove drive shaft assembly from machine Drive Shaft Cross and Bearing Service Fig 66 1 Remove snap rings that secure bearings in yokes IMPORTANT Yokes must be supported when re moving and installing bearings to prevent damage 2 Use a press to remove cross and bearings from yokes Thoroughly clean drive shaft yokes 3 To install new cross and bearings A Apply a coating of grease to bearing bores in end yoke and shaft yoke B Press one bearing
22. Figure 68 1 Piston traction pump 3 Traction cable bracket 2 Gear pump Figure 69 1 Cap screw 2 used 8 Lock nut 2 used 2 Flange nut 2 used 9 Flat washer 3 Traction cable 10 Flat washer 4 Flange nut 2 used 11 Ball joint 5 Flange screw 2 used 12 Traction lever bracket 6 Traction cable bracket 13 Cap screw 7 Cap screw 2 used 14 Lever damper Make sure lift or hoist can support the total weight of the pump assembly before removing the cap screws from the pump assembly and frame Pump assembly weighs approximately 67 pounds 30 5 kg 8 Connecta liftor hoist to hole in traction cable bracket on traction pump to support pump assembly and for pump removal Hydraulic System 9 Loosen and remove two 2 carriage screws item 12 and flange nuts item 15 that secure pump support bracket item 8 to frame 10 Remove two 2 flange screws item 3 and flange nuts item 9 that secure traction pump flange to ma chine frame IMPORTANT Make sure to not damage machine components while removing the pump assembly 11 Carefully lift pump assembly from the machine 12 Separate traction and gear pumps Fig 70 A Remove two 2 socket head screws lock wash ers and flat washers that secure gear pump to trac tion pump B Remove gear pump from traction pump Locate and discard O ring from between pumps C Ifnecessary remove two 2 lock nuts thatsecure pump support bracket to gear pump Remo
23. Keep away from cutting decks during test to pre vent personal injury from rotating blades 9 Have a second person occupy seat press PTO switch to ON and then move joystick lever forward to en gage cutting decks IMPORTANT When performing this test do not hold over relief any longer than necessary to obtain pressure reading Groundsmaster 4300 D Page 4 45 10 Watch pressure gauge carefully while slowly closing the tester flow control valve As the relief valve lifts the pressure gauge needle will momentarily stop NOTE Once the relief valve has opened system pres sure may continue to increase 11 As the relief valve lifts system pressure should be Approximately 2500 PSI 175 bar for relief valve PRV1 Approximately 3500 PSI 241 bar for relief valve PRV2 12 0 pen the tester flow control valve disengage cutting decks and stop the engine 13 If pressure is incorrect remove P RV valve on mow manifold and clean or replace valve see Deck Control Manifold Service in the Service and Repairs section of this chapter Also if pressure is still low after valve ser vice check for restriction in pump intake line Gear pump P 2 front cutting deck circuit and or pump P 1 rear cutting deck circuit could also be suspected of wear damage or inefficiency see Gear Pump P 1 and P2 Flow Test in this section 14 After testing is completed make sure that engine is stopped then relieve hydraulic syst
24. P4 Hydraulic System Lift Cylinder Internal Leakage Test TO STEERING CONTROL VALVE TO DECK CONTROL MANIFOLD FRONT CUTTING UNITS lt lt TO DECK CONTROL MANIFOLD REAR CUTTING UNITS XP XR XR PUMP P5 INTERNAL TIO CASE STRAINER DRAIN po Y FROM MOW CONTROL MANIFOLD FRONT CENTER LEFT FRONT r PARTIALLY RAISED PLUG CAP CHECK FOR CYLINDER EXTENDING sp an LIFT CONTROL MANIFOLD LEFT FRONT 4 LIFT CYLINDER TEST SHOWN Figure 55 The lift cylinder internal leakage test should be per formed ifa cutting deck raise and lower problem is iden tified This test will determine if a lift cylinder is faulty NOTE Cutting deck raise lower circuitoperation will be affected by lift cylinder binding extra weight on the cut ting decks and or binding of lift components Make sure thatthese items are checked before proceeding with lift cylinder internal leakage test Procedure for Lift C ylinder Internal Leakage Test NOTE When performing the lift cylinder internal leak age test the cutting decks should be attached to the lift arms Hydraulic System Page 4 54 1 Park machine
25. flow from the gear pump through the tester and into the hose 6 Install tester with pressure gauges and flow meter in series between disconnected hose and gear pump fit ting Make sure the flow control valve on tester is ful ly open 7 After installing tester start engine and run at idle speed Check for any hydraulic leakage from test con nections and correct before proceeding with test 8 Make sure the parking brake is engaged Move throttle to full speed 3200 RPM DO NOT engage the cutting decks Use a tachometer to verify that engine speed is correct IMPORTANT The gear pump is a positive displace ment type If pump flow is completely restricted or stopped damage to the pump tester or other com ponents could occur 9 While watching pressure gauges slowly close the tester flow control valve until 1500 PSI 103 bar is ob tained on gauge FLOW TESTER READING TO BE A pump in good condition should have a flow of approximately 13 6 GPM 51 2 LPM at 1500 PSI 103 bar 10 0pen the tester flow control valve and stop the en gine Record test results Groundsmaster 4300 D Page 4 47 11 If flow is less than 12 1 GPM 45 8 LPM or a pres sure of 1500 PSI 103 bar cannotbe obtained consider that a pump problem exists Check for restriction in pump intake line If intake is notrestricted remove gear pump and repair or replace pump as necessary see Gear Pump and Gear Pump Service in the Service and Repair
26. key from the ignition switch 2 Unlatch and open the rear screen 3 Label all hydraulic connections for assembly pur poses Thoroughly clean hydraulic connections prior to loosening hydraulic hoses 4 Loosen hose clamps that secure hydraulic hoses to oil cooler fittings Remove hoses from oil cooler Allow hoses to drain into a suitable container 5 Rotate clamps that secure oil cooler to radiator frame 6 Pull oil cooler from machine 7 If necessary remove hydraulic fittings clamps and brackets from oil cooler using Figure 104 as a guide Inspection 1 Back flush oil cooler with cleaning solvent After cool er is clean make sure all solvent is drained from the cooler A CAUTION Use eye protection such as goggles when using compressed air 2 Dry inside of oil cooler using compressed air in the opposite direction of the oil flow 3 Plug both ends of oil cooler Clean exterior of cooler Make sure oil cooler fins are clear of dirt and debris 4 The oil cooler should be free of corrosion cracked tubes and excessive pitting of tubes Groundsmaster 4300 D Page 4 117 Installation Fig 104 1 If removed install hydraulic fittings clamps and brackets to oil cooler using Figure 104 as a guide 2 Position oil cooler to radiator and secure with clamps 3 Install hydraulic hoses to oil cooler fittings and se cure with hose clamps 4 Afteroil coolerinstallation clean oil cooler hose
27. to the steering cylinder is proportional to the amount of turning on the steering wheel Fluid leaving the steering cylinder flows back through the steering control spool valve and then out of the steering control valve through the T port The steering control valve returns to the neutral position when turning is completed Groundsmaster 4300 D Page 4 21 Right Turn Fig 20 When a right turn is made with the engine running the turning ofthe steering wheel positions the steering con trol spool valve so thatflow is directed through the top of the spool Flow entering the steering control valve at the P port goes through the spool and is routed to two places As in a left turn most of the flow through the valve is bypassed outthe T portbackto the transmission oil filter and traction charge circuit Also like a left turn the remainder of the flow is directed through rotary me ter V1 butgoes outportR Pressure extends the steer ing cylinder piston for a right turn The rotary meter ensures thatthe oil flow to the steering cylinder is pro portional to the amount of the turning on the steering wheel Fluid leaving the steering cylinder flows back through the steering control spool valve then through the T port and to the hydraulic reservoir The steering control valve returns to the neutral position when turning is completed Hydraulic System Special Tools Order Special Tools from your Toro Distributor Hydraulic Pr
28. 115 0853 Bearing Installation Washer 107 8133 Tool Bearing Outer Seal O Bearing Installation Washer Figure 1 Spindle Plug The spindle plug can be used to prevent contaminant entry into the cutting deck spindle assembly when the hydraulic motor is removed from the spindle Toro Part Number 94 2703 Figure 2 Groundsmaster 4300 D Page7 5 Cutting Decks Adjustments Never install or work on the cutting decks or lift arms with the engine running Always stop en gine and remove key from ignition switch first See the Cutting Deck Operator s Manual for adjustment procedures for cutting decks on the Groundsmaster 4300 D Blade Stopping Time The blades of the cutting decks are to come to a com plete stop in approximately five 5 seconds after the PTO is disengaged NOTE Make sure the decks are lowered onto a clean section of turf or hard surface to avoid dust and debris Cutting Decks Page 7 6 To verify this stopping time have a second person stand back from the machine at least twenty 20 feet and watch the blade on one of the cutting decks Have the machine operator disengage the PTO and record the time ittakes for the cutting deck blade to come to acom plete stop If this time is greater than seven 7 seconds the deck control manifold braking valve RV may need adjustment Groundsmaster 4300 D This page is intentionally blank Groundsmaster 4300 D Page7 7 Cutting Decks Service and Rep
29. 4 Turn back the lock nutas far as possible Make sure the back up washer is not loose and is pushed up as far as possible Step 1 in Figure 9 IMPORTANT Before installing fitting into port de termine port material If fitting is to be installed into an aluminum port installation torque is reduced 5 Install the fitting into the port and tighten finger tight until the washer contacts the face of the port Step 2 in Figure 9 Make sure that the fitting does not bottom in the port during installation 6 To putthe fitting in the desired position unscrew itby the required amount to align fitting with incoming hose or tube butno more than one full turn Step 3 in Figure 9 7 Hold the fitting in the desired position with a wrench and use a torque wrench to tighten the lock nut to the recommended installation torque shown in Figure 7 This tightening process will require the use of an offset wrench e g crowfoot wrench Use of an offset wrench will affect torque wrench calibration due to the effective length change of the torque wrench Tightening torque when using a torque wrench with an offset wrench will be lower than the listed installation torque see Using a Torque Wrench with an Offset Wrench in the Torque Specifications section of Chapter 2 Product Records and Maintenance 8 Ifa torque wrench is not available or if space atthe portprevents use ofa torque wrench an alternate meth od of assembly is the Flats From Fing
30. Charge Pressure Test 36 Gear Pump P3 Flow Test 38 Front Wheel Motor Efficiency Test 40 Piston Traction Pump Flow Test 42 Relief Valve PRV1 and PRV2 Pressure Test 44 Gear Pump P1 and P2 Flow Test 46 Deck Motor Efficiency Test 48 Lift Relief Valve PRV Pressure Test 50 Gear Pump P4 Flow Test 52 Lift Cylinder Internal Leakage Test 54 Steering Relief Valve R10 Pressure Test 56 Steering Cylinder Internal Leakage Test 58 Chapter 4 Hydraulic System SERVICE AND REPAIRS 60 General Precautions for Removing and Installing Hydraulic System Components 60 Check Hydraulic Lines and Hoses 61 Flush Hydraulic System 61 Filtering Closed Loop Traction Circuit 62 Hydraulic System Start up 63 Hydraulic Reservoir 64 Hydraulic Pump Drive Shaft 66 Hydraulic Pump Assembly 68 Piston Traction Pump Service 72 Gear Pump Service 74 Front Wheel Motors 76 Rear Wheel Motors 80 Wheel Motor Service 84 CrossTrax AWD Manifold 86 CrossTrax AWD Manifold Service 88 Deck Control Manifold 90
31. Discard any removed O rings Installation Fig 77 1 If fittings were removed from AWD manifold lubri cate and place new O rings to fittings Install fittings into manifold see Hydraulic Fitting Installation in the G ener al Information section of this chapter 2 Position manifold and three 3 spacers to frame bracket Install three 3 lock washers and cap screws but do not fully tighten screws Groundsmaster 4300 D Page 4 87 3 Remove caps and plugs from disconnected lines and fittings 4 Lubricate and install new O ring s on manifold fit tings Connect hydraulic lines to hydraulic manifold fit tings and properly tighten all connections see Hydraulic Hose and Tube Installation in the General Information section of this chapter 5 Secure AWD manifold to frame by tightening three 3 cap screws 6 Check oil level in hydraulic reservoir and add correct oil if necessary 7 Follow Hydraulic System Start up procedures see Hydraulic System Start up in this section Hydraulic System CrossTrax AWD Manifold Service 220 in Ib 24 8 N m 25 ft Ib 33 N m 220 in Ib 24 8 N m 46 ft Ib 62 N m Figure 78 1 AWD manifold 5 Check valve 9 Plug zero leak 8 2 O ring 6 Plug zero leak 4 10 O ring 3 Plug zero leak 6 7 O ring 11 Seal kit 4 Sealkit 8 Orifice 040 12 Bi Directional relief valve Forcontrol manifold service procedures see Deck Con trol Manifold Ser
32. Figure 66 1 End yoke 2 Cross and bearing kit 3 Snap ring 4 used 4 Shaft yoke Hydraulic System Hydraulic Pump Assembly LOND PWNE 18 ES x Drive shaft assembly Cap screw 2 used Flange head screw 2 used Hydraulic pump assembly O ring 90 hydraulic fitting 2 used Hydraulic hose 2 used Pump support bracket Flange nut 2 used Traction cable bracket Flange head screw 2 used Carriage screw 2 used Hydraulic hose Hydraulic System Figure 67 Guard hoop Flange nut 6 used Manifold Hose clamp 2 used Hydraulic hose Hydraulic fitting Neutral switch O ring 90 hydraulic fitting O ring Hydraulic tube O ring Hydraulic fitting Page 4 68 Antiseize Lubricant Hydraulic hose Hydraulic hose Frame bracket Flange head screw 2 used Hydraulic tube O ring O ring Flat washer 2 used Lock nut 2 used O ring Hydraulic fitting 2 used Hydraulic fitting Hydraulic fitting Groundsmaster 4300 D NOTE Traction pump and gear pump should be re moved from machine as an assembly Once removed from machine pumps can be separated for service Removal Fig 67 1 Park the machine on a level surface engage parking brake lower cutting decks and stop engine Remove key from the ignition switch 2 Read the General Precautions for Removing and Installing Hydraulic System Components at the begi
33. MANIFOLD e L peti C7 G4 RIGH FRON RONT LEFT RIGH ENTE REAR REAR EFT FRON t5 e 03 Ch C2 t6 B m l s2 tel CB Ais E n pz 1 Lc LIFT CONTROL MANIFOLD P T x T p a r R10 A e v 89 a 25 STEERING CONTROL VALVE STEERING CYLINDER DISPLACEMENT FLOW RATE AND PRESSURE CHART DISPLACEMENT PRESSURE FLOW RATE COMPONENT in e cm2vrev Ibszin BARS GPM LPM P1 03 6 84 13 1 49 6 P2 03 6 84 BA 49 6 P3 37 6 1 4 7 17 8 P4 En 3 9 3 0 11 4 P5 2 14 35 27 2 103 M1 05 7 16 M2 05 7 16 M3 05 7 16 ML 05 7 16 M5 05 7 16 M6 24 7 405 M7 24 7 405 M8 86 9 30 M9 89 30 vi 6 1 100 PRV 2000 38 xxxPRV1 3500 241 xxxxpRV2 2000 38 RVI 1500 05 RV2 1500 05 R3 3625 250 Ra 3625 250 R5 200 n SVRV 2000 38 RB
34. Mode X X NOTE ForStartmachine function the joystick mustbe in the neutral center position and the PTO switch must be OFF NOTE When the Lower Mow machine function is completed the front cutting decks engage while lower ing to the ground followed shortly by the rear cutting decks engaging while lowering to the ground The timing of this sequence is provided by the TEC controller Groundsmaster 4300 D Page5 11 NOTE The Diagnostic Light Fault Retrieval ma chine function requires thatthe seatbe unoccupied the mow speed limiter be in the TRANSPORT position the PTO switch be OFF andthe cutting decks be in the low ered mow position Electrical System E b Starting Problems No electrical power to machine including gauges Battery is discharged Ignition switch or circuit wiring is faulty Fusible link harness at the engine starter motor is faulty Battery cables are loose or corroded Fuse F1 1 15 amp or F1 2 10 amp is faulty Starter solenoid clicks but starter will not crank Battery is discharged NOTE If the starter solenoid clicks the problem is not Battery cables are loose or corroded in the interlock circuit Ground cable is loose or corroded Wiring at the starter motor is faulty Starter solenoid or starter motor is faulty Engine starts but stops when the ignition switch is Engine fuel stop solenoid or circuit w
35. Rear cover 3 Flange washer 10 Dowel pin 16 Anti cavitation valve 4 Shaftseal 11 Idler gear 17 Relief valve 5 Frontflange 12 O ring 18 Cap screw 4 used 6 Pressure seal 13 Body 19 Washer 4 used 7 Backup gasket Disassembly Fig 86 1 Plug motor ports and clean the outside of the motor thoroughly After cleaning remove plugs and drain any oil out of the motor 2 Use a marker to make a diagonal line across the frontflange body and rearcoverfor assembly purposes Fig 87 IMPORTANT Prevent damage when clamping the motor into a vise clamp on the front flange only Also use a vise with soft jaws Figure 87 3 Clamp front flange of motor in a vise with soft jaws with the shaft end down Hydraulic System Page 4 96 Groundsmaster 4300 D 4 Loosen cap screws from the rear cover 5 Remove motor from the vise Turn motor so that the shaft end is facing down Remove cap screws 6 Separate rear cover from body Lift rear cover from motor 7 Carefully remove body Lift body straight up to re move Make sure the rear wear plate remains on the drive and idler gear shafts Remove and discard O rings from the body Locate and retrieve dowel pins IMPORTANT Note position of the open and closed side of the wear plates before removing Also iden tify wear plates front and rear with a marker for proper assembly IMPORTANT Mark the relative positions of the gear teeth and the wear plates so they
36. The filter will remove contamination from the traction circuit during operation Because the Toro high flow filter is bi direc tional the traction circuitcan be operated in both the for ward and reverse direction The filter should be removed from the machine after contamination has been removed from the traction circuit See Filtering Closed Loop Traction Circuitin the S ervice and Repairs section of this chapter for additional information on us ing the Toro high flow hydraulic filter The alternative to using the Toro high flow hydraulic filter kit after a traction circuit component failure would be to disassemble drain and thoroughly clean all compo nents tubes and hoses in the traction circuit If any de bris remains in the traction circuit and the machine is operated the debris can cause additional circuitcompo nent failure NOTE The traction pump case drain could allow any debris in the traction circuitto contaminate other hydrau lic circuits on the machine Groundsmaster 4300 D Hydraulic Schematic p zi6sou p Se UMOUS ae spiou los IIV 5neureu s ineap AH d 00 r Jeyseuuspunoi c sb6uiweJg 1nopio d 8 Jeydeu uri pepnjour YAGNITAD ONIYAALS 1 1 J INVA JTOYLNOD DNIU3als 7 G9 ni TA IN OUT
37. a properly labeled container away from children and pets 4 Drain coolant from radiator see Radiator Removal in this section 5 Remove air cleaner from machine see Air Cleaner Removal in this section 6 Remove exhaust system from machine see Ex haust System Removal in this section 7 Remove throttle cable from injector pump Fig 10 A Remove cap screw that secures throttle cable end to swivel in speed control lever B Loosen throttle cable clamp and remove cable from clamp Slide throttle cable end from swivel C Position throttle cable away from the engine 8 Disconnect hoses from engine A Loosen clamps and remove upper and lower ra diator hoses from the engine B Atinjector pump loosen hose clamp and discon nect supply fuel hose from the injector pump fitting Fig 11 C Loosen hose clamp and disconnect fuel return hose from front injector body Fig 11 D Plug disconnected hoses and engine openings to prevent leakage and contamination P osition discon nected hoses away from engine Figure 10 1 Throttle cable end 3 Cable clamp 2 Swivel 7 8 B 8 8 la l 2 OT ABA E DR LL LJ Figure 11 1 Fuel return hose 3 Fuel water filter 2 Fuel supply hose Figure 12 1 Negative battery cable 2 Wire harness ground Groundsmaster 4300 D Page 3 13 Kubota Diesel Engine 9 Disconnect hydraulic transmission drive shaft from engine see Hydraulic Transm
38. and circuit wiring are not functioning correctly proceed with test procedure 2 Remove control arm covers to gain access to PTO switch see Control Arm Disassembly in the Service and Repairs section of Chapter 6 Chassis 3 Make sure ignition switch is in the OFF position Dis connectwire harness electrical connector from the PTO switch 4 With the use of a multimeter ohms setting the switch functions may be tested to determine whether continuity exists between the various terminals for each switch position The PTO switch terminals are marked as shown in Figure 24 The circuitry of this switch is shown in the chart below Verify continuity between switch terminals OTHER SWITCH NORMAL POSITION CIRCUITS CIRCUITS e zu 38 5 Replace PTO switch if necessary 6 If PTO switch tests correctly and circuit problem still exists check wire harness see Electrical Schematic and Circuit Drawings in Chapter 8 Foldout Drawings Groundsmaster 4300 D Page 5 25 7 Connect wire harness electrical connector to the PTO switch 8 Install control arm cover to machine see Control Arm Assembly in the Service and Repairs section of Chapter 6 Chassis Figure 23 1 PTO switch BACK OF SWITCH Figure 24 NOTE PTO switch terminals 7 and 8 are for the switch indicator light Switch terminals 1 4 5 and 6 are
39. are not damaged 4 Slide rearshaftinto frontshaftand align roll pin holes in shafts Install new roll pin to secure shafts IMPORTANT Prevent damage when clamping the cylinder s barrel into a vise clamp on the clevis only Do not close vise on barrel 5 Mount steering cylinder barrel in a vise equipped with soft jaws by clamping on the barrel clevis 6 Coatall internal cylinder components with clean hy draulic oil Slide shaftassembly into barrel being careful to not damage seals during installation 7 Insertrear head with new seals into the barrel being careful to not damage head seals during installation 8 Secure front and rear heads in barrel with external collars Tighten collars with spanner wrench Hydraulic System Oil Cooler Figure 104 1 Screen assembly 8 Hydraulic hose 2 used 15 Pin 2 Oil cooler bracket 9 90 hydraulic fitting 2 used 16 Clamp 2 used 3 Flange head screw 8 used 10 Hose clamp 4 used 17 Flange nut 4 used 4 Foam seal 2 used 11 Foam seal 2 used 18 O ring 5 Draw latch 12 Washer 4 used 19 45 hydraulic fitting 2 used 6 Rivet 2 used 13 Cap screw 2 used 20 O ring 7 Oil cooler 14 Mount plate 2 used 21 Radiator Hydraulic System Page 4 116 Groundsmaster 4300 D Removal Fig 104 1 Park machine on a level surface lower cutting decks stop engine engage parking brake and remove
40. arm Fig 23 1 Park machine on a level surface lower cutting decks stop engine engage parking brake and remove key from the ignition switch 2 Remove cutting deck from rear liftarm to be removed see Cutting Deck Carrier Frame Removal in the Ser vice and Repairs section of Chapter 7 Cutting Decks A Remove one 1 retaining ring and thrust washer from the cylinder pin that secures lift cylinder to lift arm B Pull cylinder pin from the lift cylinder and lift arm Locate and retrieve second thrust washer Chassis Page 6 24 Groundsmaster 4300 D C Remove screw that secures r clamp to lift arm Position r clamp and hydraulic hoses away from lift arm D Pivot lift cylinder rod end away from lift arm 4 Remove fasteners that secure bridge plate item 1 and bulkhead bracket item 16 to machine Position bulkhead bracket with attached hydraulic hoses away from lift arm Remove bridge plate 5 Slide rear lift arm from lift arm pivot shaft 6 Inspect flange bushings in lift arm for wear or dam age If necessary replace bushings A Use bushing removal tool to extract both flange bushings from the lift arm Take care to not damage the lift arm bore B Clean the inside of the bore to remove any dirtor foreign material C Apply grease to the inside and outside ofthe new flange bushings D Use an arbor press to install the bushings into lift arm Bushings should be pressed until bushing flange is again
41. arm covers to gain access to hour meter and meter terminals see Control Arm Disassem bly in the Service and Repairs section of Chapter 6 Chassis 2 Make sure ignition switch is in the OFF position Lo cate the hour meter and disconnect the wire harness electrical connector from the meter 3 Connectthe positive terminal ofa 12 VDC source to the positive terminal of the hour meter 4 Connect the negative terminal of the voltage source to the other terminal of the hour meter 5 The hour meter should move 1 10 of an hour every six 6 minutes 6 Disconnect the voltage source from the hour meter 7 Replace the hour meter if necessary 8 Connect wire harness electrical connector to the hour meter 9 Install control arm covers to machine see Control Arm Assembly in the Service and Repairs section of Chapter 6 Chassis Temperature Gauge The temperature gauge on the control panel indicates engine coolant temperature level during machine op eration The changing resistance of the engine tempera ture sender signals the temperature gauge The temperature gauge should display the first green segment when the ignition switch is turned to RUN The first yellow segment on the gauge should display when engine coolant temperature is approximately 212 F 100 C When engine coolanttemperature rises to approximate ly 221 F 105 C the temperature gauge should display the first red segment At this point
42. base with two 2 flange head screws and flat washers Figs 16 and 17 4 Connectseat switch electrical connector to wire har ness Fig 16 5 Connect negative battery cable to battery see Bat tery Service in the Service and Repairs section of Chap ter 5 Electrical System 1 Figure 16 Seat switch lead 2 Throttle cable WDB Groundsmaster 4300 D Page 6 19 3 Wire harness 4 Flange head screw Figure 17 Control arm assembly Flange screw 2 used Flat washer 2 used 4 Retainer bracket assy 5 Seat base 6 Bushing Chassis a m i lt Q Mechanical Seat Suspension qc Are 6 E E gt Upper housing Weight adjust knob Lower housing Scissor assembly Lock nut Weight adjuster Drive arm Extension spring 2 used Roller guide Weight adjust knob Cap Suspension boot Pivot block 2 used Damper o 9 q i 0 N a EBH BBHB B BWNEFO Chassis gt Figure 18 Lower shock bolt Upper shock bushing 2 used Lower shock bushing 2 used Stop bumper Height adjust rod Lock nut Stop bumper 2 used Bearing tube 2 used Spring shaft Pivot pin Roller pin Spring bushing 2 used Shaft block 2 used Weight adjust spacer Page 6 20 Weight indicator assembly Weight adjust nut Rivet Roller 4 used Extension spring Bumper Hex nut 2 used Retainer 3 used Flat washer Fl
43. be illuminated when the limiter is in the TRANSPORT position 3 Ifthe mow transportswitch LED did not function cor rectly A Make sure that the mow transport switch is prop erly adjusted see Mow Transport Switch in the Ad justments section of this chapter If necessary adjust switch and return to step 2 above B Make sure ignition switch is OFF and disconnect the mow transport switch connector from machine wire harness C Verify that the machine wire harness connector terminal for black wire is closed continuity to ground D Turn ignition switch to the ON position do not start engine and verify with a multimeter that ma chine wire harness connector terminal for pink wire has system voltage 12 VDC present E If black wire is closed to ground pink wire has system voltage presentand switch LED did notfunc tion replace mow transport switch Adjust switch af ter installation see Mow Transport Switch in the Adjustments section of this chapter 4 Ifthe mow transport switch tests correctly and a cir cuitproblem still exists check wire harness see Electri cal Schematic and Circuit Drawings in Chapter 8 Foldout Drawings 5 Makesure thatmow transportswitch is connected to wire harness when testing is complete 1 Mow speed limiter 3 Switch cable 2 Mow transport switch E u System Groundsmaster 4300 D Page 5 31 Electrical System Start Relay The start relay is used in the en
44. can be reassem bled in the same position Do nottouch the gear sur faces as residue on hands may be corrosive to gear finish 8 Carefully remove rear wear plate idler gear drive gear and front wear plate from the front flange 9 Remove and discard back up gaskets and pressure seals from wear plates 10 Turn front flange over with seal side up IMPORTANT Make sure to not damage the front flange counter bore when removing the seals from the front flange 11 Carefully remove dust seals retaining ring flange washer and shaft seal from the front flange Fig 88 Discard seals Inspection 1 Remove any nicks and burrs from all parts with A CAUTION emery cloth Use eye protection such as goggles when using compressed air 2 Clean all parts with solvent Dry all parts with com pressed air 3 Inspect drive gears and idler gears for the following Fig 89 Groundsmaster 4300 D Page 4 97 A Gear shafts should be free of rough surfaces and excessive wear at bushing points and sealing areas Scoring rough surfaces or wear on gear shafts indi cates need for replacement B Gear teeth should be free of excessive scoring and wear Any broken or nicked gear teeth must be replaced C Inspect gear face edge for sharpness Sharp edges of gears will mill into wear plates and thus must be replaced 4 Inspect wear plates for the following A Bearing areas should nothave excessive wear or scor
45. circuit components are also damaged Possible Causes Solenoid valve PRV2 on deck control manifold is faulty NOTE Solenoid valves PRV1 and PRV2 are identical and can be reversed for testing purposes An electrical problem exists that prevents PRV2 solenoid coil on deck control manifold from being energized see Troubleshooting in Chapter 5 Electrical System Front deck spindle s is binding Gear pump section P 2 is worn or damaged Solenoid valve PRV1 on deck control manifold is faulty NOTE Solenoid valves PRV1 and PRV2 are identical and can be reversed for testing purposes An electrical problem exists that prevents PRV1 solenoid coil on deck control manifold from being energized see Troubleshooting in Chapter 5 Electrical System Rear deck spindle s is binding Gear pump section P 1 is worn or damaged Cutting deck motor is worn or damaged Cross over relief valve in cutting deck motor is stuck or faulty NOTE If appropriate transfer a suspected damaged motor to another cutting deck If problem follows the motor motor needs repair or replacement Page 4 28 Groundsmaster 4300 D Lift Circuit Problems Single cutting deck raises slowly or not Cutting deck has excessive debris buildup Lift arm or lift cylinder is binding Flow control orifice in lift control manifold for the affected cutting deck is plugged stuck or damaged Lift cylinder leaks internally Cutting decks raise but will n
46. components for flow and pressure capacities as recommended in the Testing section of this chapter This testerincludes the following 1 LOAD VALVE A simulated working load is created in the circuit by turning the valve to restrict flow 2 PRESSURE GAUGE Glycerine filled 0 to 5000 PSI gauge to provide operating circuit pressure 3 FLOW METER This meter measures actual oil flow in the operating circuit with a gauge rated from 4 to 40 GPM 20 to 150 LPM Toro Part Number AT40002 Figure 23 NOTE Thistesterdoes notinclude hoses see Hydrau lic Hose Kit TOR 6007 below Hydraulic Hose Kit This kitincludes fittings and hoses neededto connect40 GPM hydraulic tester AT40002 or high flow hydraulic filter kit TOR 6011 to machine hydraulic traction system components Toro Part Number TOR6007 Figure 24 O Ring Kit The O ring kit includes O rings in a variety of sizes for face seal and port seal hydraulic connections It is rec ommended that O rings be replaced whenever a hy draulic connection is loosened Toro Part Number 117 2727 Figure 25 Groundsmaster 4300 D Page 4 23 Hydraulic System High Flow Hydraulic Filter Kit The high flow hydraulic filter kit is designed with large flow 40 GPM 150 LPM and high pressure 5000 PS1 345 bar capabilities This kit provides for bi direc tional filtration which prevents filtered debris from being allowed back into the circuit regardless of flow direction
47. control manifold Both circuits share manifold portT which drains to the oil cooler oil filterand hydraulic reservoir Cutting deck motors are equipped with a cross over re lief valve to prevent hydraulic component damage in case a single cutting deck should stall The machine controller uses inputs from various ma chine switches to determine when the solenoids for pro portional relief valves PRV1 and PRV2 are to be energized The controller also provides a slight delay in activation of rear cutting decks PTO Not Engaged When proportional relief valves PRV1 and PRV2 are notenergized PTO switch in the OFF position orcutting decks raised flow from pump sections P 1 and P 2 is directed through the unshifted proportional relief valves outthe mow control manifold port T and then returns to the hydraulic reservoirthrough the oil filter and oil cooler bypassing the deck motors The manifold logic car tridges LC1 and LC2 remain in the unshifted position to prevent any return flow from the deck motors so the motors will not rotate PTO Engaged Fig 11 When proportional relief valve PRV1 is energized by the controller PTO switch in the ON position and cutting decks lowered the proportional relief valve shifts and prevents pump section P1 flow through the valve Pump flow that entered deck control manifold port P 1 is then directed toward the rear cutting deck motors Be cause logic cartridge LC1 is unshifted
48. fuel tank 5 Remove fuel tank using Figure 2 as a guide Fuel Tank Installation Fig 2 1 Install fuel tank to frame using Figure 2 as a guide 2 Using labels placed during fuel tank removal cor rectly connect fuel hoses to suction item 7 and return item 6 fittings on the top of the fuel tank Secure fuel hoses with hose clamps 3 Make sure that fuel tank draincock is closed F ill fuel tank Figure 3 3 Fuel gauge 1 Fuelsupply hose 2 Fuel return hose Kubota Diesel Engine 9 W 9 8 8 Air Cleaner NOR WNE Air cleaner assembly Indicator Adapter Spring Hex nut Bolt Hose Kubota Diesel Engine Figure 4 Hose Mount bracket Air cleaner stand Hose clamp 3 used Flange nut 8 used Cap screw 2 used Hose clamp 2 used Page 3 6 Thread Sealant 12 to 15 in Ib 1 4 to 1 6 N m VACUATOR DIRECTION Flange head screw 4 used Air cleaner mounting band Spacer Hose Hose clamp Flange head screw 2 used Groundsmaster 4300 D Removal Fig 4 1 Park machine on a level surface lower cutting decks stop engine engage parking brake and remove key from the ignition switch Raise and support hood 2 Remove air cleaner components as needed using Figures 4 as a guide 3 See Operator s Manual for air cleaner service and maintenance procedures Installation Fig 4 IMPORTANT Any leaks in the air filt
49. harness connector to the fuel stop so lenoid 8 Lower and secure hood Figure 53 1 Injection pump 2 Fuel stop solenoid Figure 54 3 Hold coil terminal 1 Fuel stop solenoid 2 Pull coil terminal Groundsmaster 4300 D Fuel Pump The fuel pump used on the Groundsmaster 4300 D is attached to the inside of the left side frame rail near the fuel tank Fig 55 IMPORTANT When testing fuel pump make sure that pump is not operated without fuel Because diesel fuelis highly flammable use cau tion when handling it Do notsmoke while testing the fuel pump Do nottestfuel pump while engine is hot Make sure that there is adequate ventila tion when testing Always wipe up any spilled fuel before starting the engine Fuel Pump Capacity Test 1 Park machine on a level surface lower cutting decks stop engine and engage parking brake Remove key from ignition switch Raise and support operator seat and hood 2 Disconnect wire harness electrical connector from the engine fuel stop solenoid to preventthe engine from starting see Fuel Stop Solenoid in this section 3 Disconnect fuel hose pump discharge from the fuel water separator inlet fitting Fig 56 4 Make sure fuel hoses attached to the fuel pump fuel filter and fuel tank suction tube screen are free of ob structions 5 Place disconnected fuel hose into a large graduated cylinder sufficient enough to collect 1 quart 0 95 liter IMPOR
50. hot oil All testing should be performed by two 2 people One person should be in the seat to oper ate the machine and the other should read and record test results Keep body and hands away from pin hole leaks or nozzles that eject hydraulic fluid under high pressure Do not use hands to search for leaks use paper or cardboard Hydraulic fluid escap ing under pressure can have sufficient force to penetrate the skin and cause serious injury If fluid is injected into the skin itmustbe surgical ly removed within a few hours by a doctor famil iar with this type of injury Gangrene may result from such an injury 1 Clean machine thoroughly before disconnecting or disassembling any hydraulic components Always keep in mind the need for cleanliness when working on hy draulic equipment Contamination can cause excessive wear or binding of hydraulic components Hydraulic System Page 4 32 2 Review all test steps before starting the test proce dure 3 Before testing check all control linkages for improp er adjustment binding or broken parts 4 Allhydraulic tests should be made with the hydraulic oil at normal operating temperature Before disconnecting or performing any work on the hydraulic system all pressure in the system must be relieved See Relieving Hydraulic Sys tem Pressure in the General Information section of this chapter 5 Put metal caps or plugs on any hydraulic lines left open or expose
51. ignition switch to the RUN position The oil pressure indicator light on the control panel should be illuminated 2 If the indicator light is not illuminated open hood to gain access to engine 3 Locate oil pressure switch on engine and disconnect the wire harness connector from the switch 4 With the ignition switch in the RUN position ground the disconnected wire to the engine block 5 Ifthe indicator lightcomes on the oil pressure switch is faulty 6 If the indicator light does not come on after step 5 check the oil pressure indicator light and circuit wiring see Indicator Lights in this section 7 After testing is completed connect the wire harness connector to the oil pressure switch Lower and secure hood 1 Oil filter Groundsmaster 4300 D Page 5 41 Figure 52 2 Oil pressure switch Electrical System E u System Fuel Stop Solenoid The fuel stop solenoid used on your Groundsmaster must be energized for the diesel engine to run The sole noid is mounted to the injection pump on the engine Fig 53 The TEC controller monitors the operation of the fuel stop solenoid The solenoid and its circuit wiring should be tested as a controller output with the Diagnostic Dis play see Special Tools and Troubleshooting in this chapter If the controller detected a fuel stop solenoid problem during engine operation the Diagnostic light can be used to identify the fault see Diagnosti
52. in each end of the roller shaft 3 Align roller shaft grease hole with the roller mount grease groove Use alignment mark on end of roller shaft to assist with alignment 4 Positionskid brackets to roller mounts and install cap screws to retain brackets in place 5 Ifequipped with scraper rod install and adjustscrap er rod assembly to roller mounts Fig 10 The gap be tween the scraper rod and roller should be from 0 020 to 0 040 in 0 5 to 1 0 mm Torque cap screws 30 ft Ib 41 N m 6 Install and tighten fasteners that secure each end of roller to roller mounts Torque roller shaft screws item 4 and cap screws item 8 from 29 to 35 ft Ib 40 to 47 N m 7 After assembly raise and lower the cutting deck to verify that hydraulic hoses and fittings do not contact anything 1 Grease fitting 2 Roller shaft screw 3 Scraper plate Groundsmaster 4300 D Page 7 13 29 to 35 ft lb 40 to 47 N m Figure 10 4 Cap screw 5 Roller scraper 6 Roller mount Cutting Decks Rear Roller Service Disassembly Fig 11 1 Remove bearing lock nut from each end of roller shaft 2 Loosely secure roller assembly in bench vise and lightly tap one end of roller shaft until outer seals and bearing are removed from opposite end of roller tube Remove second set of outer seals and bearing from roll er tube by tapping on opposite end of shaft Remove shaft from roller tube 3 Carefully remove inner seal from bot
53. intentionally blank a m i o Groundsmaster 4300 D Page 6 3 Chassis Service and Repairs Wheels 70 to 90 ft Ib 95 to 122 N m Figure 2 1 Front wheel motor LH shown 5 Brake drum 9 Rear wheel hub 2 Brake assembly LH shown 6 Front wheel 10 Rear wheel 3 Front wheel hub 7 Lug nut 5 used per wheel 11 Lock nut 4 Lock nut 8 Rear wheel motor LH shown Chassis Page6 4 Groundsmaster 4300 D Removal Fig 2 Installation Fig 2 1 Park machine on a level surface lower cutting 1 Install wheel and secure with five 5 lug nuts decks stop engine engage parking brake and remove f key from the ignition switch 2 Lower machine to ground 2 Chock wheels to prevent machine from shifting 3 Torque lug nuts evenly in a crossing pattern from 70 to 90 ft Ib 95 to 122 N m 3 Loosen wheel lug nuts When changing attachments tires or perform ing other service use correctsupports hoists and jacks Make sure machine is parked on a solid level surface such as a concrete floor Prior to raising machine remove any attach ments that may interfere with the safe and properraising ofthe machine Always chockor block wheels Use jack stands or other ap propriate load holding devices to support the raised machine If the machine is not properly supported the machine may move or fall which may result in personal injury 4 Using a jack raise machine so wheel is off ground see J acking Instruction
54. is at normal operating tem perature by operating the machine under load for Before opening hydraulic system operate all hy approximately ten 10 minutes draulic controls to relieve system pressure and p avoid injury from pressurized hydraulic oil See 2 Park machine on a level surface with the cutting Relieving Hydraulic System Pressure in the Gen decks lowered and PTO switch off Make sure engine is eral Information section of this chapter off Apply the parking brake Hydraulic System Page 4 36 Groundsmaster 4300 D 4 Raise and support operator seat to allow access to hydraulic pump assembly 5 Thoroughly clean ends of hydraulic tubes that con nect to the oil filter Fig 37 Disconnect hydraulic tubes from oil filter adapter Remove two 2 flange head screws thatsecure oil filter adapter to frame and remove oil filter and adapter assembly from machine 6 Install tee fitting with 1000 PSI 70 bar pressure gauge in place ofthe removed hydraulic filter assembly 7 Make sure thattraction pedalis in neutral the steer ing wheel is stationary and parking brake is engaged 8 Startengine and run atidle speed Checkfor any hy draulic leakage from test connections and correct be fore proceeding with test 9 Place throttle to full speed 3200 RPM and monitor pressure gauge on tester GAUGE READING TO BE approximately 200 to 250 PSI 13 8 to 17 2 bar 10 Next determine charge pressure undertraction load
55. m Then torque 5 8 fasten ers item 18 from 135 to 165 ft Ib 183 to 223 N m 5 Connect lift cylinder to lift arm Fig 21 A Align lift cylinder rod end to liftarm mounting hole B Slide cylinder pin with retaining ring and thrust washer through the lift cylinder and lift arm C Install second thrust washer on pin and secure with second retaining ring 6 Mountcutting deck to liftarm see Cutting Deck Car rier Frame Installation in the Service and Repairs sec tion of Chapter 7 Cutting Decks 7 Lubricate lift arm and lift cylinder grease fittings Figure 21 1 Liftarm 1 shown 2 Lift cylinder 3 Retaining ring 4 Thrust washer 5 Cylinder pin Chassis K m k o Rear Lift Arms N Pd Antiseize Lubricant Antiseize Lubricant 135 to 165 ft Ib 183 to 223 N m 75 to 95 ft Ib 102 to 128 N m 135 to 165 ft Ib Permatex 183 to 223 N m Threadlocker Permatex Threadlocker Permatex Threadlocker Figure 22 1 Bridge plate 7 Flange nut 12 Flange bushing 2 used per lift arm 2 2 liftarm 8 Flange head screw 13 Roll pin 1 used per pivot shaft 3 3 liftarm 9 Lift arm pivot shaft 2 used 14 Cap screw 1 used per pivot shaft 4 Cap screw 10 Flat washer 2 used 15 Grease fitting 1 used per lift arm 5 Thrust washer 2 used 11 Pivot shaft 1 used per lift arm 16 Bulkhead bracket 6 Cap screw 2 used Removal Fig 22 3 Disconnect lift cylinder from lift
56. machine It is not designed to withstand the environment of the machine s every day use When use of Diagnostic Display is com pleted disconnect it from the machine and recon nect loopback connector to harness connector Machine will not operate without loopback connec torinstalled on harness Store Diagnostic Display in a dry secure indoor location not on machine Battery Hydrometer Use the Battery Hydrometer when measuring specific gravity of battery electrolyte Obtain this tool locally Groundsmaster 4300 D Page5 5 DIAGNOSTIC DISPLAY OVERLAY 117 0171 Figure 4 GROUNDSMASTER 4300 D DIAGNOSTIC ACE OUTPUT INPUT INPUT OUTPUT TAR SV1 UNUSED UNUSED UNUSED UNUSED E F W UNUSED UNUSED UNUSED UNUSED Figure 5 Figure 6 Electrical System Troubleshooting Remove all jewelry especially rings and watches before doing any electrical trouble shooting or testing Disconnect the battery cables unless the test requires battery voltage Diagnostic Light Groundsmaster 4300 D machines are equipped with a diagnostic light that indicates if the machine electrical system is functioning correctly The diagnostic lightis lo cated on the control panel Fig 7 When the ignition switch is moved to the RUN position and the machine electrical system is functioning pro perly the diagnostic light will be illuminated for approxi mately three 3 seconds and then will turn
57. machine on a level surface lower the cutting decks stop the engine and engage the parking brake 2 Open control panel cover Locate wire harness and connectors near TEC controller Carefully unplug loop back connector from harness connector Fig 9 3 Connectthe Diagnostic Display connectorto the har ness connector Fig 10 Make sure correct overlay de cal is positioned on the Diagnostic Display Fig 11 4 Turn the ignition switch to the RUN position but do not start machine NOTE The red text on the overlay decal refers to con troller inputs and the green text refers to controller out puts Electrical System Page5 8 Figure 9 1 TEC controller location 3 Harness connector 2 Loopback connector Figure 10 1 Diagnostic display 2 Loopback connector GROUNDSMASTER 4300 D DIAGNOSTIC ACE DIAGNOSTIC DISPLAY OVERLAY 117 0171 INPUT OUTPUT OUTPUT INPUT START SV1 Figure 11 Groundsmaster 4300 D 5 The INPUTS DISPLAYED LED on lower right col umn of the Diagnostic Display should be illuminated If the green OUTPUTS DISPLAYED LED is illuminated press the toggle button on the Diagnostic Display to change to INPUTS DISPLAYED LED 6 The Diagnostic Display will illuminate the LED associated with each of the inputs when that input is in the position identified on the Diagnostic Display overlay Individually change the position of each of the inputs i e siton seat press tracti
58. motor housings to rear axle see Rear Axle Motor Housing Installation in this section 5 Install steering cylinder to rear axle see Steering Cylinder Installation in the Service and Repairs section of Chapter 4 Hydraulic System Chassis Page 6 14 6 Position tie rod to axle and inserttie rod ends to drag links Secure tie rod ends to drag links with slotted hex nuts and cotter pins 7 Install both rearwheel assemblies see Wheel Instal lation in this section Make sure that lug nuts are torqued evenly in a crossing pattern from 70 to 90 ft Ib 95 to 122 N m 8 Check rear wheel toe in see Operator s Manual 9 Check oil level in hydraulic reservoir 10 Lubricate the rear axle grease fittings 11 After all adjustments have been made make sure thatno contact is made between any machine compon ents as the rear wheels are moved from lock to lock Ad just if necessary 12 0perate machine and check hydraulic connections for leaks Groundsmaster 4300 D This page is intentionally blank a m i o Groundsmaster 4300 D Page 6 15 Chassis Control Arm 1 2 3 4 5 6 7 8 9 10 Arm rest Headlight switch LH control arm cover Screw 2 used Lock nut Screw RH control arm cover Bushing Control arm assembly Seat wire hamess Chassis 11 12 13 14 Access cover 16 17 18 19 20 Figure 12 Clevis pin Cap screw Latch Swell latch 2 used Washer he
59. not used on Groundsmaster 4300 D machines Electrical System E b u System Headlight Switch The headlight switch is located on the operator side of the controlarm This rocker switch allows the headlights to be turned on and off Testing 1 Remove inside control arm cover to gain access to headlight switch see Control Arm Disassembly in the Service and Repairs section of Chapter 6 Chassis 2 Make sure ignition switch is in the OFF position Dis connect wire harness electrical connector from the headlight switch 3 With the use of a multimeter ohms setting the switch functions may be tested to determine whether continuity exists between the various terminals for each position The switch terminals are marked as shown in Figure 26 The circuitry of the headlight switch is shown in the chart below Verify continuity between switch ter minals SWITCH NORMAL OTHER POSITION CIRCUITS CIRCUITS x ON 25 ss e 2H 5M 4 Replace headlightswitch if necessary Connect wire harness electrical connector to the headlight switch 5 Install control arm cover to machine see Control Arm Assembly in the Service and Repairs section of Chapter 6 Chassis Electrical System Page 5 26 Figure 25 1 Headlight switch BACK OF SWITCH Figure 26 NOTE Headlight switch terminals 3 4 5 and 6 are not
60. not met inspect steering control valve see Steering Control Valve Service in the Service and Repairs section of this chapter 13 After testing is completed make sure that engine is stopped then relieve hydraulic system pressure see Relieving Hydraulic S ystem Pressure in the General In formation section of this chapter Remove tee fitting and pressure gauge from hydraulic hose and steering cylinder Connecthydraulic hose to steering cylinder fit ting S Figure 60 1 Steering cylinder 2 Rod end fitting Hydraulic System Steering Cylinder Internal Leakage Test STEERING WHEEL TURNED FOR RIGHT TURN STEERING CONTROL VALVE L LOOK FOR LEAKAGE I STEERING CYLINDER FULLY EXTENDED Figure 61 The steering cylinder internal leakage test should be NOTE Steering circuit operation will be affected by performed if a steering problem is identified This test rear tire pressure steering cylinder binding extra will determine if the steering cylinder is faulty weighton the vehicle and orbinding of rearaxle steering components Make sure that these items are checked before proceeding with steering cylinder internal leak age test Hydraulic System Page 4 58 Groundsmaster 4300 D Procedure for Steering Cylinder Internal Leakage Test 1 Make
61. nut and piston from the shaft Carefully slide head off the shaft 6 Taking care to not scratch or damage components remove and discard all seals back up rings and O rings from head and piston Inspection A CAUTION Use eye protection such as goggles when using compressed air 1 Wash all lift cylinder components in clean solvent Dry parts with compressed air 2 Inspectinternal surface of barrel for deep scratches out of roundness and bending 3 Inspect head shaft and piston for excessive pitting scoring and wear 4 Replace liftcylinder ifinternal components are found to be worn or damaged Groundsmaster 4300 D Page 4 107 Assembly Fig 96 1 Make sure all lift cylinder parts are clean before as sembly 2 Coatnew O rings back up washer and other seals with clean hydraulic oil Carefully install new seals back up rings and O rings to head and piston IMPORTANT Do not clamp vise jaws against the shaft surface Clamp on the clevis ONLY 3 Mountshaftsecurelyin a vise by clamping on the cle vis ofthe shaft A Coat shaft with clean hydraulic oil B Slide head onto the shaft C Install piston onto the shaft and secure with lock nut Torque lock nut 40 ft Ib 54 N m D Remove shaft assembly from the vise IMPORTANT Prevent damage when clamping the hydraulic cylinder into a vise clamp on the clevis end of the barrel ONLY 4 Mount barrel securely in a vise by clamping on the Cl
62. off The light should remain off during normal machine operation If the machine TEC controller detects an electrical sys tem malfunction fault during machine operation the diagnostic light will flash rapidly The light will stop flash ing and will automatically reset when the ignition switch is turned to the OFF position The fault however will be retained in controller memory and can be retrieved ata future time see Retrieving Fault Codes below If the diagnostic light does not illuminate when the igni tion switch is turned to the RUN position possible causes are e The loopback connector is not connected to the machine wire harness Fig 8 e The diagnostic light or circuit wiring is faulty e TEC controller fuses are faulty see Fuses in the Component Testing section of this chapter e The TEC controller is faulty Check electrical connections controller fuses and the diagnostic light to determine malfunction Make sure thatthe loopback connector is secured to the wire har ness connector Electrical System Page5 6 Foreffective troubleshooting and repairs there mustbe a good understanding ofthe electrical circuits and com ponents used on this machine see Chapter 8 Foldout Drawings If the machine has any interlock switches by passed they must be reconnected for proper trou bleshooting and safety NOTE Use the Diagnostic Display see Special Tools in this chapter to test Toro Electronic Cont
63. on a level surface with the cutting decks lowered and PTO switch off Make sure engine is off and mow speed limiter is in the mow position Apply the parking brake Groundsmaster 4300 D 3 Read Precautions For Hydraulic Testing in this sec tion Before opening hydraulic system operate all hy draulic controls to relieve system pressure and avoid injury from pressurized hydraulic oil See Relieving Hydraulic System Pressure in the Gen eral Information section of this chapter 4 Raise and support operator seat to allow access to hydraulic deck control manifold 5 Thoroughly clean junction of hydraulic inlethose and deck motor fitting on left side cutting deck for the relief valve to be tested Disconnecthose from deck motor fit ting Fig 46 2 cutting deck left rear for relief valve PRV1 4 cutting deck left front for relief valve PRV2 IMPORTANT Make sure that the oil flow indicator arrow on the flow meter is showing that the oil will flow from the disconnected hose through the tester and into the deck motor 6 Install tester with pressure gauge and flow meter in series with the disconnected hose and hydraulic fitting on deck motor Make sure the flow control valve on tester is fully open 7 After installing tester start engine and run at idle speed Check for any hydraulic leakage from test con nections and correct before proceeding with test 8 Move throttle to full speed 3200 RPM A CAUTION
64. on your Groundsmaster Groundsmaster 4300 D Adjustments Traction Neutral Switch The traction neutral switch is a normally open proximity switch that closes when the traction pedal is in the neu tral position The switch mounts to a bracket on the trac tion pump Fig 14 The sensing plate for the traction neutral switch is the traction lever bracketthatis secured to the pump control arm Adjustment 1 Before adjusting the traction neutral switch check and adjusttraction system neutral position see Traction Unit Operator s Manual IMPORTANT To prevent traction neutral switch damage make sure thattraction lever bracket does not contact switch 2 When the traction leveris in the neutral position the Figure 14 gap between the head of neutral switch and the traction 1 Traction pump 4 Pump control arm lever bracketshould be from 0 070 to 0 100 1 8 to 2 5 2 Traction neutral switch 5 Jam nut 2 used mm Fig 15 3 Traction lever bracket 6 Lock washer 2 used 3 If gap is incorrect loosen jam nuts that secure neu tral switch to pump bracket Position switch with jam nuts to allow correct gap between switch and traction le ver bracket Jam nuts should be torqued from 162 to 198 in Ib 18 4 to 22 4 N m After jam nuts are tight ened make sure that clearance between head of neu tral switch and traction lever bracket has not changed Electrical System 4 After adjustment to the tract
65. output from the controller is provided to the lift control manifold proportional relief valve P RV to vary counter balance pressure As traction pressure increases e g climbing a hill the counterbalance pressure also in creases to increase the weight on the tires and improve traction LIFT CIRCUIT NOT RAISING OR LOWERING RIGHT FRONT FRONT RIGHT CENTER REAR S1 S2 AND PRV DE ENERGIZED 1 1 LC SHIFTED XK a PRV s LES me LIFT gt lt g o CONTROL MANIFOLD E P FROM gt PUMP TO OIL _ FILTER Figure 19 Hydraulic System Mo 4 uonons JO WINS d eGueuDd aunssad MO eunssajig BupuoAA Hn 6uueas Q 00 r 491seuuspunouc LNAWSAOW NOLSId YSACNITAD ONIYAALS 1 zo Y 3ATVA TOYLNOD ONIYAALS 1 I I tolli N Le ce zx Y Y I I a 78 i E mE d dNNd WOY NYNL 14331 y LINDYID ADYVHD NOLLOV L OL lt gt YSACNINAD LNAWSAOW NOLSId SNIu3als 3ATVA TOYLNOD ONIYAALS Hi 69 L CO LINDYID ADYVHD NOLLOV L OL d did WOU Nn 1LHOld
66. port material is steel tighten the fitting to the listed F F F T If port material is aluminum tighten fit ting to 60 of listed F F F T Size F F F T O ring Figure 6 Installation Torque Into Fitting Fitting Port Side Installation Torque Into Dash Size Thread Size Steel Port 7 16 20 15 to 19 ft lb 21 to 25 N m 1 2 20 18 to 22 ft lb 25 to 29 N m 9 16 18 34 to 42 ft lb 47 to 56 N m 3 4 16 58 to 72 ft Ib 79 to 97 N m 7 8 14 99 to 121 ft lb 135 to 164 N m 11 16 12 134 to 164 ft lb 182 to 222 N m 13 16 12 160 to 196 ft lb 217 to 265 N m 15 16 12 202 to 248 ft lb 274 to 336 N m 15 8 12 247 to 303 ft lb 335 to 410 N m Figure 7 Hydraulic System Page4 6 Aluminum Port 9 to 11 ft lb 13 to 15 N m 11 to 15 ft lb 15 to 20 N m 20 to 26 ft Ib 28 to 35 N m 35 to 43 ft Ib 48 to 58 N m 60 to 74 ft lb 82 to 100 N m 81 to 99 ft lb 110 to 134 N m 96 to 118 ft lb 131 to 160 N m 121 to 149 ft lb 165 to 202 N m 149 to 183 ft lb 202 to 248 N m Groundsmaster 4300 D Adjustable Fitting Fig 8 1 Make sure all threads and sealing surfaces of fitting and component port are free of burrs nicks scratches or any foreign material 2 As a preventative measure againstleakage itis rec ommended that the O ring be replaced any time the connection is opened 3 Lightly lubricate the O ring with clean hydraulic oil Fitting threads should be clean with no lubricantapplied
67. pumpP 1 connection portand P RV2 is the loca tion for the proportional relief valve P RV2 see Hydraulic Schematic in Chapter 8 Foldout Drawings to identify the function of the hydraulic lines and cartridge valves at each manifold port Hydraulic System Page 4 92 Groundsmaster 4300 D NOTE The deck control manifold uses several zero leak plugs These plugs have a tapered sealing surface on the plug head that is designed to resist vibration in duced plug loosening The zero leak plugs also have an O ring to provide a secondary seal If zero leak plug re moval is necessary lightly rap the plug head using a punch and hammer before using an allen wrench to re move the plug the impact will allow plug removal with less chance of damage to the socket head of the plug When installing plugs into the control manifold torque plugs to the values identified in Figures 81 Deck Control Manifold Service 1 Make sure the manifold is thoroughly cleaned before removing any cartridge valve 2 Ifsolenoid cartridge valve is being serviced remove nutsecuring solenoid coilto the cartridge valve Careful ly slide solenoid coil off the valve Before opening hydraulic system operate all hy draulic controls to relieve system pressure and avoid injury from pressurized hydraulic oil See Relieving Hydraulic System Pressure in the Gen eral Information section of this chapter IMPORTANT Use care when removing cartridge valves Slight bendin
68. some specialized test equipment is explained in the en gine workshop manual included atthe end of this chap ter However the cost of the test equipment and the specialized nature of some repairs may dictate that the work be done at an engine repair facility Operator s Manual The Operator s Manual provides information regarding the operation general maintenance and maintenance intervals for the Kubota diesel engine that powers your Groundsmaster machine Refer to that publication for additional information when servicing the machine Stopping the Engine IMPORTANT The engine used on the Ground smaster 4300 D is turbo charged Before stopping the engine after mowing or full load operation cool the turbo charger by allowing the engine to idle at low speed for five 5 minutes Failure to do so may lead to turbo charger trouble Groundsmaster 4300 D Page3 1 Chapter 3 Kubota Diesel Engine SERVICE AND REPAIRS 4 FuelSystem erri tpai ei una gan RR 4 Ait Cleaner u sas merda tete ated 6 Exhaust System ssssssessssn 8 Radiator areant ent oor arp E E 10 EAE uu atm ete T Rs goad e oce 12 KUBOTA WORKSHOP MANUAL DIESEL ENGINE 05 E3B SERIES Service and repair parts for Kubota diesel engines are supplied through yourlocal Toro Distributor Ifa parts list is not available be sure to provide your distributor with the Toro model and serial number Kubota Diesel Engine 9 u
69. switch 2 Read the General Precautions for Removing and Installing Hydraulic System Components at the begin ning of the Service and Repairs section of this chapter 3 Label all hydraulic connections for assembly pur poses Thoroughly clean hydraulic connections prior to loosening hydraulic lines from deck motor Hydraulic System Page 4 94 Before opening hydraulic system operate all hy draulic controls to relieve system pressure and avoid injury from pressurized hydraulic oil See Relieving Hydraulic System Pressure in the Gen eral Information section of this chapter 4 Disconnecthydraulic hoses from fittings in deck mo tor Allow lines to drain into a suitable container Remove and discard O rings Groundsmaster 4300 D 5 Putcaps orplugs on disconnected hoses and fittings to prevent contamination 6 Remove two 2 socket head screws and flat wash ers that secure hydraulic motor to the cutting deck Fig 84 Remove hydraulic motor and O ring from deck 7 Cover top of spindle to prevent debris from entering spindle A spindle plug See Special Tools in this chap ter can be used to cover spindle 8 If hydraulic fittings are to be removed from motor mark fitting orientation to allow correct assembly Re move fittings from motor and discard O rings Installation Fig 82 1 If hydraulic fittings were removed from motor lubri cate new O rings position O rings to fittings and install fittings int
70. system is contaminated see Flush Hydraulic System in this section 4 Make sure hydraulic reservoir is full Add correct oil if necessary 5 Check control linkage for proper adjustment binding or broken parts 6 Disconnect wire harness electrical connector from the engine fuel stop solenoid to preventthe engine from starting Groundsmaster 4300 D Page 4 63 7 Make sure traction pedal is in neutral and the PTO switch is OFF Turn ignition key switch to start engage starter for ten 10 seconds to prime hydraulic pumps Wait fifteen 15 seconds to allow the starter motor to cool and then repeat cranking procedure again 8 Connect wire harness electrical connector to fuel stop solenoid to allow engine to start 9 Make sure traction pedal is in neutral and the PTO switch is OFF Start engine and run it at low idle The charge pump should pick up oil and fill the hydraulic sys tem If there is no indication of fill in thirty 30 seconds stop the engine and determine the cause 10 If the traction pump was replaced or rebuilt run the traction unitso the wheels turn slowly forten 10 minu tes 11 Operate the traction unit including steering and cut ting deck lift lower by gradually increasing the work load to full over a ten 10 minute period 12 Stop the machine Check oil level in hydraulic reser voir and add correct oil if necessary Check hydraulic components for leaks and tighten any loose connec tions
71. that secure steering column to machine 10 Remove steering column and steering control valve assembly from machine 11 Loosen and remove four 4 sockethead screws that secure steering control valve to steering column 12 Remove steering control valve from steering col umn 13 If necessary remove fittings and O rings from steer ing control valve Discard all removed O rings Installation Fig 97 1 If fittings were removed lubricate new O rings with clean hydraulic oil and install fittings to steering control valve see Hydraulic Fitting Installation in the General Information section of this chapter 2 Apply antiseize lubricantto splines of steering con trol valve shaft 3 Slide steering control valve shaft into steering col umn universal joint Position control valve with ports to ward front of machine Secure steering control valve to steering column with four 4 socket head screws Torque screws in a criss cross pattern from 84 to 120 in Ib 9 5 to 13 5 N m 4 Position steering column assembly to machine Se cure steering column in place with two 2 socket head screws and flange nuts at rear two mounting holes 5 Remove caps and plugs from disconnected lines and fittings 6 Lubricate new O rings and connect hydraulic lines to fittings on steering control valve Tighten connections see Hydraulic Hose and Tube Installation in the Gener al Information section of this chapter Groundsmaster 4300 D
72. the PTO switch is OFF Turn ignition key switch to start engage starter for ten 10 seconds to prime hydraulic pumps Wait fifteen 15 seconds to allow the starter motor to cool and then repeat cranking procedure again 9 Connect wire harness electrical connector to fuel stop solenoid to allow engine to start 10 Startengine and letitidle atlow speed fora minimum of two 2 minutes ll Increase engine speed to high idle for minimum of one 1 minute under no load 12 Rotate steering wheel in both directions several times Raise and lower cutting decks several times 13 MovePTO switch to ON to engage cutting decks and let them run for several minutes Move PTO switch to OFF 14 Shut off engine and check for hydraulic oil leaks Check oil level in hydraulic reservoir and add correctoil if necessary 15 0 perate the machine fortwo 2 hours under normal operating conditions 16 Check condition of hydraulic oil Ifthe fluid shows any signs of contamination repeatsteps 1 through 14 again 17 Resume normal operation and follow recommended maintenance intervals Hydraulic System Filtering Closed Loop Traction Circuit Filtering of a closed loop hydraulic system after a major component failure e g traction piston pump or wheel motor is a requirementto prevent debris from transmit ting throughout the system If a closed loop hydraulic system filtering toolis notused to ensure system cleanli ness repeat failures a
73. the temperature gauge provides an inputto the TEC controller This con troller input causes the high temperature warning light on the control panel to illuminate and the cutting decks to shut down Electrical System Page 5 24 1 Control panel QUARTZ 00001 10 HOURS Hobbs 2 Figure 21 Figure 22 2 Temperature gauge Groundsmaster 4300 D PTO Switch The PTO switch is mounted on the control panel and al lows the cutting decks to operate when the front of the switch is depressed An indicator light on the switch identifies when the PTO switch is engaged The TEC controller monitors the position of the PTO switch up or down Using inputs from the PTO switch and other switches in the interlock system the controller controls the energizing of the hydraulic solenoid valves used to drive the cutting deck motors NOTE To engage the PTO the seat has to be occu pied the mow speed limiter has to be in the mow posi tion and the cutting decks have to be fully lowered Testing 1 Before disconnecting the PTO switch for testing the switch and its circuit wiring should be tested as a TEC controller input with the Diagnostic Display see Diag nostic Display in the Troubleshooting section of this chapter If the Diagnostic Display verifies that the PTO switch and circuitwiring are functioning correctly no fur ther switch testing is necessary If however the Diag nostic Display determines that the PTO switch
74. throttle control lever on control console to FAST position 2 Check position of the engine speed control lever on fuel injection pump The speed control lever should be contacting the high speed screw when the throttle con trol lever is in the FAST position 3 Ifnecessary throttle control can be adjusted by loos ening cable clamp screw and repositioning control cable until speed control lever contacts high speed screw when the throttle control lever is in the FAST position gt Tighten cable clamp screw after adjustment has been 3 completed Groundsmaster 4300 D Page 3 3 Throttle cable High speed screw Speed control lever Figure 1 4 Swivel 5 Cable clamp Kubota Diesel Engine 7 8 8 8 Service and Repairs Fuel System Figure 2 1 Fuel cap 8 Hose clamp 14 Draincock 2 Bushing 9 Hose clamp 15 Fuel supply hose 3 Washer head screw 2 used 10 Fuel tank 16 Fuel return hose 4 Flange nut 3 used 11 Grommet 17 Bumper 5 Clamp 2 used 12 Fuel gauge 18 Flat washer 6 Return fitting 13 Hose clamp 19 Cap screw 7 Suction fitting Kubota Diesel Engine Page3 4 Groundsmaster 4300 D Because diesel fuel is highly flammable use caution when storing or handling it Do not smoke while filling the fuel tank Do not fill fuel tank while engine is running when engine is hot or when machine is in an enclosed area Always fill fuel tank outside and
75. to values identified in Figure 80 Groundsmaster 4300 D Page 4 91 2 Position deck control manifold to frame Install three 3 flange head screws but do not fully tighten 3 Remove caps and plugs from disconnected lines and fittings 4 Lubricate and install new O rings on manifold fit tings Connect hydraulic lines to hydraulic fittings on manifold and properly tighten all connections see Hy draulic Hose and Tube Installation in the General Infor mation section of this chapter 5 Secure hydraulic manifold to frame by tightening three 3 flange head screws 6 Plug wire harness leads to solenoid coils on man ifold 7 Lower and secure operator seat 8 Check oil level in hydraulic reservoir and add correct oil if necessary 9 Follow Hydraulic System Start up procedures see Hydraulic System Start up in this section 5 lt __ 81to 99 ft lb 110 to 134 N m Figure 80 1 Deck control manifold 5 Hydraulic fitting 2 Hydraulic fitting 6 used 6 O ring 3 O ring 7 O ring 4 O ring Hydraulic System Deck Control Manifold Service Figure 81 1 Deck control manifold 5 Nut 9 O ring 2 Logic element LC1 LC2 6 Plug zero leak 4 10 Relief valve RVI RV2 3 Proportional relief valve PRVI PRV2 7 O ring 11 Pilot piston 4 Solenoid coil 8 Plug zero leak 8 NOTE The ports on the deck control manifold are marked for easy identification of components E xample Plisthe
76. torque value should be determined based on the fastener size the aluminum or base material strength length of thread engagement etc Product Records and Maintenance Page2 4 SAE Grade 8 Bolts Screws Studs amp Sems with Regular Height Nuts SAE J 995 Grade 5 or Stronger Nuts SAE Grade 5 Bolts Screws Studs amp Sems with Regular Height Nuts SAE J 995 Grade 2 or Stronger Nuts 169 23 262 34 192 23 282 34 328 34 463 56 350 45 486 56 475 56 678 68 542 56 768 79 o o B A co o w I I I I M o Ui Ui 100 10 1130 113 140 15 160 17 300 30 325 33 1582 169 115 12 1299 136 1808 192 200 25 2260 282 3390 339 225 25 2542 282 3672 373 95 9 104 11 5 6 7 102 11 142 15 600 60 667 66 NOTE The nominal torque values listed above for Grade 5 and 8 fasteners are based on 75 of the mini mum proof load specified in SAE J 429 The tolerance is approximately 10 of the nominal torque value Thin height nuts include jam nuts 77 8 115 12 163 16 150 15 203 20 285 28 170 18 230 24 325 33 265 27 359 37 508 52 300 30 407 41 569 58 430 45 583 61 813 81 c ul oco oco N N co A ul co N n fie Jit oco N ul 475 48 644 65 904 89 Groundsmaster 4300 D Standard Torque for Dry Zinc Plated and Steel Fasteners Metric Series Regular Height Nuts Thread Size M5 X 0 8 57 6 in Ib 96 10 in Ib
77. used on Groundsmaster 4300 D machines Groundsmaster 4300 D Seat Switch The seat switch is normally open and closes when the operator seat is occupied This switch is used as an in put for the TEC controller If the traction system or PTO switch is engaged when the operator raises out of the seat the engine will stop The seat switch is located di rectly under the operator seat Testing 1 Before disconnecting the seat switch for testing the switch and its circuit wiring should be tested as a TEC controller input with the Diagnostic Display see Diag nostic Display in the Troubleshooting section of this chapter If the Diagnostic Display verifies that the seat switch and circuitwiring are functioning correctly no fur ther switch testing is necessary If however the Diag nostic Display determines that the seat switch and circuit wiring are not functioning correctly proceed with test procedure 2 Make sure ignition switch is in the OFF position 3 Disconnect wire harness electrical connector from the seat switch electrical lead near the operator manual tube under the operator seat Fig 27 4 Check the continuity of the switch by connecting a multimeter ohms setting across the switch connector terminals 5 With no pressure on the seat there should be no continuity open between the seat switch terminals 6 Press directly onto the seat switch through the seat cushion There should be continuity closed as
78. warning light to illuminate and the cutting decks to shut down The temperature gauge temperature send er and circuit wiring should be tested as a controller in put with the Diagnostic Display see Special Tools and Troubleshooting in this chapter Ifthe excessive coolanttemperature caused the control ler to shut down the cutting decks the Diagnostic light can be used to identify the fault see Diagnostic Light in the Troubleshooting section of this chapter Testing 1 Park machine on a level surface lower cutting decks stop engine apply parking brake and remove key from ignition switch Open and support hood Make sure engine is cool before removing the temperature sender from engine 2 Lower the coolant level in the engine remove wire harness connector from temperature sender and re move the sender from the engine 3 Putthe end ofthe sender in a container of oil with a thermometer and slowly heat the oil Fig 49 Handle the hot oil with extreme care to prevent personal injury or fire NOTE Priorto taking resistance readings with a digital multimeter shortthe meter test leads together The me ter will display a small resistance value usually 0 5 ohms or less This resistance is due to the internal re sistance of the meter and testleads Subtract this value from from the measured value of the componentyou are testing Groundsmaster 4300 D Page 5 39 4 Check resistance of the sender with a multi
79. 0 90625 23 019 27 64 0 421875 10 716 59 64 0 921875 23 416 7 16 0 4375 11 112 15 16 0 9375 23 812 29 64 0 453125 11 509 61 64 0 953125 24 209 15 32 0 46875 11 906 31 32 0 96875 24 606 31 64 0 484375 12 303 63 64 0 984375 25 003 1 2 0 5000 12 700 1 1 000 25 400 1 mm 0 03937 in 0 001 in 0 0254 mm U S to Metric Conversions To Convert Into Multiply By Linear Miles Kilometers 1 609 Measurement Yards Meters 0 9144 Feet Meters 0 3048 Feet Centimeters 30 48 Inches Meters 0 0254 Inches Centimeters 2 54 Inches Millimeters 25 4 Area Square Miles Square Kilometers 2 59 Square Feet Square Meters 0 0929 Square Inches Square Centimeters 6 452 Acre Hectare 0 4047 Volume Cubic Yards Cubic Meters 0 7646 Cubic Feet Cubic Meters 0 02832 Cubic Inches Cubic Centimeters 16 39 Weight Tons Short Metric Tons 0 9078 Pounds Kilograms 0 4536 Ounces Avdp Grams 28 3495 Pressure Pounds Sq In Kilopascal 6 895 Pounds Sq In Bar 0 069 Work Foot pounds Newton Meters 1 356 Foot pounds Kilogram Meters 0 1383 Inch pounds Kilogram Centimeters 1 152144 Liquid Volume Quarts Liters 0 9463 Gallons Liters 3 785 Liquid Flow Gallons Minute Liters Minute 3 785 Temperature Fahrenheit Celsius 1 Subract 32 2 Multiply by 5 9 ance Page 2 2 Product Records and Mainten Groundsmaster 4300 D Torque Specifications Recommended fastener torque
80. 12 to secure lower clamp item 17 F Tighten fasteners items 8 and 12 to secure tail pipe brackets items 9 and 16 Groundsmaster 4300 D Page 3 9 Kubota Diesel Engine Radiator Overflow bottle Hose clamp 3 used Hose Foam seal 2 used Foam seal 4 used Mounting bracket 2 used Oil cooler Pipe plug Hydraulic fitting 2 used Hose clamp 4 used Foam seal 2 used Flange nut 4 used Flange nut 17 used Oil cooler mount plate 2 used Flange head screw 6 used Hose clamp 4 used E Fa EB EE EB QCOMOUL RUN Fa euvtbRBEBOCOLHOURUN Kubota Diesel Engine 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 Figure 8 Flange head screw 8 used Clamp 2 used Cap screw 2 used Washer 4 used Radiator Radiator frame Reservoir bracket Reservoir bracket Upper radiator hose Lower radiator hose Fan shroud Hydraulic hose 2 used Rivet 2 used Flange head screw 10 used Draw latch Washer head screw 6 used Page 3 10 Flange head screw Lock nut O ring Screen Intake screen Hose Oil cooler bracket O ring Hydraulic tube Foam seal Spacer 5 used Flange head screw 5 used Hydraulic fitting 2 used Pin Radiator cap Groundsmaster 4300 D Removal Fig 8 1 Park machine on a level surface lower cutting decks stop engine apply par
81. 18 The measured effective length of the torque wrench with the offset wrench installed distance from the center of the handle to the center of the offset wrench is 19 The calculated torque conversion factor for this torque wrench with this offset wrench would be 18 19 0 947 Groundsmaster 4300 D Page 2 3 As noted inthe following tables torque values should be reduced by 25 for lubricated fasteners to achieve the similar stress as a dry fastener Torque values may also have to be reduced when the fastener is threaded into aluminum or brass The specific torque value should be determined based on the aluminum or brass material strength fastener size length of thread en gagement etc The standard method of verifying torque shall be per formed by marking a line on the fastener head or nut and mating part then back off fastener 1 4 of a turn Measure the torque required to tighten the fastener until the lines match up Class 8 8 Class 10 9 Metric Bolts and Screws Figure 2 If the listed torque recommendation for a fastener is from 76 to 94 ft lb the proper torque when using this torque wrench with an offset wrench would be from 72 to 89 ft lb Offset h Torque wrench ME effective length of i torque wrench A m I 3 effective length of torque wrench offset wrench TORQUE CONVERSION FACTOR A B Figure 3 Product Records and Maintenance W
82. 1H91I98 Hydraulic System Page 4 9 Groundsmaster 4300 D Hydraulic Flow Diagrams Mo 4 uonons Jo UNY G IOJINVIA ley d mss id MOT OUWLNOD 94a BINSSS d BupuoAA umous PAeNUOY HND UOHIeAL C OO r 4 1seuuspunoisS EW We zn E m3 1103913 MON uv3u IW kd T 19 G IOJINVIA AOYLNOD L4 l dWnNd od NOLLOVW D NOLSId J gt YSAGNITAD SNIu3als 3ATVA TOYLNOD SNIu3als A x 7 ANOUS j 9 QOdJINVIN ii XVulSSOuD FORW ARD ANWA AINI VALS ONivag SSVdA8 NOIRS ASV HS3W 00L VOVNH3LNI
83. 2 Blade speed All deck blades should rotate at the same speed See items in Troubleshooting Section of Chapter 4 Hydraulic S ystem 3 Tire pressure Check air pressure of each tire Adjustto pressures specified in Operator s Manual 4 Blade condition Sharpen blades if their cutting edges are dull or nicked Inspect blade sail for wear or damage Replace blade if needed 5 Mower housing condition Make sure that cutting chambers are in good condition Keep underside of deck clean Debris buildup will reduce cutting performance 6 Height of cut Make sure all cutting decks are set atthe same height of cut Adjust cutting decks as specified in the Cutting Deck Operator s Manual Adjust height of cut setting to remove only 1 inch 25 mm or 1 3 of the grass blade when cutting 7 Cutting deck alignment and ground following Check lift arms and cutting deck pivot linkages for wear damage or binding Also inspect for bent or damaged pivot shafts 8 Roller condition All rollers should rotate freely Replace bearings if worn or damaged 9 Grass Conditions Mow when grass is dry for best cutting results Cutting Decks Page7 4 Groundsmaster 4300 D Special Tools Order special tools from your Toro Distributor Rear Roller Bearing and Seal Installation Tools These tools are used to assemble the cutting deck rear roller Inner Seal Tool Toro Part Numbers ers Inner Seal Tool 115 0852 Bearing O uter Seal Tool
84. 2 J am nut 1 used per bracket 11 O ring 22 Wheel stud 5 used per wheel 33 Cap screw 1 used per bracket 3 Loosen but do not remove wheel lug nuts and lock nut item 17 from wheel motor shaft Removal Fig 6 1 Park the machine on a level surface lower the cut ting decks and stop the engine Remove the key from the ignition switch 4 J ack up frontof machine and remove front wheel as sembly see Wheel Removal in this section Make sure to support machine with jack stands 2 Chock rear wheels to prevent machine from shifting 5 Make sure parking brake is disengaged Chassis Page 6 8 Groundsmaster 4300 D 6 Remove return spring and clevis pin that secure brake cable to brake actuator lever P osition brake cable end away from lever 7 Remove brake drum IMPORTANT DO NOT hitwheel hub puller or wheel motor with a hammer during wheel hub removal or installation Hammering may cause damage to the wheel motor 8 Make sure thatlock nuton wheel motor shaftis loos ened atleasttwo 2 turns Use hub puller see Special Tools to loosen wheel hub from wheel motor 9 Remove lock nut and wheel hub from motor shaft Discard lock nut Locate and retrieve square key NOTE If desired the complete brake assembly can be removed from the machine for disassembly see step 12 10 Remove upper and lower shoe springs from brake shoes ll Remove shoe hold down cups and hold down springs Remove brake shoes and h
85. 20 OHM Groundsmaster 4300 D Seat Wire Hamess Diagram Page 8 9 J9 TEMP SW 115 J3 OIL PRESSURE J8 ENG INE GROUND P2 FUEL SOLENOID P9 MAIN HARNESS INTERCONNECT P4 LIEJ P STARTER 6 J4 ALT P7 STARTER SOL Groundsmaster 4300 D Engine Wire Hamess Drawing Page 8 10 OIL PRESSURE J3 GREENMWHITE ARTER GER S ENGINE ALT ALT D SOL STARTER G FUEL SOLENOID GLOW PLUGS GROUND B P5 P3 PT PI P2 J5 J8 J4 a a z x 1 5 y m 5 ui x m a Uu m 2 a uw lu ac o e P9 is ORANGE t z SP1 a MAIN HARNESS INTERCONNECT BLACK ALT L FUEL SOL NOT USE OIL PRESS BLUE o gt STARTER TEMP SENDER ALT R e OT SHUTDOWN x 2 lt ac oO t TEMP SENDER Groundsmaster 4300 D Engine Wire Hamess Diagram Page8 11
86. 3 Reverse R4 3625 PSI 250 bar 3625 PSI 250 bar Front Wheel Motors Displacement per revolution Parker orbital rotor motor TG Series 24 1 in 405 cc Rear Wheel Motors Displacement per revolution Parker orbital rotor motor TL Series 18 9 in 310 cc Mow Circuit Relief P ressure Rear Mow Circuit PRV1 Front Mow Circuit PRV2 2500 PSI 175 bar 3500 PSI 241 bar Cutting Deck Motor Displacement per revolution Cross Over Relief Valve Pressure Casappa gear motor 1 05 in 17 16 cc 1813 PSI 125 bar Steering Valve Displacement per revolution Sauer Danfoss Steering Unit Type OSPMS 6 1 in 100 cc Steering Circuit Relief R10 Pressure 1000 PSI 70 bar Lift Circuit Relief P RV P ressure 2000 PSI 138 bar Hydraulic Filter Charge and Steering Circuits Spin on Cartridge Type with 50 PSI 3 4 bar Relief in Adapter Hydraulic Filter Mow and Lift Circuits Spin on Cartridge Type with 50 PSI 3 4 bar Relief in Adapter filter adapter includes filter change indicator Hydraulic Oil See Operator s Manual Hydraulic Reservoir Capacity 14 U S Gallons 53 Liters Hydraulic System Page 4 2 Groundsmaster 4300 D General Information Operator s Manual The Operator s Manual provides information regarding the operation general maintenance and maintenance intervals for your Groundsmaster 4300 D Refer to that p
87. 3 Battery cables must be tight on terminals to provide good electrical contact Connecting battery cables to the wrong bat tery postcould resultin personal injury and or damage to the electrical system 4 If corrosion occurs atterminals disconnect cables Always disconnect negative cable first Clean clamps and terminals separately Reconnect cables with positive cable first Coatbattery posts and cable connectors with Battery Terminal Protector Toro Part No 107 0392 or petroleum jelly to prevent corrosion 5 Check electrolyte level every 25 operating hours and every 30 days if machine is in storage 6 Maintain cell level with distilled or demineralized wa ter Do not fill cells above the fill line Groundsmaster 4300 D Battery Service The battery is the heart of the electrical system With regular and proper service battery life can be extended Additionally battery and electrical component failure can be prevented When working with batteries use extreme cau tion to avoid splashing or spilling electrolyte Electrolyte can destroy clothing and burn skin or eyes Always wear safety goggles and a face shield when working with batteries Electrolyte Specific Gravity Fully charged 1 265 corrected to 80 F 27 C Discharged less than 1 240 Battery Specifications BCI Group Size 55 585 CCA at 0 F 18 C Reserve Capacity of 95 minutes at 80 F 27 C Dimensions including terminal posts
88. 4300 D Page 4 75 Hydraulic System Front Wheel Motors WENDT P t N 80 to 100 ft lb 109 to 135 N m 315 to 385 ft lb 427 to 521 N m LH wheel motor Lug nut 5 used per wheel Hub Wheel assembly Hydraulic fitting 2 used per motor Hydraulic tube Hydraulic tube Cap screw 2 used per wheel shield O ring 10 Hydraulic tube 11 O ring Hydraulic System Figure 74 Lock nut 4 used per wheel motor Cap screw 4 used per wheel motor Brake bracket 2 used Lock nut 2 used per wheel shield RH wheel motor Lock nut 2 used Flat washer 2 used per wheel shield Brake drum 2 used Front wheel shield LH shown Rear wheel shield LH shown Wheel stud 5 used per wheel Page 4 76 70 to 90 ft Ib 95 to 122 N m Clevis pin 2 used LH brake assembly RH brake assembly Cap screw 4 used per brake assy Lock nut 4 used per brake assy Square key 1 used per motor Retum spring 1 used per bracket Brake spring bracket 2 used Flange nut 1 used per bracket Jam nut 1 used per bracket Cap screw 1 used per bracket Groundsmaster 4300 D Before opening hydraulic system operate all hy draulic controls to relieve system pressure and avoid injury from pressurized hydraulic oil See Relieving Hydraulic System Pressure in the Gen eral Information section of this chapter Removal Fig 74 1 Park the machine on a level surface engage p
89. 50 34 R9 50 34 R10 1000 RT 4813 25 FLOW RATE CALCULATED AT 3000 RPM AND 98 EFFICIENCY XX PRESSURE RATING APPLICABLE FOR INPUT CURRENT OF 0 87 AMPS xxs PRESSURE RATING APPLICABLE FOR INPUT CURRENT OF 1 2 AMPS Xxx PRESSURE RATING APPLICABLE FOR INPUT CURRENT OF 0 8 AMPS Groundsmaster 4300 D Hydraulic Schematic Page 8 3 ALTERNATOR RUN SOLENOID PK HOLD dus d 4 R BK 9 RUD lt i ig SEs PULL a HOUR METER a ap x OT WARNING BK BK i R W GN cy BU W GY cY Pit TEMP SENDER Cc 97e GN W GN W GN W I ENGINE OIL PRESSURE SHEET 2 W GN W GN ENGINE OVER TEMP 115 C igre T T i SHEET 2 1 BU W rm GN W R BK R BK W GN BU W FUEL PUMP SHEET 2 BK n w GLOW PLUGS E OR BU BU amp BU x oa Es 2 rr 3 2 Be 28 x 3S 8I amp GLOW El 9 o mtn MESA VS amp RELY rF le l del Ee L H4 SG EE R 4 de us FL PK FL FL FUSIBLE LINK I BK SU ES LNG PK SP q1 P rj K l 875 30 B _ BU EN 87 re VIO BK D VIO BK R D1 Ru dr ER BN BK BN BK START RELAY DIOD
90. C START MAIN POWER oS7E SUX 8 252m 230 5 m POWER RELAY RELAY TO SEAT HARNESS Sz 7Z652U57i5 TO SEAT HARNESS 41 ox c F eave e TO SEAT HARNESS 2 P50 POI P02 Pe PIT PIs A 123 4 12 3 4 65 A B C 182 3 45 6 7 8 9 OH 12 I 2 3 4 5 6 T 8 9 10 l 12 13 14 15 16 a ui a RED x BROWN BLACK VIOLET BLACK BATTERY soi 1 WHITE 12 VDC a ul a I 2 BLUE GLOW p 3 RELAY 4 PINK E 5 BLACK S z P 5 a RED sd PINK c SP1 x lt m a a a Poo B BLACK SPS ENGINE a INTERCONNECT w a ALT L WHITE GREEN FUEL SOL OT WARNING 3 OIL PRESS pg 4 GREEN WHITE STARTER 5 BLUE PINK MOW TRANSPORT TEMP SENDER 5 GRAY YELLOW B P53 SWITCH ALT R 1 PINK BLACK t OT SHUTDONN 8 ae a ui AC P ti A ha STARTER poy 3 E S M z RED E eae ui S eo lt s m BLACK e ui ow SP6 lt E x m e 5 E o a Er E u FUEL py RED BLACK RED BLACK S PUMP 8 Sl BLACK m PINK PARKING BRAKE P55 B ORANGE y C BLACK SPHO SP3 A NEUTRAL SPT Seu P GREEN lt gt gt z Eu 2 e o a zm uz s e go lt lt lt lt lt x x sac a a a a a Q 2 23an 3 3 ea ex ea m tt CS ey ey 5 Ges Cay xw P27 P28 PIO P08 PI3 Pla P40 P39 PRESSURE PRV FRONT DECK REAR DECK SI 2 HEADLIGHT LH HEADLIGHT RH Groundsmaster 4300 D TRANSDUCER ENGAGE ENGAGE n PRV2 PRVI Main Wire Hamess Diagram GND Page 8 7 P29 CAP P14 P28 DIAGNOSTIC CAN DIAGNOSTIC LIGHT LEAK POR
91. CK ENCAGE PRV2 V5 Bie Vio Bk P l 36 KEY START out 7_ P1 41 AG FR PRV T 12V A l OUTPUT B PARKING BRAKE SWITCH P1 11 IN 1 OUT 8 P1 42 DECK IGND C 9 B OR lt p COUNTERBALANCE E 4 CAP 3b m VoM P1 32 IN2 OUT9 P1 44 T 12V A IN CONFIGURE COUNTERBALANCE MODE EUTRAL SWITCH E s ND C QUTPUT B CN Y P1 12 IN 3 OUT 10 P1 46 z L oe af cx 1 o SEAT SWITCH GY P1 33 IN 4 OUT 11 P1 3 W BU rr S m T 1 S1 12V A OUTPUT B MOW TRANSPORT SWITCH P1 13 INS OUT 12_ p1 5 GND C F Y lt gt vio nh zl RAISE yo UE P1 23 N 6 OUT 13 P1 4 A 12 1 B TX 3 E Z BKC uevenck m P1 54 N7 OUT 14 P1 2 5 5 J C T 5 e 0 m uci NP P1 24 N8 TX LyPI U7 ORDRE Ae GY CN W CN W P1 14 IN 9 RX P1718 OR BK E RX F BUAN BUAN P1 35 IN 10 TX RX GND_ P1 19 E 3 COMMUNICATION PORT LOOP BACK CONNECTOR 1 T P1 19 IN 11 CAN LOW yh 1 49 BK W 4 WHEN WAN P1 16 IN 12 CAN HIGH P1 50 Evil 1 3 cef P1 28 ANALOG IN 1 GND P1 22 0 2 PRESSURE P1 39 ANALOG IN 2 GND P1 26 i TRANSDUCER P1 48 ANALOG IN 3 GND_ P1 30 gt BK P1 38 ANALOG IN 4 N A P1 21 A 3 CAN HIGH A R W H P1 47 ANALOG IN 5 N A P1 27 4 CAN LOW B BK W l PaT BN Y 1 2 tT P1 37 ANALOG IN 6 N A P1 29 va TORO DIAGNOSTIC CONNECTOR fa dee TORO Ee ce ELECTRONIC BK GY BN Y 6 CONTROLLER L 8 3 7 mo T po PTO SWITCH PK E PK S BK BK
92. Cor rect any leaks before proceeding All wheels will be offthe ground and rotating dur ing this procedure Make sure machine is well supported so it will not move and accidentally fall to prevent injuring anyone around machine IMPORTANT While engaging the traction circuit monitor the indicator on the high flow hydraulic fil ter If the indicator should show red either reduce pressure on the traction pedal or reduce engine speed to decrease hydraulic flow through the filter Hydraulic System Page 4 62 7 With engine running atlow idle speed slowly move the traction pedal to the forward direction to allow flow through the traction circuitand high flow filter Keep trac tion circuit engaged for five 5 minutes while gradually increasing both forward pressure on traction pedal and engine speed Monitor filter indicator to make sure that green color is showing during operation 8 With engine running at high idle speed and traction pedal moved to the forward direction periodically apply brakes to increase pressure in traction circuit While monitoring filter indicator continue this process for an additional five 5 minutes IMPORTANT If using a filterthatis notthe Toro high flow filter that is bi directional do not press the traction pedal in the reverse direction If flow is re versed when using a filter thatis not bi directional debris from the filter will re enter the traction cir cuit 9 With engine runnin
93. Deck Control Manifold Service 92 Cutting Deck Motor 94 Cutting Deck Motor Service 96 Lift Control Manifold 100 Lift Control Manifold Service 102 Lift Cylinder 2 oet aera Retro 104 Lift Cylinder Service 106 Steering Control Valve 108 Steering Control Valve Service 110 Steering Cylinder 112 Steering Cylinder Service 114 Oil COO ss nem LED cide de ku ustus 116 SAUER DANFOSS LPV CLOSED CIRCUIT AXIAL PISTON PUMPS REPAIR MANUAL SAUER DANFOSS LPV CLOSED CIRCUIT AXIAL PISTON PUMPS SERVICE INSTRUCTIONS PARKER TORQMOTOR SERVICE PROCEDURE TC TB TE TJ TF TG TH AND TL SERIES SAUER DANFOSS STEERING UNIT TYPE OSPM SERVICE MANUAL Groundsmaster 4300 D Page4 1 Hydraulic System Specifications Item Description Piston Traction Pump Maximum Pump Displacement per revolution Sauer Danfoss LPV Closed Circuit Axial Piston Design 2 14 in3 35 cc Gear Pump Section P1 P 2 Displacement per revolution Section P3 Displacement per revolution Section P4 Displacement per revolution Casappa 4 section positive displacement gear type pump 1 03 in3 16 84 cc 0 37 in 6 1 cc 0 24 in 3 9 cc Charge Circuit Relief R5 Pressure 200 PSI 14 bar Traction Circuit R elief Pressure Forward R
94. E 4 ENGINE BK n ENGINE GROUND R R i 1 e Sl E s zt t POWER FRAME de RELAY GROUND g ae ss l a BATTERY SHEET 2 4 R R STOP NONE RUN B C F D E START A B C IGNITION SWITCH p 4 PK OFF RUN START FI 1 15A F1 2 10 A OR B S Y PK lol F oJ p VIO BK D ot BK o 4 l z EET o EF OPTIONAL AIR RIDE SEAT F2 4 10A t R W R W ENA rers p F1 3 10A 1p BU BU 2 x 3 4 GY Groundsmaster 4300 D RIEN lt T Electrical Schematic EX os massa D D x BK Sheet 1 of 2 LIGHT SWITCH HEAD LIGHTS All relays and solenoids are shown as de energized All ground wires are black BK Page 8 4 SHEET 1 SHEET 1 F2 1 7 5A BN W Edo PYR OUT T 5 LSSPTZB BN BK BN BK x F2 2 7 5A 5 T BK Pisi PWR 3 OUT 2 iyP1 10 R BK R BK SHEET 1 S F2 3 7 5A A E P1 l PWR 4 OUT3 P1 7 85 Au F3 2A DIAGNOSTIC LIGHT J a AS Weak P1 40 PWR LOGIC OUT 4 P1 6 AW e Z Y EI P1 20 5V_ OUT OUT S P1 45 EN r REAR DECK ENGAGE PRV1 EN 2 Ze Sis P1 25 KEY RUN OUT 6 P1 43 BN rr SE BK FRONT DE
95. FT CIRCUIT NOT RAISING OR LOWERING The lift control manifold includes three 3 electrically FRONT operated valves Solenoid valve S 1 is used to directoil flow to extend the liftcylinders when energized or retract them when de energized Solenoid valve S2 allows hydraulic flow from the rod end of the lift cylinders when energized and prevents oil passage from the lift cylin ders when de energized Proportional relief valve PRV is used to control the operation of the manifold logic cartridge LC and also acts as a circuit relief valve While operating the machine during conditions of not raising or lowering the cutting decks joystick in the neu tral center position Fig 17 all of the lift manifold valves 1 S2 and PRV are de energized The de en ergized relief valve PRV allows hydraulic flow to return to tank through the manifold This flow causes a pres eid AMD PRY sure differential thatshifts the logic cartridge LC which DE ENERGIZED allows pump flow to bypass the lift cylinders Flow re turns to the oil filter and then to the hydraulic reservoir i Y LC SHIFTED Raise Cutting Decks Fig 16 gs us CONTROL MANIFOLD When the joystick is moved to the raise position the con troller energizes the proportional relief valve PRV
96. ION DRAIN STRAINER ee Y FROM MOW CONTROL MANIFOLD FRONT CENTER PRESSURE GAUGE LIFT CONTROL MANIFOLD Y e Figure 51 The lift relief valve PRV pressure test should be per formed to make sure thatthe lift circuit relief pressure is correct Procedure for Lift Relief Valve PRV Pressure Test 1 Make sure hydraulic oil is at normal operating tem perature by operating the machine under load for approximately ten 10 minutes 2 Park machine on a level surface with the cutting decks lowered and PTO switch off Make sure engine is off Apply the parking brake 3 Read Precautions For Hydraulic Testing in this sec tion Hydraulic System Page 4 50 Before opening hydraulic system operate all hy draulic controls to relieve system pressure and avoid injury from pressurized hydraulic oil See Relieving Hydraulic System Pressure in the Gen eral Information section of this chapter 4 Gain access to hydraulic lift control manifold by re moving the operator floor plate The lift control manifold is attached to a frame bracket under the floor plate Fig 52 Groundsmaster 4300 D 5 Thoroughly clean test port G4 on bottom of lift con trol manifol
97. Inspect all machine hydraulic hoses frequently for signs of deterioration or damage Hard cracked cut abraded charred leaking or otherwise damaged hose Kinked crushed flattened or twisted hose Blistered soft degraded or loose hose cover Cracked damaged or badly corroded hose fittings When replacing a hydraulic hose be sure that the hose is straight not twisted before tightening the fittings This can be done by observing the imprint layline on the hose Use two wrenches when tightening a hose hold the hose straight with one wrench and tighten the hose swivel nut onto the fitting with the second wrench see Hydraulic Hose and Tube Installation in this sec tion If the hose has an elbow at one end tighten the swivel nut on that end before tightening the nut on the straight end of the hose For additional hydraulic hose information refer to Toro Service Training Book Hydraulic Hose Servicing Part Number 94813SL Hydraulic System Page 4 4 Before disconnecting or performing any work on hydraulic system relieve all pressure in system see Relieving Hydraulic System Pressure in this section Keep body and hands away from pin hole leaks or nozzles that eject hydraulic fluid under high pressure Use paper or cardboard not hands to search for leaks Hydraulic fluid escaping under pressure can have sufficient force to penetrate the skin and cause serious injury If fluid is in jected into the skin it m
98. Length 8 3 inches 211 mm Width 6 0 inches 152 mm Height 8 5 inches 216 mm Battery Removal and Installation Fig 57 1 Raise and support hood 2 Loosen and remove negative cable from battery After negative cable is removed loosen and remove positive cable 3 Loosen flange nut that secures battery retainer 4 Carefully remove battery from machine 5 Install battery in reverse order making sure to con nectand tighten positive cable to battery before con necting negative cable NOTE Before connecting the negative ground cable to the battery connect a digital multimeter set to DC Amps between the negative battery post and the nega tive ground cable connector The reading should be less than 0 1 amp If the reading is 0 1 amp or more the machine s electrical system should be tested for short circuits or faulty components and repaired 6 Lower and secure hood Battery Inspection and Maintenance 1 Perform the following inspections and maintenance A Check battery case for cracks Replace battery if cracked or leaking Groundsmaster 4300 D PWN Page 5 45 Figure 57 Battery 5 Carriage screw Battery tray 6 Negative battery cable Retainer 7 Positive battery cable Flange nut 8 Fusible link B Check battery terminals for corrosion If corrosion occurs at terminals disconnect cables Always dis connect negative cable first Clean cable clamps and battery terminals sepa
99. NK HOUR METER Pol BLACK OIL PRESSURE ALT L TO MAIN HARNESS s2 FRONT DECK PRV2 REAR DECK PRV1 MOW TRANSPORT PRESSURE TRANS CAN HIGH IGN PRV TEMP SENDER 5 CAN LOW SI EI oa 14 05 16 GREEN WHITE WHITE PINK GRAY GRAY BLACK WHITE BLUE 31 VIOLET TAN WHITE BLUE BROWN BROWN WHITE 1 RED BLACK ORANGE GREEN YELLOW 4 YELLOW GREEN WHITE 4 TAN WHITE GREEN BLACK ORANGE BLACK BLACK RED PINK BLUE YELLOW __ BLACK YELLOW BLUE 4 PI BROWN YELLOW PINK RED PINK 3 mQ K WHITE RED BLACK YELLOW GREEN SP2 BLACK TAN BLACK VIOLET WHITE GRAY ORANGE BLUE WHITE 4 FUSE 82 P20 VIOLET BLACK WHITE BLACK WHITE VIOLE T D e 9 6 x 6 P3l CONF IGURE COUNTERBALANCE MODE P32 CONFIGURE COUNTERBALANCE MODE CAP P30 BROWN BLACK GRAY BLACK BLACK RED
100. Part No 10178SL Service Manual Groundsmaster 4300 D Preface The purpose ofthis publication is to provide the service technician with information for troubleshooting testing and repair of major systems and components on the Groundsmaster 4300 D REFER TO THE OPERATOR S MANUAL FOR OPER ATING MAINTENANCE AND ADJUSTMENT INSTRUCTIONS Space is provided in Chapter 2 of this book to insert the Operator s Manual and Parts Catalog for your machine Additional copies of the Operator s Manual and Parts Catalog are available on the internet at www Toro com The Toro Company reserves the rightto change product specifications or this publication without notice This safety symbol means DANGER WARNING or CAUTION PERSONAL SAFETY INSTRUC TION When you see this symbol carefully read the instructions that follow Failure to obey the instructions may result in personal injury NOTE A NOTE will give general information aboutthe correct operation maintenance service testing or re pair of the machine IMPORTANT The IMPORTANT notice will give im portantinstructions which mustbe followed to pre vent damage to systems or components on the machine O The Toro Company 2010 This page is intentionally blank Groundsmaster 4300 D Table Of Contents Chapter 1 Safety Safety Instructions 1 2 Jacking Instructions 1 5 Safety and Instruction Decals
101. System Pressure in the Gen eral Information section of this chapter 3 Label all hydraulic connections for assembly pur poses Thoroughly clean hydraulic hose ends prior to disconnecting hoses from the steering cylinder 4 Disconnect hydraulic hoses from steering cylinder 5 Putcaps or plugs on disconnected hoses and fittings to prevent contamination 6 Remove two 2 jam nuts item 16 thatsecure steer ing cylinder to axle Remove cotter pin item 20 and slotted hex nut item 29 that secure steering cylinder to RH drag link 7 Separate steering cylinder ball joints from axle as sembly and remove steering cylinder from machine 8 If necessary remove ball joints from steering cylin der barrel and shaft If ball joint is to be removed from cylinder shaft fully retract cylinder shaft and measure distance from cylinder fronthead to center of ball joint to ease installation of ball jointinto cylindershaft Fig 102 9 If hydraulic fittings are to be removed from steering cylinder mark fitting orientation to allow correct assem bly Remove fittings from steering cylinder and discard O rings Installation Fig 101 1 Ifhydraulic fittings were removed from steering cylin der lubricate new O rings with clean hydraulic oil posi tion O rings to fittings and install fittings into steering cylinder ports see Hydraulic Fitting Installation in the General Information section of this chapter Make sure that fittings
102. T FRONT LF MOTOR OUTLET CASE DRAIN CROSSTRAX MANIFOLD PISTON TRACTION PUMP FROM STEERING CONTROL VALVE C U 3 REAR MOW CIRCUIT C U gna Th 3 RELIEF VALVE PRV1 1 TEST SHOWN FRONT MOW CIRCUIT DECK CONTROL MANIFOLD FROM LIFT CONTROL MANIFOLD Figure 45 The relief valve PRV1 and PRV2 pressure test should be performed to make sure that the cutting deck circuit relief pressures are correct NOTE The frontcutting deck circuitis protected by pro portional relief valve PRV2 in the deck control man ifold The rear cutting deck circuit is protected by proportional relief valve PRV1 see Hydraulic Flow Diagrams in this chapter Hydraulic System Page 4 44 Procedure for Relief Valve PRV1 and PRV2 Pres sure Test 1 Make sure hydraulic oil is at normal operating tem perature by operating the machine under load for approximately ten 10 minutes 2 Park machine
103. T DETECTOR P74 NOTE CLOCK POSITION TEC 5002 a MASTER JOYSTICK TERMINATOR 120Q P11 OT GLOW P17 TO MAIN HARNESS 1 POS SEAT SWITCH P10 OIL PRESS ALT U P25 AIR RIDE SEAT P18 OPTIONAL p02 TO MAIN IGN SWITCH HARNESS 2 B s LH c B e zi pop a l CAN TERMINATOR 120 OHM P32 CONF IGURE COUNTERBALANCE MODE P3 E 2 GND GAUGE P30 S J5 TO MRIN CONFIGURE P13 SS 1 42V IGHT Oss HARNESS COUNTERBALANCE LIG se MODE CAP SWITCH 1 P07 xe PTO SWITCH P01 HOUR METER d J4 TEMP P23 LOOP BACK CONNECTOR P19 P20 FUSE 2 FUSE 1 Cite Lr Er P19 Mocca A 1 o o Zamm P20 FUSE 42 P24 POWER 2 1 POINT Groundsmaster 4300 D Seat Wire Hamess Drawing Page 8 8 LOOP BACK P23 CONNECTOR GRAY amon ew gt FUSE 1 P19 COMM PORT P06 LCC POWER HEAD LIGHT 5 VOC TO MAIN HARNESS 1 TEMP GAUGE PARKING BRAKE OT SHUTDOWN NEUTRAL FUEL SOL START RELAY COIL IGN S GLOW m GND 3 J5 JE 3 OUT J TET 1 1 1 PINK BLUE PINK BLACK BLUE WHITE Pio OIL PRESS ALT L IA 18 2A 28 PINK WARNING LIGHT PI OT GLOW IA IB 2A 28 PINK PI
104. TANT When testing the fuel pump DO NOT turn ignition switch to START 6 Collect fuel in the graduated cylinder by turning igni tion switch to the RUN position Allow pump to run for 15 seconds then turn ignition switch to OFF 7 Fuel collected in the graduated cylinder should be approximately 16 fl oz 475 ml after 15 seconds 8 Replace fuel pump if necessary 9 Install fuel hose to the fuel water separator Make sure to secure fuel hose with hose clamp Groundsmaster 4300 D Page 5 43 10 Connect wire harness electrical connectorto the en gine fuel stop solenoid 11 Bleed the fuel system 12 Lower and secure operator seat and hood Fuel Pump Specifications Pump Capacity 64 fl oz min 1 9 l min 7 PSI 48 3 kPa Figure 55 1 Fuel pump 3 Hydraulic gear pump 2 Pump discharge hose Figure 56 1 Fuel water separator 3 2 Fuel hose from pump Inlet fitting Electrical System E u System Service and Repairs NOTE See the Kubota Workshop Manual Diesel En gine 05 E3B Series at the end of Chapter 3 Kubota Diesel Engine for engine electrical component repair in formation Battery Storage If the machine will be stored for more than 30 days 1 Remove the battery from the machine and charge it fully see Battery Service in this section 2 Either store battery on a shelf or on the machine 3 Leave cables disconnected ifthe battery is stored on the machine Ba
105. The om zy energized relief valve PRV prevents flow through the TOO at valve which returns logic cartridge LC to the unshifted PUTER position With lift manifold cartridges in this position Figure 17 pump flow is directed to the rod end of all lift cylinders to retract the cylinders and raise all cutting decks Flow to the liftcylinders bypasses the control manifold fixed ori fices to prevent flow restriction during deck raising fr amp lt lt S S While the cutting decks are being raised the proportion al relief valve P RV has a secondary function as a cir cuit relief to limit lift circuit pressure to 2000 PSI 138 bar Lift circuit pressure can be monitored at lift control manifold port G4 When the joystick is returned to the neutral center position the proportional relief valve PRV is de ener gized The de energized relief valve PRV allows hy draulic flow to return to tank through the manifold This flow causes a pressure differential that shifts the logic cartridge LC which allows pump flow to bypass the lift cylinders All lift cylinders and cutting decks are held in the raised position by de energized valve S2 Groundsmaster 4300 D Page 4 17 Hydraulic System MO 4 uonons JO uunjo d 9600405 inss id wo eunssajig BUPHOM s 5 cql Bumn J9wo7 JND YI Q 00 r Jo1seuuspunouc GIOJINVIN TOYLNOD 353q EW
106. WHITE BLACK BLACK A B P25 AIR RIDE SEAT OPTIONAL C Pee TO MAIN HARNESS ORANGE YELLOW BLACK PINK BLUE VIOLET BLACK GRAY Pee BROWN YELLOW IGNITION SWITCH PTO SWITCH PIs LIGHT SWITCH DIAGNOSTIC LIGHT SP3 GREEN BLACK WHITE RED WHITE BLACK BLACK BLACK P24 POWER POINT BLACK SEAT SWITCH CAI e a BLACK P6 RED WHITE 4 s BLACK WHIT P27 TERMINATOR 120 OHM SPT RED WHITE RED WHITE 4 BLACK WHITE RED WHITE 1 gt BLACKAWHITE Qo GRAY s BLACKWHITE E P28 CAN DIAGNOSTIC PORT P29 CAP P14 Pod P03 P26 PWR S 2 DIAGNOSTIC LIGHT GLOW START RELAY PWR RUN SOL PARKING BRAKE SW NEUTRAL SW MOW TRANSPORT LOW OIL PRESS HIGH TEMP 115 C ALT TX RX TX RX GND 5V OUT GND JOYSTICK RAISE REEL ENGAGE SW OK RUN TEC 5002 MASTER GND EC 5002 MASTE PRESSURE TRANSDUCER GND PWR CONFIGURE COUNTERBALANCE MODE SEAT SW JOYSTICK LOWER HIGH TEMP 105 C KEY START SW LOGIC PWR PRV FRONT DECK ENGAGE PRV2 REAR DECK ENGAGE PRV1 CAN CAN RAISE JOYSTICK LOWER CAN TERMINATOR 1
107. ad screw 10 used Flat washer Foam seal Cotter pin Throttle control assembly Page 6 16 21 22 23 24 25 26 27 28 29 Foam seal Flange nut Spacer Cotter pin Retainer bracket Spring Clevis pin Flange head screw 2 used Flat washer 2 used Groundsmaster 4300 D Disassembly Fig 12 1 Park machine on a level surface lower cutting decks stop engine and engage parking brake Remove key from ignition switch 2 Loosen latches and remove access cover from out side of control arm 3 At front of control arm remove screw item 6 and lock nut item 5 that secure control arm covers to each other 4 Remove five 5 washer head screws item 16 that secure each cover to control arm 5 Remove control arm covers from machine As LH Figure 13 control arm cover item 3 is removed from control arm 1 Wire hamess 3 Throttle control cable unplug wire harness connector from headlight switch 2 Harness foam seal 4 Cable foam seal 6 Remove electrical components from control arm as needed using Figure 14 as a guide Assembly Fig 12 1 Install all removed electrical components to control arm using Figure 14 as a guide 2 Position covers to control arm As LH cover item 3 is placed plug wire harness connector to headlight switch Also make sure that wire harness and throttle control cable are routed correctly through cover open ings Fig 13 3 Secure each coverto control
108. agram 7 Seat Wire Harness Drawing 8 Seat Wire Harness Diagram 9 Engine Wire Harness Drawing 10 Engine Wire Harness Diagram 11 Groundsmaster 4300 D Page 8 1 Foldout Drawings This page is intentionally blank Foldout Drawings Page 8 2 Groundsmaster 4300 D GEAR PUMP INTERNAL 400 MESH CASE SUC TION DRAIN STRAINER AC gt HUP CHANISOLD RIGHT amp FRONT MANIFESTE 66 REAR x LF z i RRF e PORT fed An o RRR F rs x Hd E i T NES 4 E k De Lo L 1 cto U o Y R5 I 2 RR Li uw PORT 16 re up 2 TE aen LEFT oT LEFT FRONT REAR PISTON TRACTION RO PUMP PS Z N NU 61 P1 if T Mi fame REAR VERDE LE MOW CIRCUIT avi 1 C U 3 CU 2 X PRV1 _ R1 R1 L c 3 4 mat m R M2 a FRON i MOW CIRCUI C U 5 C U 1 C U h R1 R1 R1 ti I x n Ms T s pot LL PRV2 B RV2 T NY ES T P2 M3 CE G2 DECK CONTROL
109. airs Never install or work on the cutting decks or lift arms with the engine running Always stop en gine and remove key from ignition switch first Blade Spindle Assembly 88 to 108 ft Ib 120 to 146 N m Figure 3 1 Flange nut 6 used 5 O ring 9 Anti scalp cup 2 Hydraulic deck motor 6 Spindle assembly 10 Blade bolt 3 Spindle plate 7 Stud 6 used 11 Socket head screw 2 used 4 Cutting deck 8 Cutting blade 12 Flat washer 2 used Cutting Decks Page7 8 Groundsmaster 4300 D Removal Fig 3 1 Park machine on a level surface lower cutting decks stop engine engage parking brake and remove key from the ignition switch 2 Remove two 2 socket head screws and flat wash ers that secure hydraulic motor to the cutting deck Fig 4 Remove hydraulic motor and O ring from deck 3 Cover top of spindle to prevent debris from entering spindle A spindle plug See Special Tools in this chap ter can be used to cover spindle 4 Startthe engine and raise the cutting deck Stop en gine and remove key from the ignition switch Support the cutting deck so itcannot fall accidentally If required for easier service remove cutting deck from machine 5 Remove blade bolt anti scalp cup and cutting blade 6 Remove six 6 flange nuts that secure spindle as sembly to cutting deck Slide spindle assembly out the bottom of the deck Remove spindle plate from top of deck 7 If necessary press studs from
110. and flange nuts item 15 6 Install hydraulic hoses to fittings on pump assembly in positions noted during removal see Hydraulic Hose and Tube Installation in the General Information section of this chapter 7 Connect machine wire harness electrical connector to traction neutral switch 8 Secure traction cable assembly to traction pump Fig 69 A Position traction cable assembly to pump assem bly B Secure traction lever bracket item 12 in Fig 69 to pump lever with cap screws items 7 and 13 in Fig 69 and lock nut item 8 in Fig 69 C Secure lever damper item 14 in Fig 69 to trac tion cable bracket with flange nut item 4 in Fig 69 D Secure traction cable to traction cable bracket item 6 in Fig 69 with jam nuts 9 Install hydraulic pump drive shaft see Hydraulic Pump Drive Shaft Installation in this section 10 Check oil level in hydraulic reservoir and add correct oil if necessary 11 Follow Hydraulic System Start up procedures see Hydraulic System Start up in this section 12 Check traction drive for neutral and traction neutral switch operation Adjust if necessary Groundsmaster 4300 D Hydraulic System This page is intentionally blank Groundsmaster 4300 D Page 4 71 Hydraulic System Piston Traction Pump Service Auxiliary shaft Retaining ring Ball bearing Retaining ring Seal Backup washer Bearing O ring Trunnion cover Screw 4 used Plug O ring S
111. ar ness connector from the relay Remove relay from ma chine for easier testing NOTE Priorto taking small resistance readings with a digital multimeter short the meter test leads together The meter will display a small resistance value usually 0 5 ohms or less This resistance is due to the internal resistance ofthe meter and testleads Subtractthis val ue from from the measured value ofthe component you are testing 4 Verify coil resistance between terminals 85 and 86 with a multimeter ohms setting Fig 37 Resistance should be approximately 72 ohms 5 Connectmultimeter ohms setting leads to relay ter minals 30 and 87 Ground terminal 86 and apply 12 VDC toterminal85 The relay should have continuity be tween terminals 30 and 87 as 12 VDC is applied to ter minal 85 The relay should not have continuity between terminals 30 and 87 as 12 VDC is removed from termi nal 85 6 Disconnectvoltage and testleads from the relay ter minals Replace relay if necessary 7 Secure relay to machine and connect machine wire harness connector to relay 8 Lower and secure hood Figure 36 1 Pump drive shaft 3 Glow relay 2 Main power relay Electrical System Figure 37 Groundsmaster 4300 D Page 5 33 Electrical System Toro Electronic Controller TEC The Groundsmaster 4300 D uses a Toro Electronic Controller TEC to monitor the condition of various switches inputs and the
112. are equal on both sides of the machine If necessary adjustlocation of ball jointon cylinder shaft FRONT HEAD a Es j lt gt MEASURE DISTANCE FOR ASSEMBLY PURPOSES Figure 102 Hydraulic System Steering Cylinder Service Figure 103 1 Front shaft 1 7 O ring 13 Dust seal 2 Rear shaft 1 250 8 External collar 2 used 14 Barrel 3 Front head 1 9 Piston 15 Piston seal 4 Rear head 1 250 10 Rear head seal 16 Rear head O ring backup ring 5 Roll pin 11 Front head seal 17 Front head O ring backup ring 6 Dust seal 12 Wear ring Disassembly Fig 103 1 Remove oil from steering cylinder into a drain pan by slowly pumping the cylinder shaft Plug both ports and clean the outside of the cylinder IMPORTANT Prevent damage when clamping the steering cylinder into a vise clamp on the barrel cle vis ONLY Do not close vise on barrel 2 Mountsteering cylinder securely in a vise by clamp ing onthe barrel clevis Use ofa vise with softjaws is rec ommended 3 Using a Spanner wrench loosen and remove exter nal collars from both ends of barrel 4 Use a twisting and pulling motion to carefully extract the rear head from the barrel and rear shaft Hydraulic System Page 4 114 5 Grasp end of front shaft and use a twisting and pull ing motion to carefully extractthe rear shaft piston front shaft and front head assembly from the barrel 6 Remove cyli
113. are orientated correctly Groundsmaster 4300 D Page 4 113 2 Ifremoved press balljointinto barreland secure with retaining ring 3 If ball joint was removed from cylinder shaft fully re tract cylinder shaft and thread ball joint into shaftso that distance from cylinder front head to center of ball joint is as measured during removal process Tighten jam nut 4 Thoroughly clean tapers on ball joints and axle as sembly 5 Position steering cylinder to machine 6 Secure steering cylinder to axle with jam nuts item 16 Tighten firstjam nutand then while holding firstjam nut with wrench tighten second jam nut 7 Secure steering cylinder to RH drag link with slotted hex nut item 29 Install cotter pin item 20 8 Remove caps and plugs from hydraulic hoses and fittings 9 Lubricate and install new O rings on steering cylin der fittings Correctly connect hydraulic hoses to steer ing cylinder see Hydraulic Hose and Tube Installation in the General Information section of this chapter 10 Check oil level in hydraulic reservoirand add correct oil if necessary 11 Lubricate steering cylinder ball joint grease fittings 12 Follow Hydraulic System Start up procedures see Hydraulic System Start up in this section 13 Check that steering cylinder does not contact the axle or frame as cylinder moves from fully retracted to fully extended Also check that distance between the drag links and steering stops
114. arking brake lower cutting decks and stop engine Remove key from the ignition switch 2 Chock rear wheels to prevent machine from shifting 3 Loosen but do not remove five 5 wheel lug nuts and lock nut item 17 that secures wheel hub to wheel motor 4 Read the General Precautions for Removing and Installing Hydraulic System Components at the begin ning of the Service and Repairs section of this chapter A WARNING Before jacking up the machine review and follow J acking Instructions in Chapter 1 Safety 5 Jack up machine enough to allow the removal of the front wheel Support machine with jack stands 6 Remove front wheel from machine see Front Wheel Removal in the Service and Repairs section of Chapter 6 Chassis 7 Remove return spring and clevis pin that secure brake cable clevis to brake actuator lever Position brake cable clevis away from actuator lever 8 Remove brake drum 9 Make sure wheel hub lock nut item 17 is loosened at least two 2 turns IMPORTANT DO NOT hit wheel hub puller or wheel motor with a hammer during wheel hub removal or installation Hammering may cause damage to the wheel motor 10 Use hub puller see Special Tools in this chapter to loosen wheel hub from wheel motor 11 Remove lock nut and wheel hub from motor shaft Discard lock nut Locate and retrieve square key Groundsmaster 4300 D Page 4 77 12 Thoroughly clean hydraulic line ends and fittings on
115. arm with five 5 washer head screws item 16 Install screw item 6 and lock nut item 5 to secure covers at front of control arm 2 4 Install access cover to outside of control arm o Figure 14 1 Fuse block 6 Temperature gauge 2 Hour meter 7 Diagnostic light 3 Joystick assembly 8 PTO switch 4 Ignition switch 9 Indicator light 5 Indicator light 10 TEC controller Groundsmaster 4300 D Page 6 17 Chassis Operator Seat Figure 15 1 Seat 10 Armrest 2 Seat base 11 Cap screw 3 Seat adjuster w latch 12 Flange nut 4 Flat washer 4 used 13 Flat washer 4 used 5 Seat switch harness 14 Flange head screw 3 used 6 Seat switch 15 Socket head screw 4 used 7 Washer head screw 2 used 16 Seat adjuster 8 Armrest bracket 17 Flat washer 9 Spacer 18 Seat bracket 2 used IMPORTANT The operator seat seat base and con trol arm assembly are attached to the machine with the same fasteners Make sure to support the seat base and control arm to prevent them from shifting when removing the seat Damage to the throttle cable control arm electrical components and con trol arm wiring harness can occur if the seat base and control arm are not properly supported during seat removal Chassis Page 6 18 Cap screw 4 used Housing cap R clamp 2 used Manual housing Cap 4 used Flange nut 4 used Seat suspension Flange head screw 4 used Groundsmaster 4300 D Removal F
116. at 12 VDC exists at both of the ter minal test points on the fuse If 12 VDC exists at one of the fuse test points butnotatthe other the fuse is faulty If necessary remove fuse from the fuse block to check fuse resistance Fuse should have continuity between the fuse terminals Figure 39 1 Fuse block OPTIONAL 7 5A Electrical System 7 5A Figure 41 1 Battery 2 Fuse F3 Groundsmaster 4300 D Page 5 35 Electrical System Diode Assembly A diode assembly Fig 42 is used in the Groundsmas ter 4300 D engine wire harness The diode is used for circuit protection from voltage spikes that occur when the engine starter solenoid is de energized Refer to wire harness drawings in Chapter 8 Foldout Drawings for additional diode assembly information Testing Locate diode assembly and remove cable tie that se cures diode to wire harness Unplug the diode from the wire harness for testing The diode Fig 43 can be tested using a digital multimeter diode testor ohms set ting and the table below After testing is complete make sure that diode is fully installed into harness connector and secured to harness with cable tie Figure 42 1 Engine wire harness 2 Diode assembly Multimeter Multimeter Red Lead 4 Black Lead Continuity on Terminal on Te
117. at washer Thread forming screw 8 used Roll pin 2 used Roll pin Clip 20 used Groundsmaster 4300 D IMPORTANT When removing the seat suspension make sure to support the control arm to prevent damage to the throttle cable control arm electrical components and control arm wiring harness Removal Figs 18 and 19 1 Park machine on a level surface lower cutting decks stop engine engage parking brake and remove key from the ignition switch 2 Disconnect negative battery cable from battery see Battery Service in the Service and Repairs section of Chapter 5 Electrical System 3 Remove seat from machine see Operator Seat Re moval in this section IMPORTANT Take care to not damage the throttle cable or electrical harness when removing seatsus pension from machine 4 Tilt and support seat frame to allow access to seat suspension fasteners 5 Support seat suspension to prevent it from falling Figure 19 Remove four 4 flange head screws Figure 19 item 8 oen uon di a EM 4 used H ES B eat bracket use B ap use and flange nuts Figure 19 item 5 thatsecure seatsus 3 Screw used 10 Manual tibe pension to seat frame 4 Seatframe 11 R clamp 2 used 5 Flange nut 8 used 12 Flat washer 4 used j ine tean 6 Seatbase cover 13 Seat adjuster 6 Remove seatsuspension from machine Locate and 7 Spacer 4 used 14 Seat adjuster w latch retrieve four 4 spacers Figure 19 item 7 fro
118. ation in the G ener al Information section of this chapter 6 Make sure that tapers of wheel motor shaft and wheel hub are thoroughly clean 7 Position woodruff key to keyslotin wheel motor shaft IMPORTANT Do not reuse lock nut that secures wheel hub to wheel motor after ithas been removed Hydraulic System 8 Place wheel hub on motor shaft and secure with new lock nut item 14 9 Install wheel assembly to the machine and secure with five 5 lug nuts 10 Lower the machine to the ground Failure to properly tighten wheel hub lock nut or wheel lug nuts could result in failure or loss of wheel and may result in personal injury Hydraulic System Page 4 82 11 Torque wheel hub lock nut item 14 from 270 to 330 ft lb 366 to 447 N m 12 Torque wheel lug nuts evenly in a crossing pattern from 70 to 90 ft Ib 95 to 122 N m 13 Make sure hydraulic tank is full Add correct oil if nec essary 14 After assembly is completed verify that hydraulic hoses and fittings do not contact anything through full range of axle motion Also check for any hydraulic leaks 15 Follow Hydraulic System Start up procedures see Hydraulic System Start up in this section Groundsmaster 4300 D Hydraulic System This page is intentionally blank Groundsmaster 4300 D Page 4 83 Hydraulic System Wheel Motor Service 45 to 55 ft lb 61 to 75 N m Figure 76 1 Cap screw 7 used 9 Vane 7 used 2 En
119. ation section of this chapter 6 After repairs check control linkages and cables for proper adjustment binding or broken parts 7 Afterrepairs are completed clean hydraulic compo nents hose connections and fittings to prevent future accumulation of dirt and debris on hydraulic compo nents 8 After disconnecting or replacing any hydraulic com ponents operate machine functions slowly until air is outofsystem see Hydraulic System StartUp in this sec tion 9 Check for hydraulic oil leaks If any leaks are discov ered shut off engine and correct leaks 10 Check oil level in hydraulic reservoir and add correct oil if necessary Groundsmaster 4300 D Check Hydraulic Lines and Hoses Keep body and hands away from pin hole leaks or nozzles that eject hydraulic fluid under high pressure Use paper or cardboard not hands to search for leaks Hydraulic fluid escaping under pressure can have sufficient force to penetrate the skin and cause serious injury If fluid is in jected into the skin it must be surgically re moved within a few hours by a doctor familiar with this type of injury Gangrene may resultfrom such an injury Flush Hydraulic System IMPORTANT Flush the hydraulic system any time there is a severe component failure or the system is contaminated Contaminated oil may appear milky or black or may contain metal particles IMPORTANT If a component failure occurred in the closed loop traction circuit
120. attery charges Glow Plug System Test This is a fast simple test that can help to determine the integrity and operation of your Groundsmaster glow plug system The test should be run anytime hard start ing cold engine is encountered on a diesel engine equipped with a glow plug system Use a digital multimeter and or inductive Ammeter AC DC CurrentTransducer Properly connectthe ammeter to the digital multimeter refer to manufacturers instruc tions and set the multimeter to the correct scale With the ignition switch in the OFF position place the Groundsmaster 4300 D Page 5 17 Voltage Measured Battery Charge Level 12 68 volts Fully charged 10096 12 45 volts 7596 charged 12 24 volts 12 06 volts 5096 charged 2596 charged 11 89 volts 096 charged Startthe engine and run athigh idle 3200 RPM Allow the battery to charge for at least three 3 minutes Re cord the battery voltage After running the engine for at least three 3 minutes battery voltage should be atleast 0 50 volt higher than initial battery voltage E b System An example of a charging system that is functioning At least 0 50 volt over initial battery voltage Initial Battery Voltage 12 30 v Battery Voltage after 3 Minute Charge 12 85 v ammeter pickup around the main glow plug power sup ply wire and read the meter prior to activating the glow plug system Adjust the meter to read zero if applica ble Activat
121. by operating the machine in a directforward and reverse direction not steering Make sure that engine is run ning at full speed 3200 RPM Apply the brakes and press the traction pedal in the forward direction and then to reverse while monitoring the pressure gauge Stop engine and record test results GAUGE READING TO BE approximately 150 to 250 PSI 13 8 to 17 2 bar 11 Compare measured charge pressure from step 9 with pressure from step 10 A If charge pressure is good underno load step 9 but drops below specification when under traction load step 10 the piston pump should be suspected of wear and inefficiency When the pump is worn or damaged the charge system is notable to replenish losttraction circuitoil due to excessive leakage in the worn pump B Ifthere is no charge pressure or pressure is low check for restriction in gear pump intake line Inspect charge relief valve and valve seat in the traction pump see Traction Pump Service in the Service and Repairs section of this chapter Also consider a worn or damaged gear pump P3 see Gear Pump P3 Flow Test in this section Groundsmaster 4300 D Page 4 37 NOTE If gear pump P3 is worn or damaged both charge circuit and steering circuit will be affected 12 After charge pressure testing is completed make sure that engine is notrunning and then relieve hydrau lic system pressure See Relieving Hydraulic S ystem Pressure in the General Information se
122. c Light in the Troubleshooting section of this chapter Testing 1 Park machine on a level surface lower cutting decks stop engine apply parking brake and remove key from ignition switch Open hood to gain access to engine 2 Disconnect wire harness connector from fuel stop solenoid NOTE The fuel stop solenoid may be removed from the engine or tested in place 3 If the solenoid is removed from the engine make sure that the solenoid plunger moves freely and is free of dirt debris and corrosion NOTE Prior to taking small resistance readings with a digital multimeter shortthe testleads together The me ter will display a small resistance value usually 0 5 ohms or less This resistance is due to the internal re sistance ofthe meterand testleads Subtractthis value from the measured value ofthe componentyou are test ing 4 Using a digital multimeter ohms setting touch one test lead to the pull coil terminal and the other test lead to the fuel stop solenoid frame ground Fig 54 The resistance ofthe pull coil should be less than 1 ohm but not zero Electrical System Page 5 42 5 Using a digital multimeter ohms setting touch one test lead to the hold coil terminal and the other test lead to the fuel stop solenoid frame ground Fig 54 The resistance of the hold coil should be approximately 15 ohms 6 If either coil resistance is incorrect replace fuel stop solenoid 7 Connect wire
123. c fittings are to be removed from reservoir mark fitting orientation to allow correct assembly Re move fittings from reservoir and discard O rings Inspection Fig 64 1 Clean hydraulic reservoir and suction strainer with clean solvent 2 Inspecthydraulic reservoir for leaks cracks or other damage Groundsmaster 4300 D Page 4 65 Installation Fig 64 1 Iffittings were removed from reservoir lubricate and place new O rings onto fittings Install fittings into reser voir openings using marks made during the removal process to properly orientate fittings Tighten fittings see Hydraulic Fitting Installation in the General Infor mation section of this chapter 2 Lubricate new suction strainer O ring and install onto strainer Thread suction strainer into hydraulic res ervoir and torque strainer 105 to 115 ft Ib 143 to 155 N m 3 Position hydraulic reservoir to machine Secure re servoir to frame with two 2 clamps item 13 washer head screws item 12 and flange nuts item 14 4 Remove all plugs and caps placed in hoses and fit tings during the removal process 5 Install hydraulic hoses to fittings on hydraulic reser voir in positions noted during removal see Hydraulic Hose and Tube Installation in the General Information section of this chapter 6 Fill hydraulic reservoir with new hydraulic fluid 7 Operate machine Check hydraulic lines and fittings forleaks Tighten any loose connections
124. cessary to re place the original large snap ring If the original large snap ring is in good condition with no evi dence of damage e g spun bearing leavethe snap ring in the housing and discard the large snap ring that comes with the new bearings If the large snap ring is found to be damaged replace the snap ring 1 Iflarge snap ring was removed from spindle housing Figure 6 install snap ring into housing groove Make sure snap 1 Bearing 4 Inner bearing spacer NE 2 Spacer ring 5 Outer bearing spacer ring is fully seated in groove 3 Large snap ring 2 Install outer bearing spacer into top of spindle hous ing The spacer should fit against the large snap ring Cutting Decks Page 7 10 Groundsmaster 4300 D 3 Using anarbor press push the bearing cups into the top and bottom of the spindle housing The top bearing cup must contact the outer bearing spacer previously installed and the bottom bearing cup must contact the large snap ring Make sure that the assembly is correct by supporting the first bearing cup and pressing the sec ond cup against it Fig 7 4 Pack the bearing cones with grease Apply a film of grease on lips of oil seals 5 Install lower bearing cone and greased oil seal into bottom of spindle housing Note The bottom seal must have the lip facing out down Fig 8 This seal installa tion allows grease to purge from the spindle during the Figure 7 lubricati
125. cifications General Information Special Tools Service and Repairs Chapter 7 Cutting Decks Specifications General Information Troubleshooting Special Tools Adjustments Service and Repairs Chapter 8 Foldout Drawings Hydraulic Schematic Electrical Schematic Wire Harness Drawings Product Records and Maintenance E Qos 5 E Electrical System Eod D Foldout Drawings This page is intentionally blank Groundsmaster 4300 D Chapter 1 Safety P 7 Table of Contents SAFETY INSTRUCTIONS 2 Before Operating 0 ccc eee ee 2 While Operating 3 Maintenance and Service 4 JACKING INSTRUCTIONS 5 SAFETY AND INSTRUCTION DECALS 6 Groundmaster 4300 D Pagel 1 Safety Safety Instructions Your Groundsmaster meets or exceeds safety standard specifications when weights are installed according to information in the Operator s Manual Although hazard control and accident prevention are partially dependent upon the design and configuration of the machine these factors are also dependent upon the awareness con cern and proper training of the personnel involved in the operation transport maintenance and storage of the machine Improper use or maintenance of the machine can result in inj
126. circuit pressure increases until manifold relief valve RV1 is opened by a manifold pilot piston The shifted relief valve allows a small amount of hydraulic flow to return to tank through Groundsmaster 4300 D Page 4 13 a manifold sensing line This flow passes through an ori fice which causes a pressure differential thatshifts logic cartridge LC 1 The shifted LC1 allows circuit flow to ro tate the rear cutting deck motors Return oil from the deck motors is directed through the shifted logic car tridge LC 1 manifold port T oil cooler oil filter and then to the reservoir Deck motor case drain leakage returns directly to the hydraulic reservoir Mow circuit pressure for the rear cutting decks pump section P 1 can be measured at deck control manifold port G1 The front cutting deck circuit operates the same as the rear cutting deck circuit Deck control manifold propor tional relief PRV2 relief valve RV2 and logic car tridge LC2 are used to control the front cutting deck circuit Mow circuit pressure for the front cutting decks pump section P2 can be measured at deck control manifold port G2 Cutting Deck Circuit Relief Maximum cutting deck circuit pressure is limited by the proportional relief valves in the hydraulic control man ifold The front deck circuit valve PRV2 is set at 3500 PSI 241 bar and the rear deck circuit valve PRV 1 is set at 2500 PSI 175 bar When increased circuit resistance is
127. clean junction of both hydraulic tubes and wheel motor fittings Disconnect both hydraulic lines from wheel motor that is not being tested Cap dis connected hydraulic lines and wheel motor fittings C Use the procedure described in steps 8 to 11 above to identify individual front wheel motor leak age Individual motor internal leakage will be shown on flow meter in GPM LPM Flow should be less than 1 5 GPM 5 7 LPM for the tested wheel motor D If other front wheel motor requires testing com plete steps A B and C for remaining wheel motor 15 After testing is completed stop engine and then re lieve hydraulic system pressure see Relieving H ydrau lic System Pressure in the General Information section of this chapter Disconnecttester from hydraulic fitting and hose Connecthose to pump elbow fitting Remove caps from hydraulic tubes and reconnecttubes to wheel motor Secure hydraulic tubes to machine with r clamps and removed fasteners Install wheel shield and wheel s see Wheels in the Service and Repairs sec tion of Chapter 6 Chassis Figure 42 4 LH elbow fitting 5 Hyd hose reverse 1 Traction pump 2 RH elbow fitting 3 Hyd hose forward Hydraulic System Piston Traction Pump Flow Test Using Tester with Flow Meter and Pressure Gauge TO STEERING CONTROL VALVE AND CHARGE CIRCUIT TO MOW CONTROL FRONT CUTTING UNITS gt TO LIFT CONTROL MANIFOLD gt TO MOW CONTROL
128. con nections fittings radiator and surrounding area of ma chine to prevent future accumulation of dirt and debris on machine components 5 Install radiatorscreento machine Lowerand secure hood 6 Check oil level in hydraulic reservoir and add correct oil if necessary Hydraulic System This page is intentionally blank Hydraulic System Page 4 118 Groundsmaster 4300 D TORO Chapter 5 Electrical System Table of Contents GENERAL INFORMATION 3 Temperature Gauge 1 24 Operator s Manual 3 P T SWIN ax nu EE ek Re rat a s 25 Toro Electronic Controller TEC 3 Headlight Switch 26 CAN bus Communications 3 Seal SWEN C eese ots ees ies atte es Lett 27 Electrical Drawings 3 J oystick Raise and Lower Switches 28 SPECIAL TOOLS ve e a ei ee Paes ER 4 Traction Neutral Switch 29 TROUBLESHOOTING asla eee 6 Parking Brake Switch 30 Diagnostic Light 6 Mow Transport Switch 31 Retrieving Fault Codes 7 Start Relay evisu a a eae tat 32 Clearing Fault Codes 8 Main Power and Glow Relays 33 Diagnostic Display 8 Toro Electronic Controller TEC 34 Verify Diagnostic Di
129. cooling ofthe closed loop traction circuit The charge system re plenishes oil that is bled from the traction circuit by the flushing valve Reverse Direction The traction circuit operates essentially the same in re verse as it does in the forward direction However the flow through the circuitis reversed Pushing the bottom of the traction pedal rotates the traction pump swash plate to create a flow of oil This oil is directed to the wheel motors to drive the wheels in the reverse direc tion Reverse traction pressure is limited to 3625 PSI 250 bar by the reverse traction relief valve R 4 located in the traction pump Oil 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 pushed The charge circuit and flushing valve function the same in reverse as they do in the forward direction Hydraulic System MO uogons JO uirgo Q103INVI OULNOD eHeuDd mss id MOJ 23d ounssaJi d BupHoAA PNIAID MOWN Q 00 r J91seuuspunoutc 110281 MOW Wa w ette uH 3 1103913 MON tv 32 ld G IOJINVIA TOYLNOD 441 dWNd NOILLOVYL NOLSId A r
130. ction of this chapter Remove pressure gauge and tee fitting from hydraulic tubes Install oil filter to machine 13 Lower and secure operator seat Figure 37 1 Hydraulic tube 3 Hydraulic tube 2 Oil filter filter adapter Figure 38 1 Traction pump 4 Shim kit 2 Plug 5 Spring 3 O ring 6 Charge relief poppet Hydraulic System Gear Pump P3 Flow Test Using Tester with Pressure Gauges and Flow Meter TO STEERING CONTROL VALVE AND CHARGE CIRCUIT TO MOW CONTROL FRONT CUTTING UNITS TO LIFT CONTROL MANIFOLD TO MOW CONTROL REAR CUTTING UNITS i INTERNAL CASE BYPASS DRAIN VALVE A aN CROSSTRAX MANIFOLD guy MY04 PISTON TRACTION PUMP FROM STEERING CONTROL VALVE WZ AND TUBE REMOVED Figure 39 The gear pump P3 flow test should be performed to 2 Park machine on a level surface with the cutting make sure that the traction charge circuit and steering decks lowered and PTO switch off Make sure engine is circuit have adequate hydraulic flow off Apply the parking brake Procedure for Gear Pump P3 Flow Test 3 Read Precautions For Hydraulic Testing in this sec tion 1 Make sure hydraulic oil is at normal operati
131. cuit Drawings in Chapter 8 Foldout Drawings 6 Make sure that parking brake switch is connected to wire harness when testing is complete Figure 32 1 Parking brake switch 2 Lock washer 2 used 3 Jam nut 2 used 4 Parking brake detent 5 Brake pedal 6 Switch LED location Groundsmaster 4300 D Mow Transport Switch The mow transport switch is a normally closed proximity switch thatopens when the mow speed limiter is placed in the transport position The switch mounts to a bracket on the footrest platform The sensing plate for the mow transport switch is the mow speed limiter The mow transport switch is used as an input for the TEC controller Testing 1 Before disconnecting the mow transport switch for testing the switch and its circuit wiring should be tested as a TEC controller input with the Diagnostic Display see Diagnostic Display in the Troubleshooting section ofthis chapter Ifthe Diagnostic Display verifies thatthe mow transport switch and circuit wiring are functioning correctly no further switch testing is necessary If how ever the Diagnostic Display determines that the mow transport switch and circuit wiring are not functioning correctly proceed with testing procedure 2 Turn ignition switch to the ON position do not start engine and check LED on cable end of mow transport switch Fig 33 LED should be illuminated when the mow speed limiter is in the MOW position The LED should not
132. current battery charger which is commonly available Follow the battery charger manufacturer s instructions when using a battery charger NOTE Using specific gravity of the battery cells is the mostaccurate method of determining battery condition 1 Determine the battery charge level from either its specific gravity or open circuit voltage Open Circuit Voltage 12 68 12 45 12 24 Battery Charge Level 2 Determine the charging time and rate using the bat tery charger manufacturer s instructions or the fol lowing table Specific Gravity 1 265 1 225 1 190 1 155 1 120 Battery Reserve Battery Charge Level Percent of Fully Charged Capacity inte 80 or less 3 8 hrs 7 5 hrs 11 3 hrs 15 hrs 3amps 3amps 3 amps 3 amps 5 3 hrs 10 5 hrs 15 8 hrs 21 hrs 4amps 4amps 4amps 4amps 126 to 5 5 hrs llhrs 16 5 hrs 22 hrs 170 5 amps 5 amps 5 amps 5 amps 171 to 5 8 hrs 11 5 hrs 17 3 hrs 23 hrs 250 6 amps 6amps 6amps 6 amps above 6 hrs 12 hrs 18 hrs 24 hrs 250 10 amps 10 amps 10 amps 10 amps Groundsmaster 4300 D Page 5 47 Do notcharge a frozen battery because itcan ex plode and cause injury Let the battery warm to 60 F 16 C before connecting to a charger Charge the battery in a well ventilated place to dissipate gases produced from charging These gases are explosive keep open flame and elec tr
133. cutting decks by providing a restriction for the return flow from the lift cylinders While the cutting decks are being lowered the propor tional relief valve PRV has a secondary function as a circuit relief to limit lift circuit pressure to 2000 P SI 138 bar Lift circuit pressure can be monitored at lift control manifold port G 4 When the joystick is returned to the neutral center position all of the lift manifold valves S1 2 and PRV are de energized The de energized relief valve PRV allows hydraulic flow to return to tank through the man ifold This flow causes a pressure differential that shifts the logic cartridge LC which allows pump flow to by pass the lift cylinders All lift cylinders and cutting decks are held in position by de energized valve S2 Groundsmaster 4300 D Page 4 19 Counterbalance Once the cutting decks are fully lowered the lift control manifold proportional relief valve P RV maintains back pressure counterbalance on the deck lift cylinders This counterbalance pressure transfers cutting deck weightto the machine to improve traction A setof wires located behind the controlarm access coverallow coun terbalance pressure to be adjusted to one of three set tings A pressure transducer located in the forward traction hy draulic tube is used by the controlleras an inputto deter mine traction circuit pressure Based on transducer inputand machine counterbalance setting an electrical
134. cutting deck make sure that grease groove in each roller mountaligns with the grease hole in each end of roller shaft Groundsmaster 4300 D Page 7 15 NOTE After roller is installed to cutting deck lubricate roller grease fittings rotate roller to properly distribute grease in bearings and clean excess grease from roller ends A properly assembled roller should rotate with less than 5 in Ibs 0 68 N m resistance Figure 14 1 Roller tube 4 Outer seal 2 Inner seal 5 Bearing outer seal tool 3 Bearing 7 KS _ x Figure 15 1 Roller tube 4 Bearing 2 Roller shaft 5 Washer 3 Innerseal 6 Bearing outer seal tool Figure 16 1 Roller tube 4 Bearing 2 Roller shaft 5 Outer seal 3 Inner seal 6 Bearing outer seal tool Cutting Decks Front Roller Service Disassembly Fig 17 1 Park machine on a level surface lower cutting decks stop engine engage parking brake and remove key from the ignition switch 2 Remove front roller mounting bolt 3 Remove front roller assembly and spacer from deck frame 4 To remove bearings and bearing spacer from front roller A Insertpunch through end of rollerand drive oppo site bearing outby alternating taps to opposite side of innerbearing race There should be a lip ofinnerrace exposed for this process B Remove bearing spacer Remove second bear ing from rol
135. d A Lubricate new seal kitcomponents with clean hy draulic oil and install on valve The O rings sealing rings and backup rings mustbe arranged properly on the cartridge valve for proper operation and sealing IMPORTANT Use care when installing cartridge valves Slight bending or distortion of the stem tube can cause binding and malfunction Make sure that deep well socket fully engages the valve base B Thread cartridge valve carefully into correctman ifold port The valve should go in easily withoutbind ing C Torque cartridge valve using a deep well socket to values identified in Figure 81 8 If solenoid coil was removed from cartridge valve A Carefully install coil onto the valve B Install nut and torque nutto 60 in Ib 6 7 N m Hydraulic System Cutting Deck Motor Figure 82 1 Hydraulic deck motor 4 9 Hydraulic hose 17 Hydraulic hose 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 Hydraulic deck motor 3 5 Hydraulic hose 13 45 hydraulic fitting 21 Hydraulic fitting 6 O ring 14 Hydraulic hose 22 Hydraulic hose 7 45 hydraulic fitting 15 Hydraulic deck motor 1 23 Hydraulic deck motor 22 8 O ring 16 Hydraulic deck motor 5 Removal Fig 82 1 Park the machine on a levelsurface engage parking brake lower cutting decks and stop engine Remove key from the ignition
136. d Connect a 5000 PSI 350 bar pressure gauge to test port 6 Afterinstalling pressure gauge to manifold test port startengine and run atidle speed Check for any hydrau lic leakage from testconnections and correctbefore pro ceeding with test 7 Move throttle to full speed 3200 RPM IMPORTANT Do notallow pressure to exceed 2500 PSI 172 bar IMPORTANT While performing this test hold joys tick lever in the raise position only long enough to geta system pressure reading Holding the lever in raise for an extended period may damage system components 8 Make sure thatPTO switch is OFF and then pull joys tick leverrearward to pressurize liftcircuit While holding lever in the raise rearward position watch pressure gauge carefully As the cutting decks fully raise and the lift relief valve lifts system pressure should be Approximately 2000 PSI 138 bar 9 Return the joystick lever to the neutral position and stop the engine 10 If measured pressure is incorrect remove pressure reducing valve P RV from liftcontrol manifold and clean or replace valve see Lift Control Manifold Service in the Service and Repairs section of this chapter Also if lift circuit pressure is low check for restriction in gear pump intake line Internal lift cylinder leakage would also cause low lift circuit pressure see Lift Cylinder Internal Leakage Testinthis section Gearpump P 4 could also be suspected of wear damage orineffici
137. d cover 10 Rotor 3 Body seal 5 used 11 Wear plate 4 Commutator ring 12 Drive link 5 Commutator 13 Thrust bearing 6 Commutator ring 14 Coupling shaft 7 Manifold 15 Thrust bearing 8 Stator 16 Thrust washer NOTE The front wheel motors on Groundsmaster 4300 D machines are Parker Torqmotor TG Series The rear wheel motors are Parker Torqmotor TL Se ries Rightand left motors are the same basic design but the right side motors have a reverse timed manifold to allow correct rotation direction for forward and reverse NOTE For wheel motor repair procedures see the Parker Torqmotor Service Procedure TC TB TE TJ TF TG TH and TL Series atthe end of this chapter Hydraulic System Page 4 84 17 Inner bearing 18 Shaft seal 19 Back up washer 20 Back up ring 21 Housing 22 Outer bearing 23 Dirt and water seal IMPORTANT Ifa wheel motorfailure occurred refer to Traction Circuit ComponentFailure in the Gener al Information section for information regarding the importance of removing contamination from the traction circuit Groundsmaster 4300 D Hydraulic System This page is intentionally blank Groundsmaster 4300 D Page 4 85 Hydraulic System CrossTrax AWD Manifold Figure 77 1 AWD manifold 6 Hydraulic fitting 7 used 11 Cap screw 3 used 2 Hydraulic tube 7 O ring 12 Lock washer 3 used 3 Hydraulic tube 8 Dustcap 2used 13 Spacer 3 used 4 Hydraulic tub
138. d during testing or component removal 6 When using hydraulic tester pressure and flow the inlet and the outlet hoses must be properly connected and not reversed to prevent damage to the hydraulic tester or components 7 Install hydraulic fittings finger tightand far enough to make sure thatthey are notcross threaded before tight ening them with a wrench 8 Position tester hoses to prevent rotating machine parts from contacting and damaging the hoses ortester 9 After connecting test equipment check oil level in the hydraulic tank to make sure that oil level is correct 10 When using hydraulic tester pressure and flow open tester load valve completely before starting engine to minimize the possibility of damaging components 11 The engine mustbe in good operating condition Use a phototac when performing a hydraulic test Engine speed can affect the accuracy of the tester readings Check actual speed of the pump when performing hy draulic flow tests 12 After hydraulic test procedures have been com pleted check oil level in the hydraulic tank to make sure that oil level is correct Groundsmaster 4300 D Which Hydraulic Tests Are Necessary Before beginning any hydraulic test identify if the prob lem is related to the traction circuit cutting mow circuit lift circuit or steering circuit Once the faulty system has been identified perform tests that relate to that circuit 1 Ifa traction circuit proble
139. d limiter in MOW LED ON ovsseetinierenansronT LED ORE o JOYSTICK RAISE J oystick moved rearward LED ON x mmksensisb rb o JOYSTICK LOWER J oystick moved forward LED ON maneno Electrical System PTO ENABLE PTO switch ON LED ON PTO switch OFF LED OFF TEMP WARNING Excessive engine temperature LED ON Demieoneemesue or TEMP SHUTDOWN Very excessive engine temperature LED ON x E EDO ALT FAULT Engine not running or alternator faulty LED ON x AEN OIL PRES LOW Engine not running OR low engine oil pressure LED ON Engine oil pressure OK LED OFF KEY START NOTE Turn PTO switch ON so en gine will not start when turning ignition switch to START KEY RUN Ignition switch in RUN or START LED ON Groundsmaster 4300 D Ignition switch in START LED ON Ignition switch in RUN LED OFF Page 5 9 Electrical System Verify Diagnostic Display Output Functions The Diagnostic Display also has the ability to detect which output solenoids or relays are turned on by the TEC controller This is a quick way to determine if a ma chine malfunction is electrical or hydraulic NOTE An open output e g an unplugged connectoror a broken wire cannot be detected with the Diagnostic Display 1 Park machine on a level surface lower the cutting decks stop the engine and engage the parking brake 2 Open control panel cover Locate wire harness and connectors near TEC controller Carefully unplug loop back connect
140. damage it is possible that other traction circuit components are also damaged Hydraulic System Page 4 26 Groundsmaster 4300 D Traction Circuit Problems Neutral is difficult to find or machine Traction control linkage is misadjusted disconnected binding or operates in one direction only damaged Piston traction pump check relief valve is not seating or is damaged NOTE Piston traction pump check relief valves for forward and reverse are identical and can be reversed for testing purposes Piston traction pump is worn or damaged Traction response is sluggish Hydraulic oil is very cold Parking brake is dragging or binding Piston traction pump bypass valve is loosened or is damaged Charge pressure is low Flushing valve in traction pump is not seating or is damaged Piston traction pump charge relief valve is not seating or is damaged Piston traction pump check relief valve is not seating or is damaged NOTE Piston traction pump check relief valves for forward and reverse are identical and can be reversed for testing purposes Piston traction pump is worn or damaged No traction in either direction Parking brake is applied dragging or binding Traction control linkage is misadjusted disconnected binding or damaged Oil level in hydraulic reservoir is low other hydraulic systems are affected as well Piston traction pump bypass valve is loosened Flushing valve in traction pump is not s
141. draulic System Steering Cylinder 90 to 120 ft Ib 123 to 162 N m Q0 qa RUNH Lug nut 5 used per wheel Rear axle assembly Hydraulic fitting 2 used per motor Hydraulic fitting 2 used Tie rod Axle pivot pin Thrust washer Roll pin Thrust washer 10 J am nut 11 12 13 Grease fitting Wheel motor LH shown Wheel hub assembly Hydraulic System 270t0330ft Ib 5 35 17 366 to 447 N m Figure 101 Grease fitting O ring Jam nut 2 used Lock nut Hydraulic hose O ring Cotter pin Steering cylinder Ball joint Ball joint Retaining ring Lock washer 4 used per motor Page 4 112 70 to 90 ft Ib 95 to 122 N m Wheel assembly Grease fitting Bushing Slotted hex nut Hydraulic hose Woodruff key Cap screw 4 used per motor O ring Wheel stud 5 used per hub Grease fitting O ring Hydraulic hose Groundsmaster 4300 D Removal Fig 101 1 Park the machine on a level surface engage the parking brake lower the cutting decks and stop the en gine Remove the key from the ignition switch 2 Read the General Precautions for Removing and Installing Hydraulic System Components at the begin ning of the Service and Repairs section of this chapter Before opening hydraulic system operate all hy draulic controls to relieve system pressure and avoid injury from pressurized hydraulic oil See Relieving Hydraulic
142. ds the use of a DIGITAL Volt Ohm Amp multimeter when testing electrical circuits The high impedance internal resistance ofa digital me ter in the voltage mode will make sure that excess cur rent is not allowed through the meter This excess current could cause damage to circuits not designed to carry it Figure 1 Skin Over Grease Special non conductive grease which forms a lightpro tective skin to help waterproof electrical switches and contacts Toro Part Number TOR50547 Figure 2 Battery Terminal Protector Aerosol spray that should be used on battery terminals to reduce corrosion problems Apply terminal protector after the battery cable has been secured to the battery terminal Toro Part Number 107 0392 FLEXIBL Non TACK f PROTECTS CcoATINO Figure 3 I Electrical System Page 5 4 Groundsmaster 4300 D Diagnostic Display The Diagnostic Display Fig 4 can be connected to the wiring harness connector located inside the control arm to verify correctelectrical functions of the machine TEC controller inputs and outputs can be checked using the Diagnostic Display Toro Part Number for Diagnostic Display 85 4750 Toro Part Number for Overlay English 117 0171 NOTE Diagnostic Display overlays are available in several languages for your Groundsmaster Refer to your Parts Catalog for overlay language options and part numbers IMPORTANT The Diagnostic Display must not be left connected to the
143. e 9 Diagnostic fitting 2 used 14 Hydraulic hose 4 used 5 O ring 10 O ring 15 Frame bracket Removal Fig 77 1 Park the machine on a levelsurface engage parking brake lower cutting decks and stop engine Remove key from the ignition switch 2 Read the General Precautions for Removing and Installing Hydraulic System Components at the begin ning of the Service and Repairs section of this chapter 3 Locate CrossTrax AWD manifold thatis attached to bracket at rear of frame 4 Label all hydraulic connections for assembly pur poses Thoroughly clean hydraulic connections prior to loosening hydraulic lines Hydraulic System Page 4 86 Before opening hydraulic system operate all hy draulic controls to relieve system pressure and avoid injury from pressurized hydraulic oil See Relieving Hydraulic System Pressure in the Gen eral Information section of this chapter 5 Disconnecthydraulic hoses andtubes from fittings in manifold Allow lines to drain into a suitable container Remove and discard O rings Groundsmaster 4300 D 6 Putcaps or plugs on disconnected lines and fittings to prevent contamination 7 Support manifold to prevent it from falling Remove three 3 cap screws and lock washers that secure man ifold to machine frame Locate and retrieve three 3 Spacers from between bracket and manifold 8 Remove AWD manifold from machine 9 Ifnecessary remove hydraulic fittings from manifold
144. e are multiple faults in controller memory there will be a three 3 sec ond pause between codes The fault codes will continu ally repeatafter a five 5 second pause until the ignition key is turned off If there are no faults that have occurred within the last forty 40 hours of operation the diagnostic light will flash continuously after performing the above switch se quence Ifa faultcode is notretrieved from the controller memory within forty 40 hours of machine operating time the fault cannot be retrieved from controller memory using this procedure If necessary contact your Toro distribu tor to retrieve older fault codes Fault Description High engine temp warning occurred PTO was shutdown by controller High engine temp shutdown occurred engine was shutdown by controller Low engine oil pressure occurred Engine alternator fault occurred Clearing Fault Codes After fault codes have been retrieved clearing of those faults can be completed using the following switch se quence 1 Place machine switches in fault retrieval see above The diagnostic light should be displaying the fault codes Groundsmaster 4300 D Page 5 7 2 Operator seat should remain UNOCCUPIED 3 Move mow speed limiter to the MOW position 4 Move joystick to the RAISE position 5 Monitor the diagnostic light for continuous flashing indicating thatall faults have been cleared from the con troller memory Electrical Sys
145. e by tightening two 2 flange head screws 6 Connect wire harness leads to solenoid coils on manifold using labels placed during removal 7 Check oil level in hydraulic reservoir and add correct oil if necessary 8 Follow Hydraulic System Start up procedures see Hydraulic System Start up in this section 20 ft Ib 27 N m Figure 91 1 Lift control manifold 7 Straight fitting 6 used 2 Straight fitting 2 used 8 O ring 3 O ring 9 O ring 4 O ring 10 Straight fitting 5 Orifice 0 030 11 45 fitting 6 Orifice 0 046 3 used 12 O ring Hydraulic System Lift Control Manifold Service Figure 92 1 Lift control manifold 4 Solenoid coil 7 Solenoid coil 2 Solenoid valve S1 5 Nut 8 Proportional relief valve PRV 3 Solenoid valve S2 6 Nut 9 Logic cartridge LC NOTE The ports on the lift control manifold are marked for easy identification of components Example P is the gear pump P4 connection port and S2 is the location for solenoid valve S2 see Hydraulic Schematic in Chap ter 8 Foldout Drawings to identify the function of the hy Make sure that cutting decks are fully lowered draulic lines and cartridge valves at each manifold port before loosening hydraulic lines cartridge location valves or plugs from lift control manifold If decks are not fully lowered as manifold compo Forcontrol manifold service procedures see Deck Con nents are loosened decks may drop unexpec
146. e g piston pump or wheel motor filtering the traction circuit is recom mended See Filtering Closed Loop Traction Circuit in this section 1 Park machine on a level surface Lower cutting decks stop engine engage parking brake and remove key from ignition switch 2 Drain hydraulic reservoir Remove suction screen from reservoir and clean thoroughly Consider removing and cleaning reservoir if necessary 3 Clean area around the mounting areas of the hy draulic filters Remove and discard hydraulic filters 4 Drain entire hydraulic system Drain all hoses tubes and components while the system is warm Flush hoses and tubes to remove any contamination 5 Make sure the mounting surfaces of the hydraulic fil ters are clean Apply clean hydraulic oil to gasketon new filters Screw filters on until gasket contacts mounting plate then tighten filter three quarters of a turn IMPORTANT Use only hydraulic fluids specified in Operator s Manual Otherfluids could cause system damage 6 Fill hydraulic reservoir with new hydraulic oil Groundsmaster 4300 D Page 4 61 Check hydraulic lines and hoses daily for leaks kinked lines loose mounting supports wear loose fittings or deterioration Make all necessary repairs before operat ing the machine 7 Disconnect wire harness electrical connector from the engine fuel stop solenoid to preventthe engine from starting 8 Make sure traction pedal is in neutral and
147. e ignition key is in start the traction pedal is in neutral and the parking brake is applied the glow plugs and other necessary engine starting components will be energized s J N g Y c LL o 9 9 9 NON 5 P p 9 o m g o N u mn ul amp Dl o Ex n o 5 c 2 y IQ 5 5 E g 48 s 2 Ajg 9 5 lt FB z v l El s 3 3 8 KEY TO CHART x 6 x 92 8 e 9 Ps 5 s 5 gt aa g s S 2 x 9 EC 9 Roe c S e al a use X Component Input Position z lt z x 9 bu cC C u gt gt uj x Z h eo B du xs Not Relevent for Function c c sigo 5 912 c 5 AES oop gt I gt gt 9 S ple 5 35 5 S x x lt 2 8 ct P Component Output Energized 5 B 9 a S m 6 a na 8 9 9g e S 5 8 SX X el l p Sixx i253 el ERE DEO 6 6 S O S g mnnn O s s s gjg i gis5 zz E Ez x x S amp amp te B 5552f0 5 ele e 95222 MACHINE FUNCTION 2 2 F mia Z a gt 3 3 ln aojo uj uj u Preheat X P Start No Operator in Seat X P P Start Operator in Seat X P P Run No Operator in Seat X X P Run Operator in Seat X X P Lower Cutting Units to Ground X X X P P P P Mow C U on Ground X X X P P P P P Raise from Mow to Turn Around Position X X X P P Lower Mow from Turn Around Position X X X X P P P P P P Raise to Transport Position X X P P Diagnostic Light Fault Retrieval X X Clearing Faults From Retrieval
148. e the glow plug system by turning the igni tion switch to RUN and record the multimeter results The Groundsmaster 4300 D glow plug system should have a reading of approximately 36 amps total 9 amps per glow plug If low current reading is observed one or more glow plugs is faulty Electrical System Check Operation of Interlock Switches The interlock switches are for the protection of the operator and bystanders and to ensure cor rect operation of the machine Do not bypass or disconnect switches Check the operation of the interlock switches daily for proper operation Re place any malfunctioning switches before oper ating the machine Interlock switch operation is described in the Traction Unit Operators Manual Your Groundsmaster is equipped with a TEC controller which monitors interlock switch operation Information on the controller is de scribed in the Traction UnitO perator s Manualand in the Component Testing section of this Chapter Electrical System Page 5 18 The interlock system used on your Groundsmaster in cludes the seat switch the traction neutral switch the parking brake switch the mow transport switch and the PTO switch Testing ofindividualinterlock switches is in cluded in the Component Testing section of this Chap ter NOTE Use the Diagnostic Display see Special Tools in this chapter to test TEC controller inputs and outputs before further troubleshooting of an electrical problem
149. eal Trunnion cover Neutral switch Lock washer Screw 4 used Q9 RUNH E E E e e e e e a ONDURWNEO Traction pump housing 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 NOTE For piston traction pump repair see the Sauer Danfoss LP V Closed Circuit Axial P iston Pumps Repair Manual and Service Instructions at the end of this chapter Hydraulic System Figure 71 Control arm 37 Cylinder block kit Screw 38 Valve plate Charge relief poppet 39 Slotted pin Spring 40 End cap gasket Bracket 41 Seal kit Nut 42 Relief valve reverse Seal nut 43 Needle bearing Pin 44 Loop flushing spool Swashplate 45 Spring Thrust plate 46 Plug Shim kit 47 O ring O ring 48 Bypass valve Charge relief plug 49 Seal kit Retaining ring 50 End cap Bearing 51 Coupling Neutral return arm 52 Screw 4 used Neutral return pivot 53 Relief valve forward Spring 54 Seal kit information IMPORTANT If a piston traction pump failure oc curred refer to Traction Circuit ComponentFailure in the General Information section for information regarding the importance of removing contamina tion from the traction circuit Page 4 72 Groundsmaster 4300 D Hydraulic System This page is intentionally blank Groundsmaster 4300 D Page 4 73 Hydraulic System Gear Pump Service 2 e CST ce Disassembly Fig 72 NOTE The gearpump mustbe replaced as a complete asse
150. eating or is damaged Piston traction pump check valve is not seating or is damaged Charge pressure is low Wheel motor s and or piston traction pump are worn or damaged NOTE If a traction circuit component has internal wear or damage it is possible that other traction circuit components are also damaged Single wheel motor turns while Wheel motor is worn or damaged NOTE If a traction circuit unloaded but slows down or stops component has internal wear or damage itis possible that other when load is applied traction circuit components are also damaged Groundsmaster 4300 D Page 4 27 Hydraulic System Traction Circuit Problems Con Wheel motor will not turn Wheel motors will not hold load when traction pedal is in neutral Mow Circuit Problems Front cutting deck motors will not operate but rear cutting deck motors will operate Rear cutting deck motors will not operate but front cutting deck motors will operate Single cutting deck motor will not operate or rotates slowly Hydraulic System tinued Possible Causes Brakes are binding Wheel motor is worn or damaged NOTE If a traction circuit component has internal wear or damage it is possible that other traction circuit components are also damaged Charge pressure is low Valve plate and or piston shoes in piston traction pump are scored NOTE If a traction circuit component has internal wear or damage it is possible that other traction
151. eck LED on cable end of neutral switch Fig 31 LED should be illuminated when the traction pedal is in the neutral position 3 With the ignition switch still in the ON position do not startengine press traction pedal outofthe neutral posi tion and check LED on cable end of neutral switch LED should not be illuminated when the traction pedal is not in the neutral position 4 If the neutral switch LED did not function correctly A Make sure thatneutral switch is properly adjusted see Traction Neutral S witch in the Adjustments sec tion of this chapter If necessary adjust switch and return to step 2 above B Make sure ignition switch is OFF and disconnect the traction neutral switch connector from the ma chine wire harness C Verify that the machine wire harness connector terminal for black wire is closed continuity to ground Groundsmaster 4300 D Page 5 29 D Turn ignition switch to the ON position do not start engine and verify with a multimeter that ma chine wire harness connector terminal for pink wire has system voltage 12 VDC present E If black wire is closed to ground pink wire has system voltage presentand switch LED did notfunc tion replace traction neutral switch Adjustswitch af ter installation see Traction Neutral S witch in the Adjustments section of this chapter 5 Ifthe neutral switch tests correctly and a circuit prob lem still exists check wire harness see Electrical Sche
152. ed for two 2 hours and monitor the lift cylinder The weight of the cutting deck may cause the lift cylinder to gradually extend Use the tape location to determine lift cylinder rod movement Fig 58 A If lift cylinder rod movement is less than 1 250 31 7 mm after two 2 hours make sure thatthe cut ting deck has notsettled to the ground If the cutting deckis still suspended aftertwo 2 hours and liftcyl inder rod movement is less than 1 250 31 7 mm consider that the lift cylinder is in good condition A cylinder in good usable condition will show minimal movement B Rod movementin excess of 1 250 31 7 mm af ter two 2 hours indicates that the lift cylinder may have internal seal damage or excessive wear Re move and inspect the lift cylinder see Lift Cylinder and Lift Cylinder Service in the Service and Repairs section of this chapter 8 Once lift cylinder condition has been determined use a jackto raise the liftarm slightly which will remove the load from the lift cylinder Leave the jack to support the liftarm and to preventit from lowering Remove the cap from the cylinder fitting and the plug from the hy draulic hose Connectthe hydraulic hose to the lift cylin der fitting 9 Carefully remove jack from under the lift arm Start engine and operate lift cylinders through several up and down cycles Stop the engine and check for any leak age 10 If needed repeatsteps 2 through 10 for other lift cyl
153. ed of wear and inefficiency 11 After testing is completed make sure that engine is stopped and then relieve hydraulic system pressure see Relieving Hydraulic System P ressure in the Gener allnformation section ofthis chapter Remove pressure gauge from machine Figure 33 1 Lower hydraulic tube 2 Forward test port Figure 34 1 AWD hydraulic manifold 2 Reverse test port Figure 35 1 Piston traction pump 3 Forward relief valve R3 2 Reverse relief valve R4 Groundsmaster 4300 D Page 4 35 Hydraulic System Traction Circuit Charge Pressure Test TO STEERING CONTROL VALVE AND CHARGE CIRCUIT TO MOW CONTROL FRONT CUTTING UNITS TS INTERNAL CASE SUCTIO BYPASS VALVE TO LIFT CONTROL MANIFOLD TO MOW CONTROL REAR CUTTING UN CROSSTRAX MANIFOLD JV M304 PISTON TRACTION PUMP PRESSURE GAUGE m M REMOVED FROM STEERING CONTROL VALVE Figure 36 The traction circuit charge pressure test should be per 3 Read Precautions For Hydraulic Testing in this sec formed to make sure that the traction charge circuit is tion functioning correctly Procedure for Traction Circuit Charge Pressure Test 1 Make sure hydraulic oil
154. egin ning of the Service and Repairs section of this chapter 3 Chock frontwheels to preventmachine from shifting 4 Loosen but do not remove five 5 wheel lug nuts and lock nut item 14 that secures wheel hub to wheel motor A WARNING Before jacking up the machine review and follow J acking Instructions in Chapter 1 Safety 5 Jack up machine enough to allow the removal of the rear wheel Support machine with jack stands 6 Remove rearwheel assembly from the machine see RearWheelRemovalinthe Service and Repairs section of Chapter 6 Chassis IMPORTANT DO NOT hit wheel hub wheel hub puller or wheel motor with a hammer during wheel motor removal or installation Hammering may cause damage to the wheel motor 7 Make sure thatlock nut item 14 that secures wheel hub to wheel motor is loosened at least two 2 turns Use hub puller see S pecial Tools in this chapter to loos en wheel hub from wheel motor 8 Remove loosened lock nut and wheel hub from mo tor shaft Discard lock nut Locate and retrieve woodruff key from wheel motor shaft 9 Thoroughly clean hydraulic hose ends and fittings on rear wheel motor to prevent hydraulic system contami nation Groundsmaster 4300 D Page 4 81 10 Label all hydraulic hoses for assembly purposes Remove hydraulic hoses from fittings on wheel motor Allow hoses to drain into a suitable container 11 Putclean plugs in disconnected hydraulic hoses and fitti
155. em pressure see Relieving Hydraulic System Pressure in the General In formation section of this chapter Remove tester from machine and connect hydraulic hose to deck motor fit ting 15 Lower and secure operator seat Figure 46 1 Cutting deck motor 2 shown 2 Deck motor inlet hose Hydraulic System Gear Pump P1 and P2 Flow Test Using Tester with Pressure and Flow Capabilities TO STEERING CONTROL VALVE AND CHARGE CIRCUIT TESTER t BYPASS VALVE m 3 S TO LIFT CONTROL MANIFOLD GEAR PUMP P1 FLOW TEST SHOWN ROSSTRAX RIGHT eee FOLD GB LEFT FRONT PISTON TRACTION PUMP ROM STEER NG CONTROL VALVE C U REAR MOW CIRCUIT R11 in E T3 3 1 C U 5 FRONT MOW CIRCUIT C U 1 RT d zl r ile RT d aa Low DECK CONTROL MANIFOLD FROM LIFT CONTROL MANIFOLD Figure 47 Over a period of time the gears and wear p
156. empt to start the engine but move the machine away from the area of spill age Avoid creating any source of ignition until fuel vapors have dissipated Wipe up any spilled fuel Groundsmaster 4300 D While Operating 1 Siton the seat when starting and operating the ma chine 2 Before starting the engine A Apply the parking brake B Make sure the traction pedal is in NEUTRAL and the PTO switch is OFF disengaged C After engine is started release parking brake and keep foot off traction pedal Machine must not move If movement is evident the traction pedal linkage is adjusted incorrectly therefore shut engine off and adjust traction pedal linkage until machine does not move when traction pedal is released see Opera tor s Manual 3 Do not run engine in a confined area without ade quate ventilation Exhaust fumes are hazardous and could possibly be deadly 4 Do not touch engine radiator or exhaust system while engine is running or soon after itis stopped These areas could be hot enough to cause burns Groundmaster 4300 D Pagel 3 5 Before getting off the seat A Ensure that traction pedal is in NEUTRAL B Lower and disengage cutting decks and wait for all movement to stop C Apply parking brake D Stop engine and remove key from ignition switch 6 Anytime the machine is parked shortor long term the cutting decks should be lowered to the ground This relieves pressure from the hydraulic l
157. ency see Gear Pump P4 Flow Test in this section 11 After testing is completed make sure that engine is stopped then relieve hydraulic system pressure see Relieving Hydraulic System Pressure in the General In formation section of this chapter Disconnect pressure gauge from lift control manifold test port 1 Lift control manifold 2 SV1 solenoid Groundsmaster 4300 D Page 4 51 Figure 52 3 SV2 solenoid 4 PRV solenoid Hydraulic System Gear Pump P4 Flow Test Using Tester with Pressure Gauges and Flow Meter TO STEERING CONTROL VALVE TO DECK CONTROL MANIFOLD FRONT CUTTING UNITS FRONT m CENTER lt TO DECK CONTROL MANIFOLD REAR CUTTING UNITS COO ee PUMP P5 INTERNAL ERI CASE STRAINER DRAIN LI TESTER Y FROM MOW CONTROL MANIFOLD LIFT CONTROL MANIFOLD Figure 53 The gear pump P 4 flow test should be performed to 3 Read Precautions For Hydraulic Testing in this sec make sure thatthe cutting deck lift circuithas adequate tion hydraulic flow Procedure for Gear Pump P4 Flow Test 1 Make sure hydraulic oil is at normal operating tem perature by operating the machine under load for Before opening hyd
158. er Tight F F F T method Hold the fitting in the desired position with a wrench and if port material is steel tighten the lock nut with a second wrench to the listed F F F T Step 4 in Fig ure 9 If port material is aluminum tighten fitting to 6096 of listed F F F T Size F F F T 4 1 4 in nominal hose or tubing 1 00 0 25 6 3 8 in 1 50 0 25 8 1 2 in 1 50 0 25 10 5 8 in 1 50 0 25 12 3 4 in 1 50 0 25 16 1 in 1 50 0 25 Groundsmaster 4300 D Page4 7 Lock Nut E C a Washer DN ring Figure 8 Figure 9 Hydraulic System Relieving Hydraulic System Pressure Before disconnecting or performing any work on the hy draulic system all pressure in the hydraulic system mustbe relieved P ark machine ona level surface lower cutting decks fully stop engine and engage parking brake To relieve hydraulic pressure in traction circuit move traction pedal to both forward and reverse directions To relieve hydraulic pressure in steering circuit rotate steering wheel in both directions System pressure in cutting circuit is relieved when the cutting decks are disengaged Traction Circuit Component Failure The traction circuit on Groundsmaster 4300 D ma chines is a closed loop system that includes the piston traction pump and four 4 wheel motors If a compo nentin the traction circuitshould fail debris and contam ination fro
159. er radiator has been properly filled with coolant install radiator cap 11 Lower and secure hood Kubota Diesel Engine 9 9 ul 8 8 8 Engine 34 to 42 ft lb 47 to 56 N m N Figure 9 1 Engine assembly 12 Lock washer 23 Negative battery cable 2 Cap screw 12 used 13 Lock washer 24 Air cleaner stand 3 Temperature sender 14 Pulley 25 Lock washer 12 used 4 Engine mount 4 used 15 V belt 26 Fusible link harness 5 Flange head screw 13 used 16 Lock washer 4 used 27 Engine mount 4 used 6 Snubbing washer 4 used 17 Cooling fan 28 Bracket 7 Cap screw 4 used 18 Flat washer 29 Bracket 8 Flange nut 4 used 19 Spring washer 30 Hex nut 9 Flange nut 14 used 20 Hex nut 31 Flange head screw 4 used 10 Fan clutch 21 Cap screw 32 Wire harness ground 11 Stud 4 used 22 Spacer 4 used Kubota Diesel Engine Page 3 12 Groundsmaster 4300 D Removal Fig 9 1 Park machine on a level surface lower cutting decks stop engine and remove key from the ignition switch Chock wheels to keep the machine from moving 2 Open and support hood 3 Disconnect negative cable and then positive cable from the battery Do not open radiator cap or drain coolant if the radiator or engine is hot Pressurized hot cool ant can escape and cause burns Ethylene glycol antifreeze is poisonous Dis pose of coolant properly orstore itin
160. er system will allow dirtinto engine and will cause serious engine damage Make sure that all air cleaner components are in good condition and are properly secured dur ing assembly 1 Assemble air cleaner system using Figure 4 as a guide A If service indicator item 2 and adapter item 3 were removed from air cleaner housing apply thread sealant to adapter threads before installing adapter and indicator to housing Install adapter so that grooves in adapter hex and adapter filter elementare installed toward service indicator Fig 5 Torque in dicator from 12 to 15 in Ib 1 4 to 1 6 N m B Make surethatvacuator valve is pointed down af ter assembly 1 Air cleaner assembly 2 Service indicator Groundsmaster 4300 D Page 3 7 Figure 5 3 Adapter 4 Vacuator valve Kubota Diesel Engine 7 8 B 8 8 Exhaust System Figure 6 7 Muffler support bracket 8 Flange head screw 2 used 9 Tail pipe bracket 10 Hex nut 2 used 11 Upper clamp Flange head screw 2 used Muffler Tail pipe bracket Exhaust header Lower clamp 13 14 15 16 17 12 Flange nut 4 used Lock washer 2 used Flange nut 4 used Cap screw 2 used Carriage screw 4 used Flange nut 4 used Gasket 1 2 3 4 5 6 Page 3 8 Groundsmaster 4300 D Kubota Diesel Engine Removal Fig 6 1 Park machine on a level surface lower cutting decks stop engine engage parking brake and remove key fro
161. ervice in the Service and Repairs section ofthis chapter Check drain pan for any evidence of oil that would indicate internal cylinder leakage 9 Remove plug from the hydraulic hose Connecthose to the steering cylinder fitting 10 If a steering problem exists and the steering cylinder tested acceptably the steering control valve requires service see Steering Control Valve and Steering Con trol Valve Service in the Service and Repairs section of this chapter 11 Check oil level in hydraulic reservoir and adjust if needed Groundsmaster 4300 D Page 4 59 Hydraulic System Service and Repairs General Precautions for Removing and Installing Hydraulic System Components Before Repair or Replacement of Components 1 Before removing any parts from the hydraulic sys tem park machine on a level surface engage parking brake lower cutting decks and stop engine Remove key from the ignition switch 2 Thoroughly clean machine before disconnecting re moving or disassembling any hydraulic components Make sure hydraulic components hose connections and fittings are thoroughly cleaned Always keep in mind the need for cleanliness when working on hydraulic components Before loosening any hydraulic component op erate all hydraulic controls to relieve system pressure and avoid injury from pressurized hy draulic oil See Relieving Hydraulic System Pres sure in the General Information section of this chapter 3 Operate al
162. essary If however the Diag nostic Display determines thatignition switch and circuit wiring are not functioning correctly proceed with test procedure 2 Remove outside control arm cover to gain access to ignition switch see Control Arm Disassembly in the Ser vice and Repairs section of Chapter 6 Chassis Dis connect wire harness electrical connector from the switch 3 With the use of a multimeter ohms setting the switch functions may be tested to determine whether continuity exists between the various terminals for each switch position The ignition switch terminals are marked as shown in Figure 18 The circuitry of this switch is shown in the chart below Verify continuity be tween switch terminals POSITION CIRCUIT B C F D E START 4 Replace ignition switch if necessary Electrical System Page 5 22 NOTE For engine componenttesting information see the Kubota Workshop Manual Diesel Engine 05 E3B Series atthe end of Chapter 3 Kubota Diesel Engine When testing electrical components for continu ity with a multimeter ohms setting make sure that power to the circuit has been disconnected 5 If switch tests correctly and circuit problem still ex ists check wire harness see Electrical Schematic and Circuit Drawings in Chapter 8 Foldout Drawings 6 Connect wire harness electrical connector to the ignition switch 7 Install control arm cover to machine see Control Arm Assemb
163. essary positions to allow that function to occur see TEC Controller Logic Chartin this section Verify correct switch function Electrical System Page 5 10 B If the output LED s are on as specified but the machine does not function properly consider that the controller is operating correctly and a problem exists with some other component Inspectelectrical components and circuit for the affected function Also suspecta non electrical problem e g hydrau lic component problem Repair as necessary C If each input switch is in the correct position and functioning correctly but the output LED s are not correctly illuminated this indicates a controller prob lem If this occurs contact your Toro Distributor for assistance 7 After output function testing is completed discon nect the Diagnostic Display from wire harness Plug loopback connector into harness connector Install con trol panel cover Figure 12 1 TEC controller location 3 Harness connector 2 Loopback connector GROUNDSMASTER 4300 D DIAGNOSTIC ACE DIAGNOSTIC DISPLAY OVERLAY 117 0171 INPUT OUTPUT OUTPUT INPUT START svi Figure 13 Groundsmaster 4300 D TEC Controller Logic Chart Each line of the following chart identifies the necessary componentposition INPUTS in order for the TEC con troller to energize the appropriate OUTPUTS for ma chine operation Example To start the engine with no operator in the seat when th
164. essure Test Kit Use to take various pressure readings for diagnostic tests Quick disconnect fittings provided attach directly to mating fittings on machine test ports without tools A high pressure hose is provided for remote readings Kit contains one each 1000 PSI 70 Bar 5000 PSI 350 Bar and 10000 PSI 700 Bar gauges Use gauges as recommended in the Testing section of this chapter Toro Part Number TORA7009 15 GPM Hydraulic Tester Kit Pressure and Flow Use to test hydraulic circuits and components for flow and pressure capacities as recommended in the Testing section ofthis chapter This testerincludes the following 1 INLET HOSE Hose connected from the system cir cuit to the inlet side of the hydraulic tester 2 LOAD VALVE A simulated working load is created in the circuit by turning the valve to restrict flow 3 PRESSURE GAUGE Glycerine filled 0 to 5000 PSI gauge to provide operating circuit pressure 4 FLOW METER This meter measures actual oil flow in the operating circuit with a gauge rated from 1 to 15 GPM 5 to 55 LPM 5 OUTLET HOSE A hose from the outlet side of the hydraulic tester connects to the hydraulic system circuit 6 FITTINGS Anassortmentof hydraulic fittings are in cluded with this kit Toro Part Number TOR214678 Hydraulic System Page 4 22 Figure 21 Figure 22 Groundsmaster 4300 D 40 GPM Hydraulic Tester Pressure and Flow Use to test hydraulic circuits and
165. etaining ring Flange head screw Page 6 10 95 to 122 N m 4 36 70 to 90 ft Ib 8 um pu 26 Wheel assembly 27 LH drag link 28 Woodruff key 29 Thrust washer 30 Grease fitting 31 Grease fitting 32 O ring 33 Hydraulic fitting 2 used 34 O ring 35 J am nut 36 Hydraulic hose 37 Flange bushing 4 used Groundsmaster 4300 D Removal Fig 8 1 Park machine on a level surface lower cutting decks stop engine engage parking brake and remove key from the ignition switch 2 Chock frontwheels to preventmachine from shifting 3 Loosen but do not remove rear wheel lug nuts 4 Jack up rear of machine and remove rear wheel as sembly see Wheel Removal in this section Make sure to support machine with jack stands 5 Remove cotter pin and slotted hex nut that secure the tie rod end to the drag link Separate the tie rod end from the drag link 6 Ifrightside motor housing is being removed remove cotter pin and slotted hex nutthatsecure steering cylin derballjointto drag link Separate steering cylinderfrom drag link 7 Remove four 4 cap screws and lock washers that secure wheel motorto motorhousing Slide wheel motor assembly with wheel hub and hydraulic hoses at tached from motor housing P osition wheel motoraway from housing 8 Support motor housing to prevent it from falling 9 Remove the flange head screw spindle cap and re taining ring that secure the motor
166. evenly in a crossing pattern from 70 to 90 ft Ib 95 to 122 N m Torque wheel hub lock nut item 17 from 315 to 385 ft Ib 427 to 521 N m 13 Check and adjust oil level in hydraulic tank 14 0perate machine functions slowly until air is out of system see Hydraulic S ystem Start up in this section Groundsmaster 4300 D Hydraulic System This page is intentionally blank Groundsmaster 4300 D Page 4 79 Hydraulic System Rear Wheel Motors 70 to 90 ft Ib 95 to 122 N m 270 to 330 ft lb 14 366 to 447 N m Figure 75 1 Lug nut 5 used per wheel 6 Wheel stud 5 used per hub 11 Steering cylinder 2 Rear axle assembly 7 O ring 12 Wheel motor LH shown 3 Hydraulic fitting 2 used per motor 8 Woodruff key 13 Wheel hub assembly 4 Wheel assembly 9 Cap screw 4 used per motor 14 Lock nut 5 Tie rod 10 Lock washer 4 used per motor 15 Hydraulic hose 2 used per motor Hydraulic System Page 4 80 Groundsmaster 4300 D Removal Fig 75 Before opening hydraulic system operate all hy draulic controls to relieve system pressure and avoid injury from pressurized hydraulic oil See Relieving Hydraulic System Pressure in the Gen eral Information section of this chapter 1 Park the machine on a level surface engage parking brake lower cutting decks and stop engine Remove key from the ignition switch 2 Read the General Precautions for Removing and Installing Hydraulic System Components at the b
167. evis end of the barrel IMPORTANT When installing the head into the bar rel pay careful attention to the retaining ring slotin the barrelto insurethatthe piston and head seals do not lodge in the slot 5 Coat all internal parts with a light coat of clean hy draulic oil Slide piston shaft and head assembly into the barrel being careful notto damage the seals 6 Secure head in barrel with retaining ring A Align retaining ring hole in the head with the ac cess slot in the barrel B Insertthe retaining ring hook into the hole and ro tate head clockwise until the retaining ring is com pletely pulled into the barrel and the ring ends are covered C Apply silicone sealer to barrel access slot Hydraulic System Steering Control Valve Antiseize Lubricant 84 to 120 in Ib 9 5 to 13 5 N m Antiseize Lubricant 4 7 20 20 to 26 ft lb 28 to 35 N m 21 Figure 97 1 Steering column 9 Hydraulic tube 16 Flange head screw 2 used 2 Hydraulic fitting 4 used 10 Hydraulic tube 17 Socket head screw 4 used 3 Steering wheel 11 Hydraulic tube 18 Flange nut 2 used 4 Steering wheel cover 12 Hydraulic tube 19 Tube clamp 5 Gear pump 13 Column brace 20 Lock nut 6 Socket head screw 4 used 14 Steering control valve 21 Flat washer 7 Flange nut 15 Flange head screw 2 used 22 O ring 8 O ring Removal Fig 97 1 Park the machine on a level surface engage t
168. fect torque wrench calibration due to the effective length change of the torque wrench Tightening torque when using a torque wrench with an offsetwrench will be lower than the listed installation torque see Using a Torque Wrench with an Offset Wrench in the Torque S pecifica tions section of Chapter 2 Product Records and Main tenance Tube or Hose Figure 3 5 Ifa torque wrench is not available or if space at the swivel nut prevents use ofa torque wrench an alternate Mark Nut zs method of assembly is the Flats From Wrench Resist and Fitting Position ance F F W R method Fig 4 A Using a wrench tighten the swivel nut onto the fit Initial ting until lightwrench resistance is reached approxi Extend Line Position mately 30 in Ib AT WRENCH RESISTANCE AFTER TIGHTENING B Mark the swivel nut and fitting body Hold the hose tube with a wrench to prevent it from turning Figure 4 Fitting Dash Size Hose Tube Side Thread Size Installation Torque 9 16 18 18 to 22 ft lb 25 to 29 N m 11 16 16 27 to 33 ft lb 37 to 44 N m 13 16 16 37 to 47 ft lb 51 to 63 N m 1 14 60 to 74 ft lb 82 to 100 N m 1 3 16 12 85 to 105 ft lb 116 to 142 N m 17 16 12 110 to 136 ft lb 150 to 184 N m 1 11 16 12 140 to 172 ft lb 190 to 233 N m Figure 5 Groundsmaster 4300 D Page 4 5 Hydraulic System Hydraulic Fitting Installation SAE Straight Thread O Ring Fitting into Component Port No
169. freely rotates and that no binding is detected If necessary lightly tap bearing and or shaft ends to align shaft and bearings Re move washer from roller C Apply a small amount of grease around the lip of both outer seals D Carefully install first outer seal into roller tube making sure that seal lip and garter spring faces end of tube Use bearing outer seal tool see Special Tools in this chapter and soft face hammer to lightly seat seal Fig 16 Make sure that shaft and bear ings still freely rotate after seal installation E Using the same process install second outer sealmaking sureto notcrush the installed outerseal Again make sure that shaft and bearings still freely rotate IMPORTANT Make sure that all grease is removed from shaftthreads to preventbearing lock nutloos ening 5 Thoroughly clean threads on both ends of roller shaft NOTE If original bearing lock nut s are being used apply Loctite 242 or equivalent to threads of lock nut s 6 Install bearing lock nut onto each end of the roller shaft Make sure thatouter seals are not damaged dur ing nutinstallation Torque lock nuts from 50 to 60 ft Ib 68 to 81 N m 7 If set screw was removed from either end of roller shaft apply Loctite 242 or equivalent to threads of re moved setscrew and install into roller shaft Tighten set screw until it bottoms in shaft and is recessed in shaft IMPORTANT When roller assembly is installed to
170. g at high idle speed alternately move traction pedalfrom forward to reverse While mon itoring filter indicator continue this process for an addi tional five 5 minutes 10 Shutengine off and remove key from ignition switch 11 Remove high flow hydraulic filter and hydraulic hose kit from machine Connect hydraulic hose to left side traction pump fitting Make sure to properly tighten hose see Hydraulic Hose and Tube Installation in the Gener al Information section of this chapter 12 Lower machine to ground 13 Check oil level in hydraulic reservoirand add correct oil if necessary Figure 63 1 Traction pump 2 RH elbow fitting 3 Hyd hose forward 4 LH elbow fitting 5 Hyd hose reverse Groundsmaster 4300 D Hydraulic System Start up NOTE When initially starting the hydraulic system with new or rebuilt components such as pumps wheel mo tors or lift cylinders itis important that this start up pro cedure be used This procedure reduces the chance of damaging the system or its components from not purg ing the system of air 1 After the hydraulic system components have been properly installed and if the traction pump was rebuilt or replaced make sure traction pump housing is at least half full of clean hydraulic oil 2 Make sure all hydraulic connections and lines are se cured tightly 3 Drain flush and refill hydraulic system and change hydraulic oil filters if component failure was severe or
171. g cavity with grease 12 Rotate spindle shaft to make sure thatit turns freely 13 Install blade spindle assembly to cutting deck see Blade Spindle Installation in this section Groundsmaster 4300 D Page 7 11 Cutting Decks Rear Roller 40 to 47 N m 29 to 35 ft lb 40 to 47 N m 29 to 35 ft lb 40 to 47 N m 29 to 35 ft lb 40 to 47 N m Figure 9 1 Deck frame 4 Roller shaft screw 7 Skid bracket 2 Rear roller assembly 5 Roller mount 8 Cap screw 3 Grease fitting 6 Flange head screw Cutting Decks Page 7 12 Groundsmaster 4300 D Removal Fig 9 1 Park machine on a level surface lower cutting decks stop engine engage parking brake and remove key from the ignition switch 2 If cutting deck is equipped with a roller scraper Fig 10 remove fasteners securing leftand rightscraper rod brackets to roller mounts Remove scraper rod assem bly 3 Remove four 4 flange head screws securing roller mounts to rear of deck frame Remove roller mounts and rear roller assembly from deck frame 4 Loosen fasteners securing each end ofrollerto roller mounts Remove mounts and skid brackets from roller Installation Fig 9 1 Slide roller mounts onto roller shaft 2 Install roller and roller mount assembly into rear of deckframe Secure assembly to deck frame with four 4 flange head screws IMPORTANT During assembly make sure the grease groove in each roller mount aligns with the grease hole
172. g or distortion ofthe stem tube can cause binding and malfunction Make sure that deep well socket fully engages the valve base 3 Using a deep well socket remove cartridge valve from manifold Note correctlocation of O rings sealing rings and backup rings Remove and discard seal kit from valve 4 Visually inspect the manifold port for damage to the sealing surfaces damaged threads and contamination 5 Visually inspectcartridge valve for damaged sealing surfaces and contamination A Contamination may cause valves to stick or hang up Contamination can become lodged in small valve orifices or seal areas causing valve malfunction B If valve sealing surfaces appear pitted or dam aged the hydraulic system may be overheating or there may be water in the system Groundsmaster 4300 D Page 4 93 Use eye protection such as goggles when using compressed air for cartridge valve cleaning Abrupt movement of internal spools can cause stored fluid to be released suddenly 6 Clean cartridge valve by submerging valve in clean mineral spirits to flush out contamination Particles as fine as talcum powder can affect the operation of high pressure hydraulic valves If cartridge design allows use a woodor plastic probe to push the internal spool in and out 20 to 30 times to flush out contamination Be ex tremely careful not to damage cartridge Use com pressed air for cleaning 7 Reinstall cartridge valve into manifol
173. ght coating of petroleum jelly to the exposed side ofthe rear cover 14 Place rear cover on assembly using marker line for proper location Firm hand pressure should be sufficient to engage the dowel pins 15 Installthe four 4 cap screws with washers and hand tighten screws IMPORTANT Prevent damage when clamping the motor into a vise clamp on the front flange only Also use a vise with soft jaws 16 Place front flange of the motor into a vise with soft jaws and alternately torque the cap screws 33 ft Ib 45 N m 17 Remove motor from vise 18 P lace a smallamountofclean hydraulic oilin the inlet ofthe motorand rotate the drive shaftaway from the inlet one revolution If any binding is noted disassemble the motor and check for assembly problems Groundsmaster 4300 D Hydraulic System This page is intentionally blank Groundsmaster 4300 D Page 4 99 Hydraulic System Lift Control Manifold Figure 90 1 Lift control manifold 7 Hydraulic hose 13 O ring 2 Flange head screw 2 used 8 Hydraulic hose 14 Diagnostic fitting 3 O ring 9 Hydraulic hose 15 O ring 4 Hydraulic hose 10 Hydraulic tube 16 Hydraulic hose 5 Hydraulic hose 11 Hydraulic tube 17 Dustcap 6 Hydraulic hose 12 O ring Removal Fig 90 4 Label all hydraulic connections for assembly pur f poses Thoroughly clean hydraulic connections prior to 1 Park the machine on a level surface engage parking loosening hydraulic lines b
174. gine starting circuit When energized by the TEC controller the start relay provides a current path to energize the engine starter solenoid The start relay is attached to a frame bracket under the hood next to the hydraulic pump drive shaft Fig 34 The TEC controller controls and monitors the operation of the start relay The relay and its circuit wiring should be tested as a controller output with the Diagnostic Dis play before disconnecting and testing the relay see Diagnostic Display in the Troubleshooting section of this chapter If the controller has detected a malfunction in the start relay circuit the Diagnostic lightcan be used to identify the fault see Diagnostic Light in the Trouble shooting section of this chapter Testing 1 Before disconnecting the start relay for testing test relay and its circuitwiring as a TEC controlleroutput with the Diagnostic Display see Diagnostic Display in the Troubleshooting section ofthis chapter If the Diagnos tic Display verifies that the relay and circuit wiring are functioning correctly no further relay testing is neces sary 2 If the Diagnostic Display determines that start relay and circuit wiring are notfunctioning correctly park ma chine on a level surface lower cutting decks stop en gine apply parking brake and remove key from ignition switch Open hood to gain access to relay 3 Locate start relay and disconnect the machine wire harness connector from the re
175. h ends of roller tube taking care to not damage tube surfaces 4 Discard removed seals and bearings 5 Clean rollershaftand allsurfaces on the inside ofthe roller tube Inspect components for wear or damage Also carefully inspect seating surface and threads of bearing lock nuts Replace all damaged components Assembly Fig 11 1 Install inner seals into roller tube making sure that seal lip and garter spring faces end of tube Use inner seal tool see Special Tools in this chapter and softface hammer to fully seat seals against roller shoulder Fig 12 Apply a small amount of grease around the lip of both inner seals after installation IMPORTANT During assembly process frequently check that bearings rotate freely and do not bind If any binding is detected consider component re moval and reinstallation 2 Install new bearing and outer seals into one end of roller tube A Position a new bearing into one end of roller tube Use bearing outer seal tool see Special Tools in this chapter with a softface hammer to fully seatbearing againstroller shoulder Fig 13 After bearing instal lation make sure thatitrotates freely with no binding B Apply a small amount of grease around the lip of both outer seals C Install firstouter seal into roller tube making sure that seal lip and garter spring faces end of tube Use bearing outer sealtool see Special Tools in this chapter and soft face hammer to lightly sea
176. h two 2 front rollers and one full width rear roller WEIGHT Individual cutting deck weighs approximately 140 Ib 63 5 kg Groundsmaster 4300 D General Information Never install or work on the cutting decks or lift arms with the engine running Always stop en gine and remove key from ignition switch first Operator s Manual The Cutting Deck Operator s Manual provides informa tion regarding the operation general maintenance and maintenance intervals for the cutting deck on your Groundsmaster machine Refer to that publication for additional information when servicing the cutting deck Groundsmaster 4300 D Page 7 3 Cutting Decks Troubleshooting There are a number of factors that can contribute to un Remember that the effective or actual height of cut satisfactory quality of cut some of which may be turf depends on cutting deck weight counterbalance setting conditions Turf conditions such as excessive thatch and turf conditions Effective height of cut will be differ sponginess uneven ground conditions or attempting ent than the bench set height of cut to cutofftoo much grass height may notalways be over come by adjusting the machine It is important to re member that the lower the height of cut the more critical these factors are Factors That Can Affect Quality of Cut 1 Maximum governed engine speed Check maximum governed engine speed Adjust speed to specifications if necessary
177. hapter 2 Position wheel motor to frame Slide brake assembly with brake bracket item 14 brake spring bracket item 30 and four 4 cap screws onto wheel motor and frame 3 Install and tighten four 4 lock nuts onto cap screws to secure motorand brake components to frame Torque cap screws from 80 to 100 ft Ib 109 to 135 N m 4 Thoroughly clean motor shaft and wheel hub taper 5 Install square key into the wheel motor shaft keyslot Align wheel hub with key and slide wheel hub onto motor shaft IMPORTANT Do not reuse lock nut that secures wheel hub to wheel motor after ithas been removed Hydraulic System 6 Install new lock nut item 17 onto the wheel motor shaft to secure wheel hub to motor shaft 7 Remove caps or plugs from disconnected hydraulic lines and fittings 8 Lubricate and position new O rings to fittings on wheel motor Use labels placed during the removal pro cess to properly install hydraulic lines to wheel motor fit tings see Hydraulic Hose and Tube Installation in the General Information section of this chapter 9 Secure brake cable clevis to brake actuator lever with clevis pin and brake return spring Make sure that return spring is attached to cap screw on spring bracket Hydraulic System Page 4 78 10 Install front wheel to machine see Front Wheel Installation in the Service and Repairs section of Chap ter 6 Chassis 11 Lower machine to ground 12 Torque lug nuts
178. he parking brake lowerthe cutting decks and stop the en gine Remove the key from the ignition switch 2 Remove fasteners that secure shroud to front of ma chine Fig 98 Remove shroud from machine to allow access to steering control valve Locate and retrieve two 2 rubber bushings and spacers 3 Slide rubber bellows up from bottom of steering col umn Support steering column to prevent it from falling Hydraulic System Page 4 108 4 Loosen and remove four 4 screws and flange nuts thatsecure steering column brace item 13 to machine Remove brace 5 Read the General Precautions for Removing and Installing Hydraulic System Components at the begin ning of the Service and Repairs section of this chapter 6 Label all hydraulic connections for assembly pur poses Note port designations on steering control valve Fig 99 Thoroughly clean hydraulic connections prior to loosening hydraulic lines Groundsmaster 4300 D Before opening hydraulic system operate all hy draulic controls to relieve system pressure and avoid injury from pressurized hydraulic oil See Relieving Hydraulic System Pressure in the Gen eral Information section of this chapter 7 Disconnect hydraulic lines from steering control valve Allow lines to drain into a suitable container 8 Putcaps or plugs on disconnected lines and fittings to prevent contamination 9 Loosen and remove remaining two 2 socket head screws and flange nuts
179. he fitting at the traction unit Leave the case drain hose from the motor open and place open end of disconnected hose into a drain pan IMPORTANT Make sure that the oil flow indicator arrow on the flow gauge is showing thatthe oil will flow from the deck motor through the tester and into the return hose 6 On deck motor to be tested thoroughly clean junc tion of hydraulic return hose and deck motor fitting Fig 50 Disconnectreturn hose fromthe motor Installtester with pressure gauges and flow meter in series with the motor and disconnected return hose Make sure the flow control valve on tester is fully open NOTE Use a graduated container special tool TOR4077 to measure case drain leakage Fig 49 7 Startengine and run atidle speed Check for any hy draulic leakage from test connections and correct be fore proceeding with test Cutting deck blades will rotate when performing the motorefficiency test Keep away from cutting decks during testto preventpersonal injury from rotating blades Do not stand in front of the ma chine 8 Sit on seat and move throttle to full speed 3200 RPM Press PTO switch to ON Move joystick lever for ward to engage cutting decks Groundsmaster 4300 D Page 4 49 9 While watching pressure gauges slowly close flow control valve on tester until a pressure of 1200 PSI 83 bar is obtained 10 After achieving 1200 PSI 83 bar place discon nected motor case drain hose in
180. heel hub to motor shaft 8 Install brake drum 9 Position brake cable end to brake actuator lever S e cure cable to actuator lever with clevis pin and return spring 10 Install front wheel assembly see Wheel Installation in this section 11 Check and adjust brakes 12 Lower machine to ground 13 Torque lug nuts evenly in a crossing pattern from 70 to 90 ft Ib 95 to 122 N m Torque lock nut item 17 that secures wheel hub from 315 to 385 ft Ib 427 to 521 N m After servicing the brakes always check the brakes in a wide open level area that is free of other persons and obstructions 1 Backing plate 8 Hold down cup 2 Rivet 4 used 9 Upper shoe spring 3 Clevis pin 10 Brake actuator 4 Retaining ring 11 Actuator lever 5 Brake shoe 12 Back up plate 6 Lower shoe spring 13 Boot 7 Hold down spring 14 Hold down pin Chassis A m i o Rear Axle Motor Housings OONO URUN E Lug nut 5 used per wheel Rear axle Motor housing 2 used RH drag link Tie rod O ring Hydraulic fitting 2 used per motor O ring Slotted hex nut 10 Jam nut 11 12 13 Grease fitting Spindle cap Retaining ring Chassis 315 to 385 ft Ib 427 to 521 N m Figure 8 Flange head screw 3 used per link Wheel hub Lock nut Wheel motor LH shown Lock washer 4 used per motor Cap screw 4 used per motor Cotter pin Steering cylinder Ball joint Ball joint R
181. hine Always chock or block wheels Use jack stands or appropriate load holding de vices to support the raised machine If the machine is not properly supported the machine may move or fall which may result in personal injury see J acking Instruc tions in this section 16 If major repairs are ever needed or assistance is de sired contact an Authorized Toro Distributor 17 When welding on machine disconnect all battery cables to prevent damage to machine electronic equip ment Disconnect negative battery cable first and posi tive cable last Also disconnect the wire harness connector from the machine controller and disconnect the terminal connector from the alternator Attach weld er ground cable no more than two 2 feet 0 61 meters from the welding location 18 At the time of manufacture your Groundsmaster conformed to the safety standards for riding mowers To assure optimum performance and continued safety cer tification ofthe machine use genuine Toro replacement parts and accessories Replacement parts and acces sories made by other manufacturers may result in non conformance with the safety standards and the warranty may be voided Groundsmaster 4300 D J acking Instructions When changing attachments tires or perform ing other service use correct supports hoists and jacks Make sure machine is parked on a solid level surface such as a concrete floor Prior to raising machine remove any attach ments tha
182. housing shaftinto the axle tube Slide the motor housing out of the axle tube Locate and retrieve thrust washer item 29 from motor housing shaft 10 If necessary remove drag link from motor housing 11 Thoroughly clean the motor housing shaft Inspect the shaft for wear and replace motor housing if shaft is worn or damaged 12 Thoroughly clean the rear axle bore and inspect the flange bushings in rear axle for wear or damage If bush ings need replacement A Usea bushing removal tool to extract both flange bushings from the axle tube Take care to not dam age the bore of the axle tube B Clean the inside of the axle tube to remove any dirt or foreign material Groundsmaster 4300 D Page 6 11 C Apply grease to the inside and outside of the new flange bushings D Press new flange bushings into the top and bot tom of the axle tube until bushing flange bottoms on tube E After bushing installation make sure that motor housing shaftslides easily into bushings If binding is noted locate and correct source of binding Installation Fig 8 1 If removed secure drag link to motor housing 2 Apply a light coating of grease to motor housing shaft 3 Install thrust washer item 29 onto the motor hou sing shaft and slide the shaft up through the axle tube Hold the motor housing in place and install the retaining ring item 13 onto the end of the spindle shaft 4 Place the spindle cap to the top of the m
183. i l YIANITAD to SNIu331S po A Sn i T 3ATVA TOYLNOD SNIu3als EE 9 QIOdINVIA ny XVulSSOu D FORWARD 3ATVA SSVdA8 831N3 NOUS D Groundsmaster 4300 Figure 11 12 Page 4 Hydraulic System Mow Circuit A four section gear pump is coupled to the piston trac tion pump Gear pump sections P 1 and P2 supply hydraulic flow for the mow circuit These gear pumps take their suction from the hydraulic reservoir The deck control manifold contains two 2 independent control circuits forthe frontand rear cutting decks Each circuit is supplied by its own pump section Pump sec tion P1 supplies hydraulic power to the rear cutting decks with circuit control by proportional relief valve PRV1 relief valve RV1 and logic cartridge LC1 in the deck control manifold Pump section P 2 supplies the frontcutting decks with circuitcontrol by proportional relief valve P RV2 relief valve RV2 and logic cartridge LC2 in the deck
184. ical sparkaway from the battery Do notsmoke Nausea may result if the gases are inhaled Un plug the charger from the electrical outlet before connecting or disconnecting the charger leads from the battery posts 3 Following the battery charger manufacturer s instructions connectthe charger cables to the battery Make sure a good connection is made 4 Charge the battery following the battery charger manufacturer s instructions 5 Occasionally check the temperature of the battery electrolyte If the temperature exceeds 125 F 52 C or the electrolyte is violently gassing or spewing the charging rate must be lowered or temporarily stopped 6 Three 3 hours priorto the end ofthe charging mea sure the specific gravity of a battery cell once per hour 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 three 3 consecu tive readings Electrical System E b System Hydraulic Solenoid Valve Coil A hydraulic solenoid valve coil on the deck control man ifold Fig 58 or lift control manifold Fig 59 can be re placed without opening the hydraulic system Removal 1 Park machine on a level surface lower cutting decks stop engine and engage parking brake Remove key from ignition switch 2 Locate the solenoid valve coil thatis to be replaced A Tilt operator seat up to gain access to hydraulic deck contro
185. ifies the Controller Area Network that is used on the Groundsmaster Two 2 specially designed twisted cables form the bus These wires provide the data pathways between machine components The en gineering term for these two 2 cables are CAN high and CAN low At the ends of the twisted pair of bus cables are 120 ohm termination resistors Electrical Drawings The electrical schematic and wire harness drawings for Groundsmaster 4300 D machines are located in Chap ter 8 Foldout Drawings Groundsmaster 4300 D Page 5 3 IMPORTANT Before performing any welding on the machine disconnect both positive and negative battery cables from the battery disconnectthe wire harness connector from the TEC controller and dis connectthe terminal connector from the alternator This will prevent damage to the electrical system of your Groundsmaster Each ofthe components that is controlled by the CAN bus link only needs four 4 wires to operate and commu nicate to the system CAN high CAN low B power and ground IMPORTANT The termination resistors at the ends of the bus cables are required for proper electrical system operation Electrical System E F System Special Tools Order Special Tools from your Toro Distributor Some tools may be available locally Multimeter The multimeter can test electrical components and cir cuits for current resistance or voltage Obtain this tool locally NOTE Toro recommen
186. ift circuit and elimi nates the risk of the cutting decks unexpectedly lower ing to the ground 7 Do notpark on slopes unless wheels are chocked or blocked Safety Maintenance and Service 1 Before servicing or making adjustments lower cut ting decks stop engine apply parking brake and re move key from the ignition switch 2 Make sure machine is in safe operating condition by keeping all nuts bolts and screws tight 3 Never store the machine or fuel container inside where there is an open flame such as neara water heat er or furnace 4 Make sure all hydraulic line connectors are tight and all hydraulic hoses and lines are in good condition be fore applying pressure to the hydraulic system 5 Keep body and hands away from pin hole leaks in hy draulic lines that eject high pressure hydraulic fluid Use cardboard or paper to find hydraulic leaks Hydraulic fluid escaping under pressure can penetrate skin and cause injury Fluid accidentally injected into the skin mustbe surgically removed within a few hours by a doc tor familiar with this form of injury or gangrene may re sult 6 Before disconnecting or performing any work on the hydraulic system all pressure in the system must be re lieved by using all of the hydraulic controls see R eliev ing Hydraulic Pressure in the General Information section of Chapter 4 Hydraulic System 7 Use care when checking or servicing the cutting decks Wear glove
187. ig 15 1 Park machine on a level surface lower cutting decks stop engine engage parking brake and remove key from the ignition switch 2 Disconnect negative battery cable from battery see Battery Service in the Service and Repairs section of Chapter 5 Electrical System 3 Disconnect seat switch electrical connector from wire harness Fig 16 4 Remove two 2 flange head screws and flatwashers thatsecure control arm assembly to seat base Figs 16 and 17 IMPORTANT Take care to not damage the throttle cable or electrical harness when removing seat and control arm assembly from machine 5 Carefully slide control arm assembly from seatbase Locate and retrieve two 2 bushings Fig 17 Position and support control arm assembly to allow seat remov al 6 Remove four 4 socket head screws and flat washers that secure seat and seat base to seat adjust ers 7 Support seat base to keep it positioned on seat ad justers 8 Remove operator seat from seat adjusters Installation Fig 15 1 Position seat and seat base to seat adjusters 2 Secure seatand seatbase to seatadjusters with four 4 flat washers and socket head screws IMPORTANT Take care to notdamage throttle cable orelectrical harness when installing control arm as sembly to machine 3 Make sure that two 2 bushings are positioned in control arm Carefully slide control arm assembly onto seat base post Secure control arm assembly to seat
188. in lb 145 20 in Ib Grade 5 3 8 16 UNC 35 10 ft lb 18 3 ft lb 108 14 N m Class 8 8 M12 X 1 5 80 10 ft lb 108 14 N m Class 8 8 For steel wheels and non lubricated fasteners Thread Cutting Screws Thread Cutting Screws Zinc Plated Steel Zinc Plated Steel T T 1 16 14 e No 6 32 UNC 20 5 in Ib 20 5i No 8 32 UNC 30 5 in Ib EO 30 5 in Ib um Las oer No 10 24 UNC 38 7 in Ib 1 4 20 UNC 85 15 in Ib 5 16 18 UNC 110 20 in Ib Hole size material strength materialthickness and fin ish must be considered when determining specific 3 8 16 UNC 200 100 in lb torque values All torque values are based on non lubri cated fasteners 8 5 85 15 in Ib Conversion Factors in Ib X 11 2985 2 N cm N cm X 0 08851 in Ib ft lb X 1 3558 N m N m X 0 7376 ft Ib Product Records and Maintenance Page2 6 Groundsmaster 4300 D Table of Contents GENERAL INFORMATION 1 Operator s Manual 1 Stopping the Engine 1 SPECIFICATIONS ssseeeesneeee 2 ADJUSTMENTS dur vtero s 3 Adjust Throttle Control 3 General Information This Chapter gives information about specifications troubleshooting testing and repair of the Kubota diesel engine used in the Groundsmaster 4300 D Most repairs and adjustments require tools which are commonly available in many service shops The use of
189. ing B Face of wear plates that are in contact with gears should be free of wear roughness or scoring C Thickness of wear plates should be equal 5 Inspect front flange and rear cover for damage or wear Figure 88 1 Dustseal 3 Flange washer 2 Retaining ring 4 Shaft seal Figure 89 3 Gear teeth 4 Gear face edge 1 Gear shaft spline 2 Gear shaft Hydraulic System Assembly Fig 86 NOTE When assembling the motor check the marker line on each part to make sure the parts are properly aligned during assembly 1 Lubricate O rings pressure seals back up gaskets and wear plate grooves with a thin coat of petroleum jel ly Lubricate all other internal parts freely with clean hy draulic oil 2 Install new seals into front flange Fig 88 A Press shaft seal into front flange until it reaches the bottom of the bore B Install flange washer into front flange and then install retaining ring into the groove of the front flange C Install new dust seals into front flange Inner dust seal should have the seal lip and spring toward the installed retaining ring The outer dust seal should have the seal lip and spring toward the outside of the motor 3 Place front flange seal side down on a flat surface 4 Install the pressure seals flat side outward into the grooves in the wear plates Follow by carefully placing
190. ion neutral switch use the Diagnostic Display see Special Tools in this chap ter to verify thattraction neutral switch and circuit wiring are functioning correctly see Traction Neutral S witch in the Component Testing section of this chapter 0 070 to 0 100 1 8 to 2 5 mm Figure 15 1 Traction pump 3 Traction neutral switch 2 Traction lever bracket Groundsmaster 4300 D Page 5 19 Electrical System Parking Brake Switch The parking brake switch is a normally open proximity switch The parking brake switch is attached to the bot tom of the brake pedal Fig 16 When the parking brake is notapplied the parking brake detent is positioned near the target end of the parking brake switch so the switch is closed The parking brake detentis moved away from the switch when the parking brake is applied causing the switch to open Adjustment 1 When the parking brake is not applied the gap be tween the parking brake switch and the tab on the park ing brake detent should be from 0 070 to 0 100 1 8 to 2 5 mm 2 If gap is incorrect loosen jam nuts that secures switch to brake lever P osition switch with jam nuts to al low correct gap between switch and detenttab Tighten jam nuts to secure adjustment J am nuts should be torqued from 162 to 198 in Ib 18 4 to 22 4 N m After jam nuts are tightened make s
191. ions Be careful to not drop parts or disengage gear mesh Groundsmaster 4300 D IMPORTANT Mark the relative positions of the gear teeth and the thrust plates so they can be reassem bled in the same position Do nottouch the gear sur faces as residue on hands may be corrosive to gear finish 7 Remove the thrust plates and seals from each pump section Before removing each gear set apply marking dye to mating teeth to retain timing Pump efficiency may be affected ifthe teeth are notinstalled in the same position during assembly Keep the parts for each pump section together do not mix parts between sections 8 Clean all parts Check all components for burrs scoring nicks and other damage 9 Replace the entire pump assembly if parts are ex cessively worn or scored Disassembly Fig 72 Figure 73 1 Apply clean hydraulic oil to all parts before assem bling NOTE Pressure seals and back up rings fitin grooves machined into thrust plates Body seals fit in grooves machined in body faces 2 Assemble pump sections starting atfront cover end Apply grease or petroleum jelly to new section seals to hold them in position during gear pump assembly 3 Afterpump has been assembled tighten cap screws and nuts by hand Rotate the drive shaft to check for binding P rotect the shaft if using a pliers 4 Tighten the cap screws and nuts evenly in a crossing pattern to a torque of 33 ft Ib 45 N m Groundsmaster
192. iring is faulty pull released from the START position coil operates but hold coil is faulty Engine cranks but does not start Engine and or fuel may be too cold Fuel tank is empty Glow plugs or circuit wiring are faulty Engine fuel stop solenoid or circuit wiring is faulty Engine or fuel system is malfunctioning see Chapter 3 Kubota Diesel Engine Hydraulic load is slowing engine cranking speed disconnect hydraulic pump drive shaft from engine to test Electrical System Page 5 12 Groundsmaster 4300 D Starting Problems Continued Engine cranks but should not when the traction pedal is depressed Nothing happens when start attempt is made Control panel lights and gauges operate with the ignition switch in RUN Groundsmaster 4300 D Page 5 13 Possible Causes Traction neutral switch is out of adjustment Traction neutral switch or circuit wiring is faulty Traction pedal is not in neutral position Operator seat is unoccupied OR the parking brake is not applied Cutting decks are engaged PTO switch is ON Traction neutral switch is out of adjustment Traction neutral switch or circuit wiring is faulty Seat switch or circuit wiring is faulty Parking brake switch or circuit wiring is faulty J oystick switch raise or lower position is faulty Ignition switch or circuit wiring is faulty Start relay or circuit wiring is faulty Main power relay or circuit wiring is faulty headligh
193. is showing that the oil will flow from the pump through the tester and into the disconnected hydraulic hose 9 Install tester with pressure gauges and flow meter in series with the traction pump and the disconnected hose Make sure the tester flow control valve is fully open 10 Start engine and move throttle to full speed 3200 RPM Use extreme caution when performing test The front tires on the ground will be trying to move the machine forward 11 Slowly push traction pedal in forward direction until 1000 PSI 70 bar is displayed on the tester pressure gauge Make sure that front wheels are not rotating 12 Total front wheel motor internal leakage will be shown on flow meter in GPM LPM Leakage for the front wheel motors should be less than 1 5 GPM 5 7 LPM 13 Release traction pedal shut engine off rotate both front wheels one third turn and retest Testing of wheel motor leakage in three 3 different wheel positions will provide the mostaccurate testresults If leakage specifi cations are not met individual front wheel motors need to be tested Groundsmaster 4300 D Page 4 41 14 To test individual front wheel motors A Remove front wheel from wheel motor thatis not being tested Remove wheel shield to allow access to hydraulic tubes and fittings on wheel motor Re move fasteners that secure front hydraulic tube r clamps to frame B On the front wheel motor that is not being tested thoroughly
194. isassembly Fig 5 1 Remove blade spindle from cutting deck see Blade Spindle Removal in this section 2 Loosen and remove spindle nut from top of spindle 130 to 160 ft lb shaft 177 to 216 N m 3 Remove the spindle shaft from the spindle housing which may require the use ofan arbor press The spindle shaft spacer should remain on the spindle shaft as the shaftis being removed 4 Carefully remove oil seals from spindle housing not ing direction of seal lips 5 Allow the bearing cones inner bearing spacer and spacer ring to drop out of the spindle housing 6 Using an arbor press remove both of the bearing cups and the outer bearing spacer from the housing 7 The large snap ring can remain inside the spindle housing Removal of this snap ring is very difficult Assembly Fig 5 Figure 5 NOTE A replacementspindle bearing set contains two Spindle aaa s cana 2 used 2 bearings a spacer ring and a large snap ring items 3 Spindle shaft 9 Spacer ring 1 2 and 3 in Fig 6 These parts cannot be purchased 4 Oil seal 10 Spacer set 2 piece separately Do not mix bearing set components from z Spo nt 5 dedi P js one deck spindle to another NOTE A replacement bearing spacer set includes the inner spacer and outer spacer items 4 and 5 in Fig 6 Do not mix bearing spacers from one deck spindle to another IMPORTANT If new bearings are installed into a used spindle housing itmay notbe ne
195. ission Drive Shaft Re moval in the Service and Repairs section of Chapter 4 Hydraulic S ystem Support drive shaftaway from en gine 10 Disconnect wire harness connectors from the follow ing engine components NOTE Before disconnecting wire harness connectors label all electrical leads for assembly purposes A Alternator connector and stud B Oil pressure switch located nearthe engine oil fil ter C Connector fusible link connector and positive battery cable from the starter motor D High temperature shut down switch and temper ature sender located on the water pump housing E Fuel stop solenoid on injector pump F Negative battery cable and wire harness ground from injector pump Fig 12 G Glow plug strip 11 Remove engine from machine A Attach shortsection of chain between lift tabs lo cated on each end of the cylinder head B Connect a hoist or lift at the center of the short section of chain Apply enough tension on the short chain so that the engine will be supported C Remove fasteners that secure the engine with brackets to the engine mounts One person should operate hoist or lift while a second person guides the engine out of the ma chine IMPORTANT Make sure to not damage the en gine fuel hoses hydraulic lines electrical har ness radiator battery or other parts while removing the engine D Raise engine and remove toward front of ma chine 12 If necessary rem
196. itch use the Diagnostic Display see Special Tools in this chap ter to verify that mow transport switch and circuit wiring are functioning correctly see Mow Transport S witch in the Component Testing section of this chapter Groundsmaster 4300 D Page 5 21 1 Mow speed limiter 2 Mow transport switch 3 Gap Electrical System E u System Component Testing For accurate resistance and or continuity checks elec trically disconnect the component being tested from the circuit e g unplug the ignition switch connector before doing a continuity check of the switch NOTE Electrical troubleshooting of any 12 volt power connection can be performed through voltage drop tests without disconnecting the component NOTE Use the Diagnostic Display see Special Tools in this chapter to test TEC controller inputs and outputs before further troubleshooting of an electrical problem on your Groundsmaster Ignition Switch The ignition key switch has three positions OFF RUN and START The switch is mounted on the control con sole Testing 1 Before disconnecting the ignition switch for testing the switch and its circuit wiring should be tested as a TEC controller input with the Diagnostic Display see Diagnostic Display in the Troubleshooting section of this chapter If the Diagnostic Display verifies that ignition switch and circuitwiring are functioning correctly no fur ther switch testing is nec
197. ition the engine will run for approxi mately ten 10 seconds before the engine shuts down again The TEC controller monitors the operation of the high temperature shutdown switch The switch and its circuit wiring should be tested as a controller input with the Diagnostic Display see Special Tools and Trouble shooting in this chapter If excessive coolant temperature caused the TEC con troller to shut down the engine the Diagnostic light can be used to identify the fault see Diagnostic Light in the Troubleshooting section of this chapter Testing 1 Park machine on a level surface lower cutting decks stop engine apply parking brake and remove key from ignition switch Open and supporthood to gain access to engine Make sure engine is cool before removing the temperature switch from engine 2 Lower the coolantlevel in the engine and remove the high temperature shutdown switch from the engine 3 Putthe end of the switch in a container of oil with a thermometer and slowly heat the oil Fig 51 Handle the hot oil with extreme care to prevent personal injury or fire 4 Check resistance of the switch with a multimeter ohms setting as the oil temperature increases The high temperature shutdown switch is normally open and should close from 234 to 244 F 112 to 118 C Electrical System Page 5 40 5 Replace shutdown switch if specifications are not met 6 After testing is complete insta
198. joystick and PTO switch in the OFF position The front cutting decks do not operate Rear cutting decks operate Cutting decks are able to raise and lower Groundsmaster 4300 D Page 5 15 Possible Causes Seat switch or circuit wiring is faulty TEC controller is faulty A hydraulic problem in cutting deck circuit exists see Troubleshooting section of Chapter 4 Hydraulic System TEC controller is faulty PTO switch or circuit wiring is faulty A hydraulic problem in cutting deck circuit exists see Troubleshooting section of Chapter 4 Hydraulic System TEC controller is faulty PTO switch is in the OFF position High coolant temperature has disabled cutting decks Seat switch or circuit wiring is faulty PTO switch or circuit wiring is faulty Mow transport switch or circuit wiring is faulty Electrical System Temperature sender or circuit wiring is faulty Circuit wiring to deck control manifold solenoids may be faulty A hydraulic problem in cutting deck circuit exists See Troubleshooting section of Chapter 4 Hydraulic System TEC controller is faulty The PTO switch or circuit wiring is faulty TEC controller is faulty Deck control manifold PRV2 solenoid coil or circuit wiring is faulty A hydraulic problem in front mow circuit exists see Troubleshooting section of Chapter 4 Hydraulic System TEC controller is faulty Electrical System Cutting Deck Operating Problems Con
199. k switches for test ing the switches and their circuit wiring should be tested as TEC controller inputs with the Diagnostic Display see Diagnostic Display in the Troubleshooting section ofthis chapter Ifthe Diagnostic Display verifies thatthe joystick switches and circuit wiring are functioning cor rectly no further switch testing is necessary If however the Diagnostic Display determines that either joystick switch and circuit wiring are not functioning correctly proceed with test procedure 2 Remove control arm covers to gain access to joys tick switches see Control Arm Disassembly in the Ser vice and Repairs section of Chapter 6 Chassis 3 Make sure ignition switch is in the OFF position 4 Disconnect wire harness electrical connector from the raise or lower switch that is to be tested Fig 29 5 Connecta multimeter ohms setting across the nor mally open NO and common terminals of the switch Fig 30 6 With the joystick in the neutral center position there should be no continuity open across the switch terminals 7 Move and hold the joystick to activate the switch be ing tested There should be continuity closed across the switch terminals Electrical System Page 5 28 8 If joystick switch is faulty replace switch 9 Ifthe joystick switch tests correctly and a circuitprob lem still exists check wire harness see Electrical S che matic and Circuit Drawings in Chapter 8 Foldou
200. king brake and remove key from the ignition switch 2 Raise and support the hood Do not open radiator cap or drain coolant if the radiator or engine is hot Pressurized hot cool ant can escape and cause burns Ethylene glycol antifreeze is poisonous Dis pose of coolant properly orstore itin a properly labeled container away from children and pets 3 Drain coolant from radiator A Slowly remove radiator cap from the radiator B Place drain pan below the radiator draincock lo cated on the bottom of the radiator Make sure that drain pan is large enough to hold cooling system con tents 10 U S quarts 9 5 liters C Loosen radiator draincock threaded in and al low coolant to drain from radiator 4 Remove screen from machine 5 Disconnect radiator hoses upper and lower from the radiator 6 Loosen hose clamp and remove overflow hose from radiator fill opening 7 Remove two 2 flange head screws and flange nuts that secure coolant reservoir and brackets to fan shroud Carefully position reservoir and brackets away from the fan shroud 8 Remove five 5 flange head screws and flange nuts that secure air intake screen item 37 to machine Re move screen and foam seal item 42 Locate and re trieve five 5 spacers item 43 9 Remove flange head screws and flange nuts that se cure fan shroud and radiator to radiator frame Position fan shroud away from the radiator Groundsmaster 4300 D
201. l i 8 8 E Specifications Item Description Make Designation Kubota V1505 T E3B 4 stroke Liquid Cooled OHV Turbocharged Diesel Number of Cylinders Bore x Stroke 3 07 in x 3 09 in 78 mm x 78 4 mm Total Displacement 91 4 in3 1498 cc Compression Ratio 23 1 Firing Order 1 fan end 3 4 flywheel end 2 Fue No 2 D Diesel Fuel ASTM D975 Fuel Injection Pump Bosch MD Type Mini Fuel Injector Nozzle Mini Nozzle DNOPD Fuel Tank Capacity 14 U S gallons 53 liters Governor Centrifugal Mechanical Low Idle S peed no load 1250 to 1350 RPM High Idle S peed no load 3050 to 3250 RPM Engine Oil API Classification Cl 4 or Higher see Operator s Manual for viscosity recommendations Oil Pump Gear Driven Trochoid Type Crankcase Oil Capacity 5 5 U S quarts 5 2 liters with F ilter Cooling System Capacity including reserve tank 10 U S quarts 9 5 liters Starter 12VDC 1 2 KW Alternator R egulator 12 VDC 40 Amp Engine Dry Weight approximate 251 Ibs 114 kg Kubota Diesel Engine Page 3 2 Groundsmaster 4300 D Adjustments Adjust Throttle Control Proper throttle operation is dependent upon proper ad justment of throttle control NOTE The throttle cable swivel should be positioned in the lowest hole in the speed control lever 1 Move
202. l manifold Fig 91 The lift manifold uses two 2 dif ferent orifice sizes If fittings are removed from man ifold and an orifice is in the manifold port make sure to remove orifice and label its position for assembly purposes 10 If necessary remove hydraulic fittings from manifold Fig 91 Discard any removed O rings Locate re trieve and label orifice from manifold port if equipped Installation Fig 90 1 If fittings were removed from manifold Fig 91 A Lubricate new O rings with clean hydraulic oil Install lubricated O rings on fittings IMPORTANT When installing orifice in manifold make sure that orifice is flat in the base of the fit ting cavity Manifold damage is possible if the orifice is cocked in the cavity B For manifold ports with orifice place correct ori fice in port with the orifice slot facing out C Install fittings into manifold Torque fittings to torque values identified in Figure 91 Groundsmaster 4300 D Page 4 101 2 Position lift control manifold to frame Install two 2 flange head screws but do not fully tighten 3 Remove caps and plugs from disconnected lines and fittings 4 Lubricate and install new O ring s on manifold fit tings Connect hydraulic lines to hydraulic manifold fit tings and properly tighten all connections see Hydraulic Hose and Tube Installation in the General Information section of this chapter 5 Secure hydraulic manifold to fram
203. l Hydraulic System Problems The charts that follow contain information to assist in troubleshooting There may possibly be more than one cause for a machine malfunction Review the hydraulic schematic and information on hy draulic system operation in the Hydraulic Flow Dia grams section of this chapter This information will be useful during the hydraulic troubleshooting process Refer to the Testing section of this chapter for precau tions and specific hydraulic test procedures Hydraulic oil leaks from machine Fitting s hose s or tube s is are loose or damaged O ring s or seal s is are missing or damaged Foaming hydraulic fluid Oil level in hydraulic reservoir is low Hydraulic system has wrong kind of oil Pump suction line has an air leak Hydraulic system operates hot Traction system pressure is high due to excessive load or brake dragging or binding Oil level in hydraulic reservoir is low Hydraulic oil is contaminated or too light Engine speed is too low Fan speed is low dues to a loose or damaged belt Oil cooler is damaged or plugged Air flow through oil cooler is obstructed Oil filter is plugged Piston traction pump bypass valve is loosened or is damaged Charge pressure is low Piston traction pump check valve is not seating or is damaged Wheel motor s and or piston traction pump are worn or damaged NOTE If a traction circuit component has internal wear or
204. l end should be attached to the machine frame 3 Slide barrel end of lift cylinder onto pivot shaft Se cure cylinder with flange head screw item 3 and flat washer item 5 Torque screw from 67 to 83 ft Ib 91 to 112 N m Groundsmaster 4300 D Page 4 105 4 Align lift cylinderto liftarm mounting holes Slide cyl inderslide pin item 13 with thrustwasher item 12 and retaining ring item 11 installed on one end through the lift cylinder and lift arm Install second thrust washer on pin and secure with retaining ring item 11 5 Remove caps and plugs from disconnected hoses and fittings 6 Coat new fitting O rings lightly with clean hydraulic oil install new O rings and connect hydraulic hoses to fittings on lift cylinder Tighten hose connections see Hydraulic Hose and Tube Installation in the General In formation section of this chapter 7 Ifliftcylinderfor deck 4 or 5 was removed secure r clampto liftcylinder with flange nutand carriage screw Fig 95 8 Check oil level in hydraulic reservoir and add correct oil if necessary 9 Lubricate lift cylinder grease fittings 10 Follow Hydraulic System Start up procedures see Hydraulic System Start up in this section pd de o CO Figure 95 1 Liftcylinder 4 shown 2 Carriage screw 3 R clamp 4 Flange nut Hydraulic System Lift Cylinder Service 4 a
205. l hydraulic controls to relieve system pres sure before loosening any hydraulic connection see Relieving Hydraulic S ystem Pressure in the General In formation section 4 Putcaps orplugs on any hydraulic lines hydraulic fit tings or components left open or exposed to prevent contamination 5 Before disconnecting hydraulic lines and hoses place labels to ensure proper installation after repairs are completed 6 Note the position of hydraulic fittings especially el bow fittings on hydraulic components before removal Mark parts if necessary to make sure that fittings will be aligned properly when reinstalling hydraulic hoses and tubes Hydraulic System Page 4 60 After Repair or Replacement of Components 1 If a component failure occurred in the closed loop traction circuit e g piston pump or wheel motor filter ing the traction circuit is recommended see Filtering Closed Loop Traction Circuit in this section 2 If component failure is severe or hydraulic system is contaminated flush hydraulic system see Flush Hy draulic S ystem in this section 3 Lubricate O rings and seals with clean hydraulic oil before installing hydraulic components 4 Make sure all caps or plugs are removed from hy draulic tubes hydraulic fittings and components before reconnecting 5 Use proper tightening methods when installing hy draulic hoses and fittings see Hydraulic Fitting Installa tion in the General Inform
206. l manifold R efer to Figure 58 forsolenoid coil locations on the deck control manifold B The lift control manifold is attached to a frame bracket under the operator floor plate Access to the lift control manifold can be obtained by removing the floor plate R efer to Figure 59 for solenoid coil loca tions on the lift control manifold 3 Disconnect the wire harness electrical connector from the solenoid valve coil to be replaced 4 Remove the nut from the hydraulic valve 5 Slide the solenoid coil from the valve 6 Clean any corrosion or dirt from the valve Installation 1 Slide new coil assembly onto the hydraulic valve 2 Install the nutonto the valve and torque nut from 48 to 60 in Ib 5 4 to 6 7 N m do not over tighten 3 Connectthe machine wire harness connector to the solenoid coil 4 Lower and secure seat if deck control manifold was accessed Install operator floor plate if lift control man ifold was accessed 48 to 60 in Ib 5 4 to 6 7 N m Figure 58 1 Deck control manifold 3 Solenoid coil PRV1 2 Solenoid coil PRV2 4 Nut 1 Lift control manifold 2 Solenoid coil PRV 3 Nut Electrical System Page 5 48 48 to 60 in Ib 5 lt 5 4 to 6 7 N m Y Figure 59 4 Solenoid coil S2 5 Nut 6 Solenoid coil S1 Groundsmaster 4300 D Chapter 6 TORO Chassis Table of Contents SPECIFICATIONS p ree exe 2 GENERAL INFORMATION 2 Operator
207. l switch is out of adjustment Traction neutral switch or circuit wiring is faulty TEC controller is faulty Parking brake is engaged Operator is raising from the seat seat switch not fully depressed Seat switch or circuit wiring is faulty Ignition switch or circuit wiring is faulty Parking brake is engaged Operator is not fully depressing the seat switch Seat switch or circuit wiring is faulty TEC controller fuses are faulty TEC controller is faulty Wiring to charging circuit components is loose corroded or damaged see Electrical Schematic and Circuit Drawings in Chapter 8 Foldout Drawings Alternator belt is loose or damaged Battery cables are loose or corroded Fusible link harness atthe engine starter motor is faulty Alternator is faulty Battery is faulty Groundsmaster 4300 D Cutting Deck Operating Problems The cutting decks remain engaged but should not with no operator in the seat Cutting decks run but should not when raised Cutting decks shut off with PTO switch Cutting decks run but should not when raised Cutting decks do not shut off with PTO switch None of the cutting decks operate Cutting decks are able to raise and lower NOTE For cutting deck operation operator seat needs to be occupied mow speed limiter needs to be in mow position decks need to be fully lowered and PTO switch needs to be engaged Cutting decks run but should not when lowered with
208. lates in the gear pump can wear A worn pump will by pass oil and make the pump less efficient Eventually enough oil can by pass to cause the decks to stall in heavy cutting con ditions Continued operation with a worn inefficient pump can generate excessive heatand cause damage to seals and other components in the hydraulic system Hydraulic System Page 4 46 Procedure for Gear Pump P1 and P2 Flow Test 1 Make sure hydraulic oil is at normal operating tem perature by operating the machine under load for approximately ten 10 minutes 2 Park machine on a level surface with the cutting decks lowered and PTO switch off Make sure engine is off Apply the parking brake Groundsmaster 4300 D 3 Read Precautions For Hydraulic Testing in this sec tion Before opening hydraulic system operate all hy draulic controls to relieve system pressure and avoid injury from pressurized hydraulic oil See Relieving Hydraulic System Pressure in the Gen eral Information section of this chapter 4 Raise and support operator seat to allow access to hydraulic pump 5 Identify suspected faulty pump section to be tested Fig 48 Thoroughly clean junction of gear pump fitting and hydraulic outlet hose Disconnect hose from pump fitting Pump section P 1 for rear cutting decks Pump section P 2 for front cutting decks IMPORTANT Make sure that the oil flow indicator arrow on the flow gauge is showing that the oil will
209. lay Remove relay from machine for easier testing NOTE Priorto taking small resistance readings with a digital multimeter short the meter test leads together The meter will display a small resistance value usually 0 5 ohms or less This resistance is due to the internal resistance ofthe meter and test leads Subtract this val ue from the measured value of the component you are testing 4 Using a multimeter ohms setting measure coil re sistance between terminals 85 and 86 Fig 35 Resist ance should be between 70 and 90 ohms 5 Connectmultimeter ohms setting leads to relay ter minals 30 and 87 Ground terminal 86 and apply 12 VDC to terminal 85 The relay terminals 30 and 87 should have continuity as 12 VDC is applied to terminal 85 The relay terminals 30 and 87 should nothave conti nuity as 12 VDC is removed from terminal 85 Electrical System Page 5 32 6 Disconnect voltage from terminal 85 and multimeter lead from terminal 87 7 Connectmultimeter ohms setting leads to relay ter minals 30 and 87A With terminal 86 grounded apply 12 VDC to terminal 85 The relay terminals 30 and 87A should nothave continuity as 12 VDC is applied to ter minal 85 The relay terminals 30 and 87A should have continuity as 12 VDC is removed from terminal 85 8 When testing is completed disconnect voltage and multimeter leads from the relay terminals Replace relay if necessary 9 Secure relay to machine and c
210. ler using a press C Discard bearings after removal 5 Inspect roller housing and bearing spacer for dam age or wear Replace components as needed Assembly Fig 17 1 Install new bearings and bearing spacer into front roller A Press first bearing into roller Press on outer race only or equally on inner and outer races B Insert bearing spacer C Press second bearing into roller pressing equally oninnerand outer races until the inner race comes in contact with the bearing spacer 2 Install front roller assembly and spacer to deck frame 3 Insert mounting bolt and torque to 65 to 95 ft Ib 89 to 128 N m 1 Mounting bolt 2 Bearing 3 Bearing spacer Cutting Decks Page 7 16 65 to 95 ft lb 89 to 128 N m Figure 17 4 Frontroller 5 Spacer 6 Deck frame Groundsmaster 4300 D This page is intentionally blank Groundsmaster 4300 D Page 7 17 Cutting Decks Cutting Deck Carrier Frame Decks 2 and 3 Figure 18 1 Carrier frame 7 Cutting deck assembly 13 Grease fitting 2 Lynch pin 8 Cap screw 4 used per deck 14 Bushing 3 Thrust washer 9 Cap screw 2 used per deck 15 Flange nut 4 used per deck 4 Pivot shaft 10 Bushing 2 used per frame 16 Pivot bracket 2 used per deck 5 Lift arm 4 shown 11 Pin 2 used per deck 17 Flange nut 6 Flange nut 2 used per deck 12 Lift arm 2 shown 18 Bumper Cutting Decks Page 7 18 Groundsmaster 4300 D Removal Fig 18
211. ll shutdown switch to the engine housing A Clean threads of housing and switch thoroughly Apply a light coating of thread sealant to the threads of the switch B Thread switch into the housing Torque switch from 22 to 28 ft Ib 30 to 39 N m C Reconnect harness wire to switch 7 Fill engine cooling system see Radiator Installation intheService and Repairs section of Chapter3 Kubota Diesel Engine 8 Lower and secure hood Figure 50 1l High temperature shutdown switch Figure 51 Groundsmaster 4300 D Oil Pressure Switch The engine oil pressure switch is located on the engine near the oil filter Fig 52 The oil pressure switch is a normally closed switch that opens with pressure The oil pressure switch should open at approximately 8 PSI 0 56 kg cm The TEC controller monitors the operation of the oil pressure switch The switch and its circuitwiring should be tested as a controller input with the Diagnostic Dis play see Special Tools and Troubleshooting in this chapter Iflow engine oil pressure allowed the oil pressure switch to close during engine operation the Diagnostic light can be used to identify the fault see Diagnostic Light in the Troubleshooting section of this chapter Testing NOTE Referto Kubota Workshop Manual Diesel En gine 05 E3B Series at the end of Chapter 3 Kubota Diesel Engine for information regarding engine lubrica tion system and testing 1 Turn the
212. lock washers and spacers that secure CrossTrax AWD control manifold to frame Fig 10 Lower and support manifold taking care to not damage hydraulic tubes 8 Remove the jam nut item 10 and thrust washer item 9 that secure the axle pivot pin item 6 to the frame 9 Support rear axle to prevent it from falling 10 P ull the axle pivot pin from frame and rear axle This will release the rear axle and thrust washers item 7 from the frame 11 Carefully remove the rear axle from the machine Take care to not damage the CrossTrax AWD control manifold or attached hydraulic tubes during axle remov al Rear Axle Service 1 Thoroughly clean the rear axle pivot pin Inspect the pin for wear and replace pivot pin if worn or damaged 2 Thoroughly clean the rear axle pivot and inspect the bushings in rear axle for wear or damage If bushings need replacement A Usea bushing removal tool to extract both bush ings from the axle pivot Take care to notdamage the bore of the axle B Clean the inside of the axle pivot to remove any dirt or foreign material C Apply grease to the inside and outside of the new bushings Groundsmaster 4300 D Page 6 13 D Press new bushings into the axle pivot bore until bushing is flush with axle E After bushing installation make sure that pivot pin slides easily into bushings If binding is noted lo cate and correct source of binding Figure 10 1 AWD control ma
213. ly in the Service and Repairs section of Chapter 6 Chassis 450 eel as REAR VIEW FRONT VIEW Figure 18 Groundsmaster 4300 D Indicator Lights Glow Plug Indicator Light The glow plug indicator light should come on when the ignition switch is placed in the RUN position prior to plac ing the ignition switch in START The light should stay lit for approximately six 6 seconds while the ignition switch is left in the RUN position The indicator light should also be illuminated when the ignition switch is in the START position High Temperature Warning Light If the engine coolant temperature reaches 221 F 105 C approximate the high temperature warning light should come on NOTE When machine is in mow operation high cool ant temperature will cause the cutting decks to shut off in addition to warning light illumination Engine Oil Pressure Light The engine oil pressure light should come on when the ignition switch is in the RUN position with the engine not running Also it should illuminate with the engine run ning if the engine oil pressure drops to an unsafe level To testthe oil pressure lightand circuitwiring ground the wire attached to oil pressure switch located on the en gine near the oil filter Turn ignition switch to the RUN position the engine oil pressure light should come on in dicating c
214. m and affect quality of cut NOTE One way to find a faulty deck motor is to have another person observe the machine while mowing in dense turf A faulty motor will run slower than other mo tors produce fewer clippings and may cause clip marks a choppy appearance on the turf Hydraulic System Page 4 48 Procedure for Deck Motor Efficiency Test 1 Make sure hydraulic oil is at normal operating tem perature by operating the machine under load for approximately ten 10 minutes 2 Determine which deck motor is malfunctioning 3 Park machine on a level surface with the cutting decks lowered and PTO switch off Make sure engine is off and mow speed limiter is in the mow position Apply the parking brake 4 Read Precautions For Hydraulic Testing in this sec tion Groundsmaster 4300 D Before opening hydraulic system operate all hy draulic controls to relieve system pressure and avoid injury from pressurized hydraulic oil See Relieving Hydraulic System Pressure in the Gen eral Information section of this chapter NOTE The deck motors are connected in series To isolate a faulty motor all motors in the circuit may have to be tested by starting with the upstream motor first 5 For deck motor to be tested thoroughly clean junc tion ofthe motor case drain hose small diameter hose where it connects to traction unit bulkhead not at the motor Fig 50 Disconnectthe case drain hose and put a steel cap on t
215. m be tween seat suspension and seat frame 7 Remove seat suspension components as needed using Figures 18 and 19 as guides Installation Figs 18 and 19 A m i to o 1 Installallremoved seatsuspension components us ing Figures 18 and 19 as guides IMPORTANT Take care to not damage the throttle cable or electrical harness when installing seatsus pension to machine 2 Position seatbase cover and four 4 spacers Figure 19 item 7 to seat frame 3 Position seat suspension to seat frame and secure with four 4 flange head screws Figure 19 item 8 and flange nuts Figure 19 item 5 Use forward holes in seat brackets to mount suspension 4 Install seat to machine see Operator S eat Installa tion in this section Make sure to connect harness elec trical connector to the seat switch 5 Connect negative battery cable to battery see Bat tery Service in the Service and Repairs section of Chap ter 5 Electrical System Groundsmaster 4300 D Page 6 21 Chassis Front Lift Arms 75 to 95 ft lb 102 to 128 N m Permatex Threadlocker Permatex Threadlocker 75 to 95 ft lb 102 to 128 N m RIGHT FRONT Pd 1 lift arm Flange bushing 2 used per lift arm Roll pin 1 used per lift arm 4 lift arm 5 lift arm Flange nut 2 used RH tipper bracket 135 to 165 ft Ib 183 to 223 N m sq Oy t Pa t N ia Chassis Antiseize Lubricant Permatex 14 Threadlocker Permatex Th
216. m exists consider perform ing one or more of the following tests Traction Circuit Relief Valve R3 and R4 Pressure Traction Circuit Charge Pressure Gear Pump P3 Flow Front Wheel Motor Efficiency and or Piston Traction Pump Flow Tests IMPORTANT Refer to Traction Circuit Component Failure in the General Information section of this chapter for information regarding the importance of removing contamination from the traction circuit Groundsmaster 4300 D Page 4 33 2 If a cutting mow circuit problem exists consider performing one or more of the following tests Relief Valve PRV1 and PRV2 Pressure Gear Pump P 1 and P2 Flow and or Deck Motor Efficiency Tests 3 If a lift circuit problem exists consider performing one ormore ofthe following tests LiftR elief Valve PRV Pressure Gear Pump P 4 Flow and or Lift C ylinder In ternal Leakage Tests 4 Ifa steering circuit problem exists consider perform ing one or more of the following tests Steering Relief Valve R10 Pressure Steering Cylinder Internal Leak age and or Gear Pump P 3 Flow Tests Hydraulic System Traction Circuit Relief Valve R3 and R4 Pressure Test TO STEERING CONTROL VALVE AND CHARGE CIRCUIT TO MOW CONTROL FRONT CUTTING UNITS TO LIFT CONTROL MANIFOLD TO MOW CONTROL REAR CUTTING UN TS INTERNAL CASE VA BYPASS LVE gt FORWARD R3 RELIEF VALVE TEST SHOWN
217. m the battery disconnect the wire harness connector from the TEC controller and dis connect the terminal connector from the alternator This will prevent damage to the electrical system of your Groundsmaster 1 TEC controller Electrical System Page 5 34 Figure 38 2 Fuse block Groundsmaster 4300 D Fuses The fuse block is located behind the control arm access cover Fig 39 In addition to the fuses in the fuse block a 2 amp fuse F 3 is included in the wire harness to protect the logic power circuit for the TEC controller This fuse resides in a fuse holder near the battery Fig 41 Identification and Function Use Figure 40 to identify each individual fuse and its cor rectamperage Fuses for your Groundsmaster have the following function F1 1 15 Amp Protects starter circuit power sup ply F1 2 10 Amp Protects main power supply F1 3 10 Amp Protects power supply for head lights F1 4 10 Amp Protects power supply for power point F2 1 7 5 Amp Protects power supply for TEC controller outputs F2 2 7 5 Amp Protects power supply for TEC controller outputs F2 3 7 5 Amp Protects power supply for TEC controller outputs F2 4 15 Amp if equipped Protects power sup ply for the optional air ride operator seat Testing Turn ignition switch to the ON position do not start en gine With the fuse installed in the fuse block use a multimeter to verify th
218. m the failed component will circulate throughout the traction circuit This contamination can damage other components in the circuitso itmustbe re moved to prevent additional component failure The recommended method of removing traction circuit contamination would be to temporarily install the high flow hydraulic filter see Special Tools in this chapter into the circuit This filter should be used when connect ing hydraulic test gauges in order to test traction circuit components or after replacing a failed traction circuit component e g traction piston pump or wheel motor The filter will ensure that contaminates are removed from the closed loop and thus do not cause additional component damage Once the Toro high flow hydraulic filter kit has been placed in the circuit raise and support the machine with all wheels off the ground Then operate the traction cir Hydraulic System Page 4 8 To relieve hydraulic pressure in lift circuit turn ignition switch to ON do notstartengine and fully lower the cut ting decks After decks are fully lowered turn ignition switch to OFF and remove key from the switch IMPORTANT If machine will be serviced on a lift or atan elevated position fully lower the cutting decks after the machine has been raised to ensure that the lift cylinders are fully extended Pressure will be maintained in the lift cylinders unless they are fully extended cuit to allow oil flow throughout the circuit
219. m the ignition switch Raise and support hood The muffler and exhaust pipe may be hot To avoid possible burns allow the engine and ex haust system to cool before working on the ex haust system 2 Remove exhaust system using Figure 6 as a guide Installation Fig 6 NOTE Make sure muffler flange and exhaust manifold sealing surfaces are free of debris or damage that may prevent a tight seal T A B Figure 7 E 1 Place new muffler gasket on the exhaust manifold 2 If muffler support bracket item 7 was removed se cure it to engine with removed fasteners IMPORTANT Finger tighten all exhaust system fas teners before tightening so that there is no preload on the exhaust system due to exhaust system as sembly 3 Installexhaustsystem components to the engine us ing Figure 6 as a guide Finger tighten all fasteners until all exhaust system components have been installed 4 Tighten exhaust system fasteners in the following or der A Lift muffler as much as holes in muffler support bracket item 7 will allow Tighten flange nuts item 6 to secure muffler to support bracket B Tighten flange nuts item 3 to secure exhaust header item 13 to engine flange using order shown in Figure 7 C Tighten hex nuts item 10 to secure upper clamp item 11 D If tail pipe bracket item 9 was removed tighten flange head screws item 14 to secure bracket to engine E Tighten flange nuts item
220. mbly Individual gears housings and thrust plates are not available separately Disassemble gear pump for cleaning inspection and seal replacement only IMPORTANT Keep bodies gears flanges and thrust plates foreach pump section together do not mix parts between pump sections 1 Plug pump ports and thoroughly clean exterior of pump with cleaning solvent Make sure work area is clean 2 Use a marker to make a diagonal line across the gear pump for assembly purposes Fig 73 Hydraulic System Page 4 74 Figure 72 1 Front cover 9 Body P1 section 17 Drive gear 2 Dowel pin 16 used 10 Flange 3 used 18 Driven gear 3 Square section seal 8 used 11 Splined connecting shaft 3 used 19 Body P4 section 4 Back up ring 8 used 12 Drive gear 20 Rear cover 5 Pressure seal 8 used 13 Body P2 section 21 Washer 4 used 6 Thrust plate 8 used 14 Drive gear 22 Stud bolt 2 used 7 Drive shaft 15 Driven gear 23 Nut 2 used 8 Driven gear 2 used 16 Body P3 section 24 Cap screw 2 used IMPORTANT Use caution when clamping gear pump ina viseto avoid distorting any pump compo nents 3 Secure the front cover of the pump ina vise with the drive shaft pointing down 4 Loosen the two 2 cap screws and two 2 nuts that secures pump assembly 5 Remove pump from vise and remove fasteners 6 Supportthe pump assembly and gently tap the pump case with a soft face hammer to loosen the pump sec t
221. met e g a cutting blade should strike an object the pressure increase is felt at the proportional relief valve If circuit pressure should exceed the relief setting the valve will open to al low circuit flow to return to tank through manifold portT When circuit pressure lowers the valve closes to allow flow to return to the deck motors GROUNDSMASTER 4300 D CUTTING DECK LOCATIONS Figure 12 Hydraulic System Mow Circuit Cutting Deck Blade Braking When the operator turns the PTO switch OFF or if the decks are raised with the PTO switch ON the deck con trol manifold proportional relief valves PRV1 and PRV2 are de energized causing circuit flow to bypass the deck motors and return to the reservoir out manifold portT refer to information in Mow Circuitin this section Without circuit flow the manifold relief valve RV1 or RV 2 returns to its neutral position which causes the log ic cartridge LC1 or LC2 to shift to its neutral position blocking return flow from the deck motors and slowing the cutting blades Fig 13 The inertia of the rotating cutting blades however effec tively turns the deck motors into pumps causing an in crease in pressure as the flow from the motor comes up against the closed logic cartridge LC1 or LC2 When this pressure builds to approximately 1500 PSI 105 bar the relief valve RV1 or RV2 re opens which al lows a small amount of hydraulic flow to return to tank through a manif
222. meter ohms setting as the temperature increases Replace sender if specifications are not met COOLANT TEMP TEMP SENDER RESISTANCE 460 ohms approximate 100 F 38 C 160 F 71 C 200 F 93 C 221 F 105 C 140 ohms approximate 54 to 78 ohms 50 ohms approximate 5 After testing install sender to the engine housing A Clean threads of housing and sender thoroughly Apply a light coating of thread sealant to the threads of the sender B Thread sender into the housing Torque sender from 16 to 20 ft Ib 22 to 27 N m C Connect wire harness connector to sender 6 Fill engine cooling system see Radiator Installation intheService and Repairs section of Chapter3 Kubota Diesel Engine 7 Lower and secure hood SSS Figure 48 1 Temperature sender Figure 49 Electrical System E b u System High Temperature Shutdown Switch The high temperature shutdown switch is located on the water pump housing Fig 50 The high temperature shutdown switch is normally open and closes when en gine coolant temperature reaches approximately 239 F 115 C When excessive coolant temperature causes the shutdown switch to close the engine shuts down There is a tan wire attached to the shutdown switch NOTE If excessive coolant temperature causes en gine shutdown the operator can restartthe engine to al low the machine to be moved a short distance After a restart in this cond
223. n ning of the Service and Repairs section of this chapter Before opening hydraulic system operate all hy draulic controls to relieve system pressure and avoid injury from pressurized hydraulic oil See Relieving Hydraulic System Pressure in the Gen eral Information section of this chapter 3 To prevent contamination of the hydraulic system thoroughly clean traction and gear pump assembly and all hydraulic connections 4 Label hydraulic hoses to assistin assembly Discon nect all hydraulic hoses and tubes from fittings on the traction and gear pump assembly Allow hydraulic lines to drain into a suitable container Plug or cap openings of pumps and lines to prevent contamination 5 Remove hydraulic pump drive shaft see Hydraulic Pump Drive Shaft Removal in this section 6 Separate traction cable assembly from traction pump Fig 69 A Remove flange nut item 4 in Fig 69 thatsecures lever damper item 14 in Fig 69 to traction cable bracket B Remove cap screws items 7 and 13 in Fig 69 and lock nut item 8 in Fig 69 thatsecure traction le ver bracket item 12 in Fig 69 to pump lever C Loosen jam nuts that secure traction cable to traction cable bracket item 6 in Fig 69 D Position traction cable assembly away from pump assembly 7 Disconnect wire harness electrical connector from traction neutral switch and position harness away from transmission Groundsmaster 4300 D Page 4 69
224. n Adjustable Fitting Fig 6 1 Make sure all threads and sealing surfaces of fitting and component port are free of burrs nicks scratches or any foreign material 2 As a preventative measure againstleakage itis rec ommended that the O ring be replaced any time the connection is opened 3 Lightly lubricate the O ring with clean hydraulic oil Fitting threads should be clean with no lubricantapplied IMPORTANT Before installing fitting into port de termine port material If fitting is to be installed into an aluminum port installation torque is reduced 4 Install the fitting into the port Then use a torque wrench and socket to tighten the fitting to the recom mended installation torque shown in Figure 7 NOTE Use ofan offset wrench e g crowfoot wrench will affect torque wrench calibration due to the effective length change of the torque wrench Tightening torque when using a torque wrench with an offset wrench will be less than the recommended installation torque See Using a Torque Wrench with an Offset Wrench in the Torque Specifications section of Chapter 2 Product Records and Maintenance to determine necessary con version information 5 Ifa torque wrench is notavailable or if space at the portprevents use ofa torque wrench an alternate meth od of assembly is the Flats From Finger Tight F F F T method A Install the fitting into the port and tighten it down full length until finger tight B If
225. n direct power output to allow certain machine functions The controller is located be hind the control arm access cover nextto the fuse block Fig 38 The handheld Diagnostic Display see S pecial Tools in this chapter with the correct overlay should be used when checking inputs and outputs ofthe controller used on your Groundsmaster see Troubleshooting in this chapter Inputs from the ignition neutral parking brake PTO seat mow transport joystick lower raise temperature gauge output hydraulic pressure engine oil pressure and engine high temperature shutdown switches are all monitored by the controller Current outputto the cutting deck circuithydraulic valve solenoid coils lift circuit hydraulic valve solenoid coils diagnostic light and engine components glow plug relay startrelay fuel pump and engine run solenoid are controlled based on the inputs received by the control ler If the controller detects a malfunction in any of the con trolled circuits the diagnostic light can be used to identi fy the fault see Diagnostic Light in the Troubleshooting section of this chapter Because of the solid state circuitry built into the control ler there is no method to test it directly The controller may be damaged if an attemptis made to testit with an electrical test device such as a digital multimeter IMPORTANT Before performing any welding on the machine disconnect both positive and negative battery cables fro
226. nder from vise IMPORTANT When removing roll pin from frontand rear shafts make sure that shaft surfaces are not damaged 7 Remove and discard roll pin item 5 that secures frontshaftto rear shaft Then remove rear shaft item 2 piston item 9 and front head item 3 from front shaft 8 Remove and discard seals O rings and wear ring from piston and heads Groundsmaster 4300 D Inspection A CAUTION Use eye protection such as goggles when using compressed air 1 Wash all cylinder components in solvent Dry parts with compressed air 2 Inspectinternal surface of barrel for deep scratches out of roundness and bending 3 Inspect head shaft and piston for excessive pitting scoring and wear 4 Replace steering cylinder if internal components are found to be worn or damaged Assembly Fig 103 1 Use a new Seal kit to replace all seals O rings and wear ring to piston and heads Apply clean hydraulic oil to all seal kit components before installing 2 Install front head item 3 with new seals onto front shaft item 1 being careful to not damage head seals during installation Groundsmaster 4300 D Page 4 115 IMPORTANT Make sure to not damage O ring item 7 as piston is installed over roll pin hole in front shaft 3 Install piston item 9 with new seal O ring and wear ring onto front shaft IMPORTANT When installing roll pin into front and rear shafts make sure that shaft surfaces
227. neral Precautions for Removing and Installing Hydraulic System Components at the begin ning of the Service and Repairs section of this chapter 3 Tiltoperator seatand engage seat prop to retain seat in the raised position 4 Locate hydraulic deck control manifold 5 Label all hydraulic and electrical connections for as sembly purposes Thoroughly clean hydraulic connec tions prior to loosening hydraulic lines Before opening hydraulic system operate all hy draulic controls to relieve system pressure and avoid injury from pressurized hydraulic oil See Relieving Hydraulic System Pressure in the Gen eral Information section of this chapter 6 Disconnect hydraulic hoses and lines from fittings in manifold Allow lines to drain into a suitable container Remove and discard O rings from fittings 7 Putcaps orplugs on disconnected hoses and fittings to prevent contamination 8 Unplug wire harness leads from solenoid coils on manifold 9 Remove three 3 flange head screws that secure manifold to machine frame 10 Remove manifold block from machine 11 If necessary remove hydraulic fittings from manifold Fig 80 Discard any removed O rings Installation Fig 79 1 If fittings were removed from deck control manifold lubricate and place new O rings on fittings Fig 80 Install fittings into manifold see Hydraulic Fitting Instal lation in the General Information section of this chapter Torque fittings
228. ng tem perature by operating the machine under load for approximately ten 10 minutes Hydraulic System Page 4 38 Groundsmaster 4300 D Before opening hydraulic system operate all hy draulic controls to relieve system pressure and avoid injury from pressurized hydraulic oil See Relieving Hydraulic System Pressure in the Gen eral Information section of this chapter 4 Raise and support operator seat to allow access to hydraulic pump 5 Thoroughly clean the ends of the hydraulic tubes connected to the oil filter and traction pump inlets Fig 40 Disconnect hydraulic tubes from oil filter inlet and traction pump inlet Remove two 2 flange head screws that secure oil filter adapter to frame Remove oil filter assembly and hydraulic tube from machine IMPORTANT Make sure that the oil flow indicator arrow on the flow meter is showing that the oil will flow from the hydraulic tube through the tester and into the traction pump 6 Install tester with pressure gauges and flow meter in place of the removed oil filter assembly and hydraulic tube Connect tester inlet hose to the hydraulic tube Connect the tester outlet hose to the traction pump fit ting Make sure the flow control valve on tester is ful ly open 7 Make sure that the traction pedal is in neutral the steering wheelis stationary and the parking brake is en gaged 8 Startengine and run atidle speed Check for any hy draulic leakage from test connection
229. ngs to prevent system contamination 12 S upportthe wheel motorto preventitfrom falling dur ing removal 13 Remove four 4 cap screws and lock washers that secure wheel motor to the steering spindle 14 Remove wheel motor from frame 15 If necessary remove hydraulic fittings from wheel motor Remove and discard O rings from fittings Installation Fig 75 IMPORTANT Because of internal differences in rear wheel motors DO NOT interchange rear wheel motors on machine i e do not put right side motor on left side of machine The left side wheel motor has a yellow identification mark on the motor hous ing If necessary use parts catalog and partnumber on wheel motor to identify RH and LH motors 1 If fittings were removed from wheel motor lubricate and install new O rings to hydraulic fittings Install fit tings into wheel motor ports see Hydraulic F itting Instal lation in the General Information section of this chapter 2 Position rear wheel motor to steering spindle Make sure that ports in wheel motor are facing toward the rear of the machine 3 Secure wheel motor to spindle with four 4 cap screws and lock washers 4 Remove caps or plugs from disconnected hydraulic hoses and wheel motor fittings that were placed during wheel motor removal to prevent contamination 5 Using labels placed during the removal process properly connecthydraulic hoses to wheel motor fittings see Hydraulic Hose and Tube Install
230. nie d 96 0eu5 ainssajid MOT eunssaJd BupuoAA s3 eg umn esiey PNUD YT d 00 r Jo1seuuspunoac G IOd3INVIA TOYLNOD 940 EW la Wa bond 1102813 MON 1N0tJ P Wa c Wa cUm tfr 1102813 MON uvas G IOJINVIA TOYLNOD 44 YAGNITAD SNIu3als ANWA TOYLNOD SNIu3als dWwnd NOLLOVW D NOLSId 1 bed ayaa ava ig 1431 4 L J G IOJINVIA Toi XVulSSOu D FORWARD Figure 16 D Groundsmaster 4300 16 Page 4 Hydraulic System Lift Circuit Raise Cutting Decks A four section gear pump is coupled to the piston trac tion pump Gear pump section P 4 supplies hydraulic flow to the liftcontrol manifold and liftcylinders The gear aaa pump takes its suction from the hydraulic reservoir FRONT LI
231. nifold 2 Frame bracket 3 Spacer 3 used 4 Lock washer 3 used 5 Cap screw 3 used Tie Rod Assembly Fig 11 NOTE The tie rod ball jointand jam nut at the grooved end of the tie rod have left hand threads 1 Loosen jam nuts and then unscrew ball joints from tie rod 2 Thread new ball joints equally into tie rod so that ball joint center to center length is 36 240 920 5 mm 3 Thoroughly clean the tapered surfaces of the tie rod ball joints before installing tie rod to drag links on rear axle 1 490 EM 37 8 mm lt 36 240 920 5 mm Figure 11 1 Tie rod 4 Ball joint 2 Ball joint LH thread 5 Jam nut 3 Jam nut LH thread 6 Tie rod groove Chassis m i o Rear Axle Installation Fig 9 1 Position the rear axle assembly to the frame Install thrust washer item 7 between each side of axle and frame Slide pivot pin through frame thrust washers and axle Make sure that roll pin on pivot pin is positioned in frame reliefs 2 Install thrust washer item 9 and jam nut item 10 onto pivot pin Torque jam nut item 10 from 90 to 120 ft lb 123 to 162 N m Make sure thatrearaxle can still pivot freely after jam nut is tightened 3 Raise the CrossTrax AWD control manifold to the frame Position spacers between manifold and frame Fig 10 Secure manifold to frame with three 3 cap screws and lock washers 4 Install wheel
232. o motor ports see Hydraulic F itting Installation in the General Information section of this chapter Make sure that fittings are orientated correctly 2 Remove cover from top of spindle that was placed to prevent debris from entering spindle 3 Make sure that O ring is positioned to top of spindle housing Secure hydraulic motor to the cutting deck with two 2 socket head screws and flat washers Fig 84 4 Remove caps or plugs from fittings and hoses IMPORTANT When installing the hydraulic hoses make sure thathydraulic hoses are straight nottwisted before tightening the hoses to the motor fittings 5 Lubricate and install new O rings on motor fittings Correctly connecthydraulic hoses to the motor using la bels placed during removal procedure see Hydraulic Hose and Tube Installation in the General Information section of this chapter 6 Check oil level in hydraulic reservoirand add correct oil if necessary 7 Follow Hydraulic System Start up procedures see Hydraulic System Start up in this section Groundsmaster 4300 D Page 4 95 GROUNDSMASTER 4300 D CUTTING DECK LOCATIONS Figure 84 1 Socket head screw 2 Flat washer 3 Hydraulic motor 4 Cutting deck ROTATION DIRECTION Figure 85 1 Flow IN 3 Case drain 2 Flow OUT Hydraulic System Cutting Deck Motor Service Figure 86 1 Dust seal 8 Front wear plate 14 Rear wear plate 2 Retaining ring 9 Drive gear 15
233. of Chapter 4 Hydraulic S ystem Groundsmaster 4300 D Electrical System Quick Checks Battery Test Open Circuit Test Use a digital multimeter to measure the battery voltage Set the multimeter to the DC volts setting The battery should be at a temperature of 60 to 100 F 16 to 38 C The ignition switch should be in the OFF position and all accessories turned off Connect the positive multimeter lead to the positive battery post and the neg ative multimeter lead to the negative battery post Record the battery voltage NOTE This test provides a relative condition of the bat tery Load testing of the battery will provide additional and more accurate information see Battery Service in the Service and Repairs section Charging System Test This is a simple testused to determine if a charging sys tem is functioning It will tell you if the charging system has an output but not its capacity Use a digital multimeter set to DC volts Connect the positive multimeter lead to the positive battery post and the negative multimeter lead to the negative bat tery post Keep the test leads connected to the battery posts and record the battery voltage NOTE Upon starting the engine the battery voltage will drop and then should increase once the engine is running NOTE Depending upon the condition of the battery charge and battery temperature the battery voltage will increase at different rates as the b
234. old down pins from backing plate 12 If necessary remove brake backing plate from ma chine by loosening and removing four 4 cap screws item 26 and lock nuts item 27 Installation Fig 6 1 Remove rust and debris from all brake parts with a wire brush prior to installation Clean all parts Inspect brake shoe contact surfaces of the brake drum for ex cessive wear Replace any worn or damaged parts 2 If brake backing plate was removed from machine secure backing plate to brake bracket with four 4 cap screws item 26 and lock nuts item 27 3 Lightly lubricate brake shoe pivot points with general purpose grease 4 Position one brake shoe to the backing plate Install brake hold down pin and secure with hold down spring and cup Repeat for second brake shoe 5 Install upperand lower shoe springs to brake shoes Make sure that brake shoes are properly positioned to pivot and actuator points IMPORTANT Before wheel hub is installed thor oughly clean tapers of wheel hub and wheel motor shaft Make sure that tapers are free of grease oil and dirt Do notuse antiseize lubricant when instal ling wheel hub Groundsmaster 4300 D Page 6 9 6 Mount square key in the wheel motor shaft then install the wheel hub onto the wheel motor shaft IMPORTANT Do not reuse lock nut that secures wheel hub to wheel motor after ithas been removed 7 Install new lock nut item 17 onto the wheel motor shaftto secure w
235. old sensing line Fig 14 This flow causes a pressure differential that shifts the logic car tridge LC1 or LC2 to once again allow oil flow from the motors Fig 15 When return pressure drops below 1500 PSI 105 bar the relief valve RV1 or RV2 re seats and causes the logic cartridge LC1 or LC2 to close again blocking return flow from the deck motors to further slow the cutting blades This action ofthe relief valve opening and the logic cartridge shifting occurs several times in a very shorttime frame as the blades fi nally come to a stop Once the blades have stopped the logic cartridge LC1 or LC2 remains in the neutral posi tion to keep the deck motors from rotating Hydraulic System REAR MOW CIRCUIT C U 3 TO I OIL COOLER ORIFICE FROM DECK FRONT OW CONTROL M CIRCUIT MANIFOLD Figure 13 REAR MOW CIRCUIT C U 2 R11 TO OIL COOLER ORIFICE FROM FRONT MOW CIRCUIT DECK CONTROL MANIFOLD Figure 14 TO OIL COOLER Page 4 14 C U 3 iM ORIFICE DECK CONTROL MANIFOLD CIRCUIT Figure 15 Groundsmaster 4300 D Hydraulic System This page is intentionally blank Groundsmaster 4300 D Page 4 15 Hydraulic System MO 4 uonons Jo u
236. on a levelsurface with the PTO switch OFF Position the cutting decks in the turn around posi tion and turn the engine off Apply the parking brake 2 For the lift cylinder that is to be tested use a jack to raise the lift arm slightly This will remove the load from the lift cylinder and relieve lift cylinder hydraulic pres sure Leave the jack under the liftarm to support the lift arm and to prevent the lift arm from lowering NOTE If either of the rear lift cylinders is being tested both rear lift arms need to be supported 3 Thoroughly clean the area around the end of the hy draulic hose atthe rod end of the liftcylinder Disconnect the hydraulic hose from the lift cylinder rod end fitting Fig 56 Groundsmaster 4300 D IMPORTANT When capping lift cylinder fitting and hydraulic hose end use a Steel cap and plug to en sure that fluid leakage will not occur Plastic plugs will not hold hydraulic pressure that will be devel oped during this test procedure 4 Place a steel cap on the open lift cylinder fitting to seal the liftcylinder Also install a steel plug in the open end ofthe disconnected hose to preventleakage or con tamination 5 Slowly lower the jack and remove it from under the lift arm The cutting deck should settle slightly and then be supported by the capped lift cylinder 6 Mark the position ofthe liftcylinder rod atthe liftcylin der head with a piece of tape Fig 57 7 Leave the machine park
237. on pedal etc and note that the appropriate LED on the Diagnostic Display toggles on and off when the inputstate is changed see chartbe low Repeat for all inputs thatcan be changed by hand 7 If appropriate LED does not toggle on and off when inputstate is changed check all wiring and connections to the switch for that input and or test switch see Com Diagnostic Display TEC Controller Inputs ponent Testing in this chapter Replace all defective switches and repair any damaged wiring NOTE The TEMP WARNING and ALT FAULT TEC controller inputs can notbe reliably tested by grounding the harness leads at the engine temperature sensor or alternator If engine temperature is very excessive or al ternator is faulty a TEC controller fault should have been detected Refer to Diagnostic Light in this section for information on retrieval and clearing of TEC control ler faults NOTE When the ignition switch is in the OFF position all Diagnostic Display LED s should be OFF 8 Afterinputfunction testing is completed disconnect the Diagnostic Display from wire harness Plug loop back connector into harness connector Install control panel cover Diagnostic Display LED Operation PARKING BRAKE OFF Parking brake released LED ON Parking brake applied LED OFF TRACTION NEUTRAL Traction pedal in neutral LED ON Traction pedal in forward or reverse LED OFF SEAT SWITCH Seatoccupied LED ON E ONE TRANSPORT OFF Mow spee
238. on process 1 Bearing cups 4 Arbor press 2 Large snap ring 5 Support IMPORTANT If bearings are being replaced make 3 Large spacer 6 Arborpress base sure to use the spacer ring thatis included with the new bearing set Fig 6 6 Slide spacer ring and inner bearing spacer into spindle housing then install upper bearing cone and greased oil seal into top of housing Note The upper seal must have the lip facing out up Fig 8 7 Inspect the spindle shaft and shaft spacer to make ACC sure there are no burrs ornicks thatcould possibly dam age the oil seals Lubricate the shaft and spacer with grease e Ze Gg e 2 2 A gt A 3 8 Install spindle shaft spacer onto shaft Place thin Sleeve or tape on spindle shaft splines to prevent seal damage during shaft installation 9 Carefully slide spindle shaft with spacer up through spindle housing The bottom oil seal and spindle spacer should fit together when the spindle is fully installed Figure 8 1 Bottom seal installation 2 Upper seal installation 10 Thread spindle nut onto shaft and tighten nut from 130 to 160 ft Ib 177 to 216 N m IMPORTANT Pneumatic grease guns can produce high pressure inside spindle housing that can dam age spindle seals Pneumatic grease guns there fore are not recommended to be used for greasing of spindle housings 11 Attach a hand pump grease gun to one ofthe grease fittings on housing and fill housin
239. onnect machine wire harness connector to relay 10 Lower and secure hood Figure 34 2 Startrelay X a 1 Pump drive shaft 85 87a 85 O 30 Figure 35 3 Normally closed term 4 Normally open term 1 Coilterminal 2 Common terminal Groundsmaster 4300 D Main Power and Glow Relays The Groundsmaster electrical system includes two identical relays for current control The main power and glow relays are attached to a frame bracket under the hood next to the hydraulic pump drive shaft Fig 36 Relays can be identified by a tag on the wire harness The main power relay is used to provide current to the TEC controller headlights power point and optional electric equipment When the ignition switch is in the RUN or START position the main power relay is ener gized The glow relay is used to provide current to the engine glow plugs when energized by the TEC controller The controller controls and monitors the operation of the glow relay The glow relay and its circuit wiring should be tested as a controller output with the Diagnostic Dis play before disconnecting and testing the relay see Special Tools and Troubleshooting in this chapter Testing 1 Park machine on a level surface lower cutting decks stop engine apply parking brake and remove key from ignition switch 2 Open hood to gain access to relay 3 Locate relay and disconnect the machine wire h
240. onnections prior to loosening hydraulic lines from lift cylinder Before opening hydraulic system operate all hy draulic controls to relieve system pressure and avoid injury from pressurized hydraulic oil See Relieving Hydraulic System Pressure in the Gen eral Information section of this chapter 5 Disconnect hydraulic hoses from fittings in lift cylin derthatis to be removed Allow hoses to drain into a suit able container Remove and discard O rings 6 Putcaps orplugs on disconnected hoses and fittings to prevent contamination 7 Remove one retaining ring item 11 and thrustwash er item 12 from the cylinder slide pin item 13 P ull pin fromthe liftcylinder and liftarm Locate and retrieve sec ond thrust washer 8 Remove flange head screw item 3 and flat washer item 5 that retain lift cylinder to pivot shaft 9 Remove lift cylinder from pivot shaft and frame 10 If hydraulic fittings are to be removed from lift cylin der mark fitting orientation to allow correct assembly Remove fittings from lift cylinder and discard O rings Installation Fig 93 1 Ifhydraulic fittings were removed from lift cylinder lu bricate new O rings position O rings to fittings and install fittings into lift cylinder ports see Hydraulic Fitting Installation in the General Information section of this chapter Make sure thatfittings are orientated correctly 2 Position liftcylinderto the frame The liftcylinder bar re
241. or from harness connector Fig 12 3 Connectthe Diagnostic Display connector to the har ness connector Make sure correctoverlay decalis posi tioned on the Diagnostic Display Fig 13 4 Turn the ignition switch to the RUN position NOTE The red text on the overlay decal refers to con troller inputs and the green text refers to controller out puts 5 The green OUTPUTS DISPLAYED LED on lower right column of the Diagnostic Display should be illumi nated If INPUTS DISPLAYED LED is illuminated press the toggle button on the Diagnostic Display to change the LED to OUTPUTS DISPLAYED NOTE It may be necessary to toggle between IN PUTS DISPLAYED and OUTPUTS DISPLAYED sev eraltimes to perform the following step To change from inputs to outputs press toggle button once This may be done as often as required Do not press and hold toggle button 6 Siton seat start engine and attempt to operate the desired function ofthe machine The appropriate output LED s should illuminate on the Diagnostic Display to in dicate thatthe TEC controller is turning on that function NOTE Ifthe DIAG LAMP outputLED is blinking this indicates that the TEC controller has detected a fault during machine operation Refer to Diagnostic Light in this section for information on retrieval and clearing of controller faults A Ifthe correctoutputLE D s do notilluminate verify thatthe required input switches are in the nec
242. orrect operation of the indicator light and cir cuit wiring Charge Indicator Light The charge indicator lightshould come on when the igni tion switch is in the RUN position with the engine notrun ning Also it should illuminate with an improperly operating charging circuit while the engine is running Testing Indicator Lights If testing of the indicator lights is necessary 1 Remove control arm covers to gain access to indica tor light and harness connectors see Control Arm Dis assembly in the Service and Repairs section of Chapter 6 Chassis 2 Locate the indicator lightto be tested and disconnect the wire harness electrical connector from the light Groundsmaster 4300 D Page 5 23 3 Apply 12 VDC to terminals 1A and 2A Fig 20 4 Ground terminals 1B and 2B Fig 20 5 Both indicator lights should illuminate 6 Connect wire harness electrical connector to the in dicator light 7 Install control arm cover to machine see Control Arm Assembly in the Service and Repairs section of Chapter 6 Chassis Figure 19 3 Engine oil pressure 4 Charge indicator 1 Glow plug indicator 2 High temp warning Figure 20 1 Glow plug indicator 4 Charge indicator 2 High temp warning 5 Indicator light front 3 Engine oil pressure 6 Indicator light back Electrical System E u System Hour Meter The hour meter is located on the outside of the control arm 1 Remove control
243. ot remain Lift circuit hydraulic lines or fittings are leaking in the raised position MAT teat cut oe Air exists in lift circuit NOTE Lift cylinders and control manifold cartridge valves cannot Lift cylinder leaks internally provide an absolutely perfect seal The cutting decks will eventually lower if left in the raised position Solenoid valve S2 in lift control manifold leaks None of the cutting decks will raise or Oil level in hydraulic reservoir is low other hydraulic systems are lower affected as well NOTE Mow speed limiter must be in An electrical problem exists that prevents lift control manifold solenoid mow speed position in order to lower valve operation see Troubleshooting in Chapter 5 Electrical System the cutting decks Solenoid valve PRV in lift control manifold is faulty Logic cartridge LC in lift control manifold is faulty Solenoid valve S2 in lift control manifold is faulty Gear pump section P 4 is worn or damaged Neither of the rear cutting decks will Flow control orifice in lift control manifold for the rear cutting decks raise or lower butthe front cutting port C8 is plugged stuck or damaged decks will raise and lower Single cutting deck lowers very slowly Lift arm or lift cylinder is binding or not at all Lift cylinder is damaged Flow control orifice in lift control manifold for the affected cutting deck is plugged stuck or damaged Groundsmaster 4300 D Page 4 29 H
244. otor housing shaft and secure with flange head screw 5 Slide wheel motor assembly with wheel hub and hy draulic hoses attached into motor housing Secure wheel motor to motor housing with four 4 cap screws and lock washers 6 Connect the tie rod end to the drag link with slotted hex nut and cotter pin 7 If right side motor housing was removed secure steering cylinder ball jointto drag link with slotted hex nut and cotter pin 8 Lubricate the motor housing shafts through the grease fittings on the rear axle 9 Install rear wheel assembly see Wheel Installation in this section Make sure that lug nuts are torqued evenly in a crossing pattern from 70 to 90 ft lb 95 to 122 N m 10 Check rear wheel toe in see Operator s Manual 11 After all adjustments have been made make sure thatno contactis made between any machine compon ents as the rear wheels are moved from lock to lock Ad just if necessary Chassis 1 m i o Rear Axle 90 to 120 ft Ib 123 to 162 N m 70 to 90 ft Ib 95 to 122 N m 315 to 385 ft lb 1 17 427 to 521 N m Figure 9 1 Lug nut 5 used per wheel 16 J am nut 2 used 31 Thrust washer 2 Rear axle assembly 17 Lock nut 32 Cap screw 4 used per motor 3 Hydraulic fitting 2 used per motor 18 Hydraulic hose 33 O ring 4 Hydraulic fitting 2 used 19 O ring 34 Wheel stud 5 used per hub 5 Tierod assembly 20 Cotter pin 35 Grease fitting 6 Axle pivo
245. ove any dirtor foreign material C Apply grease to the inside and outside ofthe new bushings D Use an arbor press to install the bushings into lift arm Liftarm bushings should be pressed until bush ing flange is against lift arm bore E After bushing installation make sure that lift arm Slides easily onto pivot shaft If binding is noted lo cate and correct source of binding 7 If necessary remove cap screw that secures pivot shaft item 16 in lift arm Remove pivot shaft from lift arm 8 Ifnecessary remove roll pin item 3 and liftarm pivot shaft item 14 from frame Discard roll pin Installation Fig 20 1 If lift arm pivot shaft item 14 was removed from frame apply antiseize lubricant to pivot shaft surface and insertshaftinto frame Align holes in frame and pivot shaft Secure pivot shaft with new roll pin Groundsmaster 4300 D Page 6 23 2 If pivotshaft item 16 was removed from lift arm in sert pivot shaft in lift arm and secure with cap screw item 19 3 Slide front lift arm onto pivot shaft 4 Secure front lift arm to machine A Apply Permatex Blue GelThreadlocker orequiv alent to threads of screws items 9 12 and 18 B Position tipper bracket to lift arm and frame bracket C Install screws flat washers items 11 and 13 and flange nut item 6 to tipper bracket pivot shaft and frame bracket D Torque 1 2 fasteners items 9 and 18 from 75 to 95 ft Ib 102 to 128 N
246. ove engine brackets item 27 from engine Kubota Diesel Engine Page 3 14 Installation Fig 9 1 Locate machine on a level surface with cutting decks lowered and key removed from the ignition switch Chock wheels to keep the machine from moving 2 Make sure that all parts removed from the engine during maintenance or rebuilding are installed to the en gine 3 If engine brackets were removed from the engine secure brackets to engine with lock washers and cap screws Torque cap screws from 34 to 42 ft Ib 47 to 56 N m 4 Install engine to machine A Attach shortsection of chain between lift tabs lo cated on each end of the cylinder head B Connect a hoist or lift at the center of the short section of chain Apply enough tension on the short chain so that the engine can be supported A CAUTION One person should operate hoist or lift while a second person guides the engine into the ma chine IMPORTANT Make sure to not damage the en gine fuel hoses hydraulic lines electrical har ness radiator battery or other parts while installing the engine C Lower engine to the machine frame Make sure fastener holes of the engine brackets are aligned with the holes in the engine mounts D Insert cap screw down through each engine bracket and mount Place spacer snubbing washer and then flange nut on four 4 cap screws Tighten fasteners to secure engine to engine mounts 5 Connect hydraulic transmis
247. partially into yoke C Insert cross into yoke and bearing D Hold cross in alignmentand press bearing in until ithits the yoke E Install snap ring into yoke groove to secure installed bearing F Place second bearing into yoke bore and onto cross shaft Press bearing into yoke and secure with snap ring G Repeat procedure for other yoke H Grease cross until grease comes outofall four 4 cups 4 Make sure that assembled joint moves without bind ing Slight binding can usually be eliminated by lightly rapping the yoke lugs with a soft faced hammer If bind ing continues disassemble joint to identify source of binding Groundsmaster 4300 D Page 4 67 Installation Fig 65 1 Apply antiseize lubricantto traction pump inputshaft 2 Position drive shaftassembly to engine and pump in put shaft 3 Apply Permatex Blue Gel Threadlocker or equiva lent to threads of cap screws item 7 that secure drive shaft flange to engine flywheel Secure drive shaft flange to flywheel with six 6 cap screws item 7 Torque cap screws from 34 to 42 ft lb 46 to 56 N m 4 Slide drive shaft yoke on pump input shaft so yoke is flush with end of input shaft Secure drive shaft yoke to pump input shaft with two 2 cap screws item 5 and flange nuts item 9 5 Position drive shaft guard hoop to machine frame and secure with two 2 flange head screws and flange nuts 6 Lubricate grease fittings on drive shaft
248. peed 3200 RPM Use a tachometer to verify that engine speed is correct IMPORTANT The gear pump is a positive displace ment type If pump flow is completely restricted or stopped damage to the pump tester or other com ponents could occur 10 While carefully watching pressure gauges slowly close the tester flow control valve until 1000 PSI 70 bar is obtained on gauge FLOW TESTER READING TO BE A pump in good condition should have a flow of approximately 3 2 GPM 11 9 LPM at 1000 PSI 70 bar 11 Open the tester flow control valve stop engine and record test results 12 Ifflow is less than 2 8 GPM 10 6 LPM or a pressure of 1000 PSI 70 bar cannot be obtained consider that a pump problem exists Check for restriction in pump in take line If intake is not restricted remove gear pump and repair or replace pump as necessary see Gear Pump in the Service and Repairs section of this chap ter NOTE Ifthe flow from gearpump P 4 is low the opera tion of all lift cylinders will be affected Groundsmaster 4300 D Page 4 53 13 After testing is completed make sure that engine is stopped then relieve hydraulic system pressure see Relieving Hydraulic System Pressure inthe General In formation section of this chapter Remove tester and connectremoved hydraulic hose to gear pump P 4 out let and lift control manifold P port 14 Lower and secure operator seat Figure 54 2 Hydraulic hose 1 Gear pump
249. ply the parking brake 3 Read Precautions For Hydraulic Testing in this sec tion Before opening hydraulic system operate all hy draulic controls to relieve system pressure and avoid injury from pressurized hydraulic oil See Relieving Hydraulic System Pressure in the Gen eral Information section of this chapter 4 Thoroughly clean the area around the hydraulic hose at the rod end of the steering cylinder Fig 60 5 Remove hydraulic hose from the fitting on the rod end of the steering cylinder 6 Installa tee fitting between the disconnected hydrau lic hose and the steering cylinder fitting Install a 5000 PSI 350 bar pressure gauge to the tee fitting 7 After installing pressure gauge start engine and run atidle speed Check for any hydraulic leakage from test connections and correct before proceeding with test 8 Move throttle to full speed 3200 RPM IMPORTANT Hold steering wheel at full lock only long enough to get a system pressure reading Holding the steering wheel against the stop for an extended period may damage the steering control valve 9 Watch pressure gauge carefully while turning the steering wheel for a left hand turn counter clockwise and holding 10 System pressure should be approximately 1000 PSI 70 bar as the relief valve lifts Return steering wheel to the neutral position 11 Shut off engine Record test results Groundsmaster 4300 D Page 4 57 12 If specification is
250. rake lower cutting decks and stop engine Remove key from the ignition switch 2 Read the General Precautions for Removing and Installing Hydraulic System Components at the begin ning of the Service and Repairs section of this chapter Before opening hydraulic system operate all hy E draulic controls to relieve system pressure and 3 Locate hydraulic lift control manifold thatis attached avoid injury from pressurized hydraulic oil See to frame bracket under the front platform Relieving Hydraulic System Pressure in the Gen eral Information section of this chapter Hydraulic System Page 4 100 Groundsmaster 4300 D Make sure that cutting decks are fully lowered before loosening hydraulic lines cartridge valves or plugs from lift control manifold If decks are not fully lowered as manifold compo nents are loosened decks may drop unexpect edly 5 Disconnecthydraulic hoses and lines from fittings in manifold Allow lines to drain into a suitable container Remove and discard O rings 6 Putcaps or plugs on disconnected lines and fittings to prevent contamination 7 Label all solenoid coil wire harness leads for as sembly purposes Unplug wire harness leads from sole noid coils on manifold 8 Remove two 2 flange head screws that secure manifold to machine frame 9 Remove lift control manifold from machine IMPORTANT A flow control orifice is placed be neath several hydraulic fittings on the lift contro
251. rately Reconnect cables with positive cable first Coat battery posts and cable connectors with Battery Terminal Protector Toro Part No 107 0392 or petroleum jelly to pre vent corrosion IMPORTANT Before cleaning the battery tape or block vent holes to the filler caps and make sure the caps are on tightly C Check for signs of wetness or leakage on the top of the battery which mightindicate a loose or missing filler cap overcharging loose terminal post or over filling Also check battery case for dirtand oil Clean the battery with a solution of baking soda and water then rinse it with clean water D Check thatthe cover seal is notbroken away Re place the battery if the seal is broken or leaking E Check the electrolyte level in each cell Ifthe level is below the tops of the plates in any cell fill all cells with distilled water between the minimum and max imum fill lines Charge at 15 to 25 amps for 15 min utes to allow sufficient mixing of the electrolyte see battery charging in this section Electrical System E b Battery Testing 1 Conducta hydrometer test of the battery electrolyte IMPORTANT Make sure the area around the cells is clean before opening the battery caps A Measure the specific gravity of each cell with a hydrometer Draw electrolyte in and out of the hydrometer barrel prior to taking a reading to warm up the hydrometer At the same time take the tem perature of the cell
252. raulic system operate all hy approximately ten 10 minutes draulic controls to relieve system pressure and i I avoid injury from pressurized hydraulic oil See 2 Park machine on a level surface with the cutting Relieving Hydraulic System Pressure in the Gen decks lowered and PTO switch off Make sure engine is eral Information section of this chapter off Apply the parking brake Hydraulic System Page 4 52 Groundsmaster 4300 D 4 Raise and support operator seat to allow access to hydraulic pump 5 Thoroughly clean both ends of the hydraulic hose that connects gear pump P4 outlet Fig 54 and lift control manifold P 4 port Remove hydraulic hose Ac cess to hydraulic hose atlift control manifold can be ob tained from below the machine IMPORTANT Make sure that the oil flow indicator arrow on the flow meter is showing that the oil will flow from pump P4 through the tester and to the lift control manifold 6 Install tester with pressure gauges and flow meter in place ofthe removed hydraulic hose Connecttester in let hose to the pump fitting Connect the tester outlet hose to the lift control manifold fitting Make sure the flow control valve on tester is fully open 7 Make sure thatthe traction pedalis in neutral and the parking brake is engaged 8 Startengine and run atidle speed Checkfor any hy draulic leakage from test connections and correct be fore proceeding with test 9 Move throttle to full s
253. readlocker Figure 20 8 LH tipper bracket 9 Cap screw 2 used 10 Bumper 4 used 11 Flat washer 12 Cap screw 1 used per lift arm 13 Flat washer 1 used per lift arm Page 6 22 Antiseize Lubricant Lift arm pivot shaft 3 used Lock nut 4 used Pivot shaft 1 used per lift arm Grease fitting 1 used per lift arm Cap screw 2 used Cap screw 1 used per lift arm Groundsmaster 4300 D Removal Fig 20 1 Park machine on a level surface lower cutting decks stop engine engage parking brake and remove key from the ignition switch 2 Remove cutting deck from front lift arm to be re moved see Cutting Deck Carrier Frame Removal in the Service and Repairs section of Chapter 7 Cutting Decks 3 Disconnect lift cylinder from lift arm Fig 21 A Remove one 1 retaining ring and thrust washer from the cylinder pin that secures lift cylinder to lift arm B Pull cylinder pin from the lift cylinder and lift arm Locate and retrieve second thrust washer C Pivot lift cylinder rod end away from lift arm 4 Remove fasteners thatsecure tipper bracket item 7 or 8 to machine Remove tipper bracket 5 Slide front lift arm from lift arm pivot shaft 6 Inspect flange bushings in lift arm for wear or dam age If necessary replace bushings A Use bushing removal tool to extract bushings from the lift arm Take care to not damage the bore B Clean the inside of the bore to rem
254. rized Toro Distributor Safety Pagel 6 Groundsmaster 4300 D Chapter 2 TORO Product Records and Maintenance Table of Contents n 0 g PRODUCTRECORDS 1 5 MAINTENANCE a a aa a as pe tings 1 ii EQUIVALENTS AND CONVERSIONS 2 tia Decimal and Millimeter Equivalents 2 3 U S to Metric Conversions 2 t TORQUE SPECIFICATIONS 3 Fastener Identification 3 Using a Torque Wrench with an Offset Wrench 3 Standard Torque for Dry Zinc Plated and Steel Fasteners Inch Series 4 Standard Torque for Dry Zinc Plated and Steel Fasteners Metric Series 5 Other Torque Specifications 6 Conversion Factors u usu l a ces 6 Product Records Insert Operator s Manual and Parts Catalog for your Groundsmaster at the end of this chapter Additionally if any optional equipment or accessories have been installed to your machine insertthe Installation Instruc tions Operator s Manuals and Parts Catalogs for those options at the end of this chapter Maintenance Maintenance procedures and recommended service in tervals for your Groundsmaster are identified in the Op erator s Manual Refer to that publication when performing regular equipment maintenance Groundsmaster 4300 D Page2 1 Product Records and Maintenance Decimal and Millimeter Equivalents Equivalent
255. rminal p 9 mae Feme wo Figure 43 1 Diode 3 Female terminal 2 Male terminal Electrical System Page 5 36 Groundsmaster 4300 D Fusible Link Harness The Groundsmaster 4300 D uses four 4 fusible links for circuit protection Three 3 of these fusible links are located in a harness that connects the starter B termi nal to the wire harness Figs 44 and 45 The remaining fusible link is included in the wire harness and connects the starter terminal to the engine run solenoid pull coil If any of these links should fail current to the protected circuit will cease Refer to wire harness drawings in Chapter 8 Foldout Drawings for additional fusible link information Testing Make sure that ignition switch is OFF Disconnect nega tive battery cable from battery terminal and then dis connect positive cable from battery see Battery Service in the Service and Repairs section of this chap ter Locate and unplug fusible link connector from ma chine wire harness Use a multimeter to make sure that continuity exists between the fusible link terminal on the starter B terminal terminal J 1 on fusible link harness and each ofthe terminals in the link harness connector P1 Ifanyofthe fusible links are open replace the fusible link harness NOTE Itis notrecommended to replace individual fus ible link conductors of the fusible link harness If any of the harness links are open failed replace the entire f
256. roller inputs and outputs when troubleshooting an electrical problem on your Groundsmaster Figure 7 1 Control panel 2 Diagnostic light Figure 8 1 TEC controller location 3 Harness connector 2 Loopback connector Groundsmaster 4300 D Retrieving Fault Codes All machine fault codes are retained in the TEC control ler memory The three 3 most recent fault codes that have occurred within the last forty 40 hours of opera tion can be retrieved using the diagnostic light To re trieve these fault codes from the controller memory perform the following switch sequence 1 Operator seat should be UNOCCUPIED traction pedal in neutral parking brake released and PTO switch in the OFF position 2 Place mow speed limiter in the TRANSPORT posi tion 3 Move and hold joystick in the RAISE position 4 Turn ignition switch to the RUN position 5 Monitor the diagnostic light for fault code s NOTE Once the diagnostic light begins to display fault codes the joystick can be released Fault Code Lamp Flashes 1 1 1 2 1 3 F aultcodes displayed by the diagnostic lightare two dig itnumbers with no digit higher than five 5 Fault codes are listed in the chart below There will be a one 1 sec ond pause between the first and second digit of a code Up to three 3 fault codes retained in controller memory will be displayed by the diagnostic lightin order from the most recent fault to the oldest fault If ther
257. rt Groundsmaster 4300 D 5 Connecta 5000 PS1 350 bar pressure gauge to test port 6 After installing pressure gauge start engine and run atidle speed Check for any hydraulic leakage from test connections and correct before proceeding with test 7 Move throttle to full soeed 3200 RPM 8 Siton seat and with brakes applied slowly depress the traction pedal in the direction to be tested forward or reverse While pushing traction pedal down careful ly watch the pressure gauge needle As the traction re lief valve lifts the gauge needle will momentarily stop Traction system pressure as the relief valve opens should be 3625 PSI 250 bar in both forward R3 and re verse R4 NOTE If traction pedal continues to be pressed after the relief valve has opened system pressure can in crease higher than relief pressure 9 Release traction pedal stop engine and record test results NOTE Forward R3 and reverse R4 relief valves are identical Relief valves can be switched in traction pump to help in identifying a faulty relief valve 10 If problem occurs in one direction only interchange the relief valves in the traction pump Fig 35 to see if the problem changes to the other direction Clean orre place valves as necessary These cartridge type valves are factory set and are notadjustable If pressure is in correct and relief valves are in good condition traction pump and or wheel motors should be suspect
258. ry see battery charging in this section B Ifthe battery has recently been charged remove the battery surface charge before performing the load test Disconnectthe engine fuel stop solenoid to prevent the engine from starting Engage the starter motor for ten 10 seconds to remove battery surface charge Reconnect the fuel stop solenoid C Make sure battery terminals are free of corrosion D Measure the temperature of the center battery cell E Connecta battery load testerto the battery termi nals following the load tester manufacturer s in structions Connect a digital multimeter to the battery terminals F Applyatestload of 295 amps one halfthe Crank ing Performance rating of the battery for 15 se conds G Take a battery voltage reading after 15 seconds then remove the load H Using the table below determine the minimum voltage for the cell temperature reading Minimum Battery Electrolyte Voltage Temperature 96 709F and up 219C and up 20 F 7 C 10 F 12 C OF l Ifthe test voltage is below the minimum voltage in the chart replace the battery If the test voltage is at or above the minimum return the battery to service Electrical System Page 5 46 Groundsmaster 4300 D Battery Charging To minimize possible damage to the battery and allow the battery to be fully charged the slow charging meth od is presented here This charging method can be ac complished with a constant
259. s Manual 2 SPEGIAL TOOLS mracan ae we este eee tete 2 SERVICE AND REPAIRS 4 Mh elS s reato EIS OS IUIS EE 4 Steering Column 0 cece 6 Brake Service eee eens 8 Rear Axle Motor Housings 10 RearAxle epis Sie eee e e eL 12 Control ATM us eec d eren Rex Een 16 Operator Seat cioe six CREER XA 18 Mechanical SeatSuspension 20 FrontLiftArms 0 cece cece eee ees 22 Rear LIAMS ccc eee eee eee atas sa 24 a m i o Groundsmaster 4300 D Page 6 1 Chassis Specifications Item Description Front Tire Pressure 26 5 x 14 0 12 4 ply tubeless 12 to 15 PSI 83 to 103 kPa Rear Tire Pressure 20 x 12 0 10 4 ply tubeless 12 to 15 PSI 83 to 103 kPa Wheel Lug Nut Torque 70 to 90 ft lb 95 to 122 N m General Information Operator s Manual The Operator s Manual provides information regarding the operation general maintenance and maintenance intervals for your Groundsmaster 4300 D machine Re fer to that publication for additional information when servicing the machine Special Tools Order Special Tools from your Toro Distributor Wheel Hub Puller The wheel hub puller allows safe removal of the wheel hub from the wheel motor shaft Toro Part Number TOR6004 Chassis Page 6 2 Figure 1 Groundsmaster 4300 D This page is
260. s and Conversions Fractions Decimals mm Fractions Decimals mm 1 64 0 015625 0 397 33 64 0 515625 13 097 1 32 0 08125 0 794 17 32 0 53125 13 494 3 64 0 046875 1 191 35 64 0 546875 13 891 1 6 0 0625 1 588 9 16 0 5625 14 288 5 64 0 078125 1 984 37 64 0 578125 14 684 3 32 0 09375 2 381 19 32 0 59375 15 081 7 64 0 109275 2 778 39 64 0 609375 15 478 1 8 0 1250 8 175 5 8 0 6250 15 875 9 64 0 140625 3 572 41 64 0 640625 16 272 5 32 0 15625 3 969 21 32 0 65625 16 669 11 64 0 171875 4 366 43 64 0 671875 17 066 3 16 0 1875 4 762 11 16 0 6875 17 462 13 04 0 203125 5 159 45 64 0 703125 17 859 7 82 0 21875 5 556 23 32 0 71875 18 256 15 64 0 234375 5 953 47 64 0 734375 18 653 1 4 0 2500 6 350 3 4 0 7500 19 050 17 64 0 265625 6 747 49 64 0 765625 19 447 9 32 0 28125 7 144 25 32 0 78125 19 844 19 64 0 296875 7 541 51 64 0 796875 20 241 5 6 0 3125 7 938 13 16 0 8125 20 638 21 64 0 328125 8 334 53 64 0 828125 21 034 11 32 0 34375 8 731 27 32 0 84375 21 431 23 64 0 359375 9 128 55 64 0 859375 21 828 3 8 0 3750 9 525 7 8 0 8750 22 225 25 64 0 390625 9 922 57 64 0 890625 22 622 13 32 0 40625 10 319 29 32
261. s and correct be fore proceeding with test 9 Move throttle to full speed 3200 RPM Use a tachometer to verify that engine speed is correct IMPORTANT The gear pump is a positive displace ment type If pump flow is completely restricted or stopped damage to the pump tester or other com ponents could occur 10 While watching pressure gauges slowly close the tester flow control valve until 800 PSI 55 bar is ob tained on gauge Groundsmaster 4300 D Page 4 39 FLOW TESTER READING TO BE A pump in good condition should have a flow of approximately 4 9 GPM 18 5 LPM at 800 PSI 55 bar 11 0 pen the tester flow control valve stop engine and record test results 12 Ifflow is less than 4 4 GPM 16 6 LPM ora pressure of 800 PSI 55 bar cannot be obtained consider that a pump problem exists Check for restriction in pump in take line If intake is not restricted remove gear pump and repair or replace pump as necessary see Gear Pump in the Service and Repairs section of this chap ter NOTE Ifthe flow from gear pump P 3 is low the opera tion of both the charge circuitand the steering circuit will be affected 13 After testing is completed make sure that engine is stopped then relieve hydraulic system pressure see Relieving Hydraulic System P ressure in the General In formation section of this chapter Remove tester and then install oil filter assembly and hydraulic tube to ma chine 14 Lower and
262. s and use caution when servicing them 8 To reduce potential fire hazard keep engine area free of excessive grease grass leaves and dirt Clean protective screen on machine frequently 9 If engine mustbe running to perform maintenance or to make an adjustment keep hands feet clothing and other parts of the body away from the cutting decks and other moving parts Keep bystanders away 10 Do not overspeed the engine by changing governor setting To assure Safety and accuracy check maximum engine speed with a tachometer 11 Shut engine off before checking or adding oil to the crankcase Safety Page 1 4 12 Disconnect battery before servicing the machine Disconnect negative battery cable first and positive cable last If battery voltage is required for troubleshoot ing or test procedures temporarily connect the battery Reconnect positive battery cable first and negative cable last 13 Battery acid is poisonous and can cause burns Avoid contact with skin eyes and clothing Protect your face eyes and clothing when working with a battery 14 Battery gases can explode Keep cigarettes sparks and flames away from the battery 15 When changing attachments tires or performing other service use correct supports hoists and jacks Make sure machine is parked on a solid level floor such as a concrete floor P riorto raising the machine remove any attachments that may interfere with the safe and proper raising of the mac
263. s in Chapter 1 Safety Sup port machine with jack stands 5 Remove lug nuts and then remove wheel from ma chine a m i o Groundsmaster 4300 D Page 6 5 Chassis Steering Column Antiseize x QD CM 84 to 120 in Ib 9 5 to 13 5 N m Antiseize x Lubricant Figure 3 1 Steering column 9 Hydraulic tube 16 Flange head screw 2 used 2 Hydraulic fitting 4 used 10 Hydraulic tube 17 Socket head screw 4 used 3 Steering wheel 11 Hydraulic tube 18 Flange nut 2 used 4 Steering wheel cover 12 Hydraulic tube 19 Tube clamp 5 Gear pump 13 Column brace 20 Lock nut 6 Socket head screw 4 used 14 Steering control valve 21 Flat washer 7 Flange nut 15 Flange head screw 2 used 22 O ring 8 O ring Removal Fig 3 3 Remove lock nut and flat washer that secure steer ing wheel to steering column 1 Park the machine on a level surface engage the parking brake lowerthe cutting decks and stop the en 4 Use a suitable puller to remove steering wheel from gine Remove the key from the ignition switch steering column 2 Remove cover from steering wheel by carefully pry ing up on one of the cover spokes Chassis Page6 6 Groundsmaster 4300 D 5 Remove platform shroud from machine to allow ac cess to steering column fasteners Fig 4 A Remove cover plate from platform B Remove fasteners that secure shroud to ma chine C Remove shroud from machine D Locate and retrieve t
264. s section of this chapter 12 After testing is completed make sure that engine is stopped then relieve hydraulic system pressure see Relieving Hydraulic System Pressure in the General In formation section of this chapter Remove tester from machine and connect hydraulic hose to gear pump fit ting 13 Lower and secure operator seat Figure 48 1 Gear pump assembly 2 Pump P1 outlet hose 3 Pump P2 outlet hose Hydraulic System Deck Motor Efficiency Test Using Tester with Pressure Gauges and Flow Meter Install tester in series between fitting and return hose at motor outlet ROTATION DIRECTION MOTOR OUTLET CASE DRAIN FRO MOW C j C U R11 aN cS D A T TESTER Y mia CAP MEASURING CONTAINER Disconnect case drain lt hose attraction deck bulkhead TO RESERVOIR 5 RH FRONT DECK MOTOR EFFICIENCY TEST SHOWN lt MOW CONTROL MANIFOLD Figure 49 NOTE Overa period oftime a deck motor can wearin ternally A worn motor may bypass oil to its case drain causing the motor to be less efficient Eventually enough oil loss will cause the deck motor to stall under heavy cutting conditions Continued operation with a worn inefficient motor can generate excessive heat cause damage to seals and other components in the hy draulic syste
265. s well as subsequent damage to other hydraulic components in the affected system will occur To effectively remove contamination from closed loop traction circuit use ofthe Toro high flow hy draulic filter and hydraulic hose kits are recommended see Special Tools in this chapter 1 Parkmachine on a level surface with engine stopped and key removed from ignition switch 2 Raise and support machine so all wheels are offthe ground see J acking Instructions in Chapter 1 Safety NOTE If wheel motor was replaced install high flow fil terto the inletof the new motor instead ofto the traction pump fitting This will prevent system contamination from entering and damaging the new wheel motor 3 Thoroughly clean junction of hydraulic hose and left side elbow fitting on bottom of traction pump Fig 63 Disconnect hose from left side pump fitting 4 Connect Toro high flow hydraulic filter in series be tween traction pump fitting and disconnected hose Use hydraulic hose kit see Special Tools in this chapter to connectfilterto machine Make sure thatfitting and hose connections are properly tightened IMPORTANT Use only hydraulic fluids specified in Operator s Manual Otherfluids could causesystem damage 5 After installing high flow filter to machine check and fill hydraulic reservoir with new hydraulic oil as required 6 Startengine and run atidle speed Checkforany hy draulic leakage from filter and hose connections
266. secure operator seat Figure 40 3 Hydraulic tube 4 Gear Pump P3 1 Hydraulic tube 2 Oil filter filter adapter Hydraulic System Front Wheel Motor Efficiency Test TO STEERING CONTROL VALVE AND CHARGE CIRCUIT TO MOW CONTROL FRONT CUTTING UNITS TO LIFT CONTROL MANIFOLD TO MOW CONTROL REAR CUTTING UNITS i 100 MES SUCTION STRAINER INTERNAL A BYPASS VALVE JV M30J gt CROSSTRAX MANIFOLD PISTON TRACTION PUMP FROM STEERING CONTROL VALVE RH FRONT WHEEL MOTOR EFFICIENCY TEST SHOWN Figure 41 Procedure for Front Wheel Motor Efficiency Test NOTE Over a period of time a wheel motor can wear internally A worn motor may bypass oil internally caus ing the motor to be less efficient Eventually enough oil loss will cause the wheel motor to stall under heavy load conditions Continued operation with a worn inefficient motor can generate excessive heat cause damage to seals and other components in the hydraulic system and affect overall machine performance IMPORTANT Refer to Traction Circuit Component Failure in the General Information section of this chapter for information regarding the importance of remo
267. sion drive shaft to engine see Hydraulic Transmission Drive Shaft Installation in the Service and Repairs section of Chapter 4 Hydrau lic System 6 Connect all wire harness connectors to correct en gine components Groundsmaster 4300 D 7 Remove plugs installed in hoses during disassem 9 Install air cleaner see Air Cleaner Installation in this bly Connect hoses to the engine section A Connect fuel supply and fuel return hoses to en 10 Install exhaust system to machine see Exhaust gine fittings Fig 11 Secure with hose clamps S ystem Installation in this section B Connect upper and lower radiator hoses to the 11 Make sure radiator draincock is closed threaded out engine Secure with hose clamps fully Fill radiator with coolant and install radiator cap see Radiator Installation in this section 8 Connect throttle cable to injector pump Fig 10 12 Check engine oil level and adjust if needed A Route throttle cable to injector pump on engine 13 Connect positive battery cable to the battery and B Install the throttle cable end into the swivel in then connect negative cable speed control lever Secure cable end with cap screw 14 Bleed fuel system C Position cable under cable clamp 15 Close and secure hood D Adjust throttle control see Adjust Throttle Con trol in the Adjustments section of this chapter 9 9 ul i 8 8 Groundsmaster 4300 D Page 3 15 K
268. spindle housing Installation Fig 3 1 If studs were removed from spindle housing press studs fully into housing holes Make sure thatstud head is seated squarely against housing 2 Position spindle assembly and spindle plate to cut ting deck Align grease fittings on spindle with notches on cutting deck and spindle plate toward front of deck 3 Secure spindle to cutting deck with six 6 flange nuts Tighten flange nuts in a star pattern 4 Install cutting blade anti scalp cup and blade bolt Tighten blade bolt from 85 to 110 ft Ib 115 to 149 N m Groundsmaster 4300 D Page7 9 5 Remove cover from top of spindle that was placed to prevent debris from entering spindle 6 Make sure thatO ring is positioned to top of spindle housing Secure hydraulic motor to the cutting deck with two 2 socket head screws and flat washers IMPORTANT Pneumatic grease guns can produce high pressure inside spindle housing that can dam age spindle seals Pneumatic grease guns there fore are not recommended to be used for greasing of spindle housings 7 Attach a hand pump grease gun to one ofthe grease fittings on housing and fill housing cavity with grease un til grease starts to come out of lower seal 8 After assembly raise and lower the cutting deck to verify that hydraulic hoses and fittings do not contact anything Figure 4 1 Socket head screw 2 Hydraulic motor Cutting Decks Blade Spindle Service D
269. splay InputFunctions 8 WII 35 Verify Diagnostic Display OutputFunctions 10 Diode Assembly 36 TEC Controller Logic Chart 11 Fusible Link Harness 37 Starting Problems 12 Hydraulic Solenoid Valve Coil 38 General Run and Transport Problems 14 Temperature Sender 39 Cutting Deck Operating Problems 15 High Temperature Shutdown Switch 40 ELECTRICAL SYSTEM QUICK CHECKS 17 Oil Pressure Switch 41 Battery Test Open Circuit Test 17 Fuel Stop Solenoid 42 Charging System Test 17 F el PUMP y ass tea em er Rea EE Le 43 Glow Plug System Test 17 SERVICE AND REPAIRS 44 Check Operation of Interlock Switches 18 Battery Storage cece eee eee eee 44 ADJUSTMENTS of tiara dit acid recettes 19 Battery Care s ees ccc eet Rd 44 Traction Neutral Switch 19 Battery Service 45 Parking Brake Switch 20 Battery Removal and Installation 45 Mow Transport Switch 21 Battery Inspection and Maintenance 45 COMPONENT TESTING 22 Battery Testing 46 Ignition S witch i ee cemere 22 Battery Charging
270. st lift arm bore E After bushing installation make sure that lift arm slides easily onto pivot shaft If binding is noted lo cate and correct source of binding 7 If necessary remove cap screw that secures pivot shaft item 11 in lift arm Remove pivot shaft from lift arm 8 Ifnecessary remove roll pin item 13 and liftarm piv ot shaft item 9 from frame Discard roll pin Installation Fig 22 1 If lift arm pivot shaft item 9 was removed from frame apply antiseize lubricant to pivot shaft surface andinsertshaftinto frame Align holes in frame and pivot shaft Secure pivot shaft with new roll pin item 13 2 If pivotshaft item 11 was removed from lift arm in sert pivot shaft into lift arm and secure with cap screw item 14 3 Slide rear lift arm onto pivot shaft 4 Secure rear lift arm to machine A Apply Permatex Blue Gel Threadlocker or equiv alent to threads of screws items 4 6 and 8 B Position bridge plate and bulkhead bracket with attached hydraulic hoses to liftarm and frame brack et Groundsmaster 4300 D Page 6 25 C Install screws flat washers items 5 and 10 and flange nut item 7 to bridge plate bulkhead bracket pivot shafts and frame bracket D Torque 1 2 fasteners items 4 and 8 from 75 to 95 ft Ib 102 to 128 N m Then torque 5 8 fasten ers item 6 from 135 to 165 ft lb 183 to 223 N m 5 Connect lift cylinder to lift arm Fig 21 A Align lif
271. supported by inde pendentliftarms and are interchangeable to any cutting deck positions The Groundsmaster 4300 D uses five 5 cutting decks CONSTRUCTION Deck chamber and frame are welded steel construction reinforced with channels and plates HEIGHT OF CUT RANGE 3 4 to 4 inch 19 to 101 mm in 1 4 inch 6 4 mm increments Height of cutad justmentis made by repositioning deck on deck frame DECK DRIVE Closed loop integrated relief hydraulic system operates cutting deck hydraulic motors Blade spindles are 1 1 4 inch 31 7 mm shafts supported by greaseable tapered roller bearings in a ductile iron housing CUTTING BLADE Each cutting deck equipped with a 22 inch 559 mm length 0 250 inch 6 4 mm thick heat treated steel blade Anti scalp cup installed on cutting blade The standard blade is optimized for most cutting applications Optional high lift angled sail and Atomic blades are available for those situations where the stan dard blade is not ideal Cutting Decks Page 7 2 DISCHARGE Clippings are discharged from the rear of the mowing decks Pre drilled mounting holes in the cutting deck allow attachment of optional mulching baffle CUTTING DECK LIFT Cutting decks on the Ground smaster 4300 D are controlled with the operator joy stick SUSPENSION SYSTEM A fully floating suspension with hydraulic counterbalance Main center pivot allows side to side deck oscillation Individual decks sup ported wit
272. sure hydraulic oil is at normal operating tem perature 2 Park machine on a level surface with the cutting decks lowered and PTO switch off Make sure engine is off Apply the parking brake 3 Read Precautions For Hydraulic Testing oH Before opening hydraulic system operate all hy Figure 62 draulic controls to relieve system pressure and 1 Steering cylinder 2 Rod end fitting avoid injury from pressurized hydraulic oil See Relieving Hydraulic System Pressure in the Gen eral Information section of this chapter 4 Turnthe steering wheel fora rightturn clockwise so the steering cylinder rod is fully extended 5 Thoroughly clean the area around the hydraulic hose at the rod end of the steering cylinder Fig 62 6 Place a drain pan under the steering cylinder Re move hydraulic hose from the fitting on the rod end ofthe steering cylinder Cap the end of the hose 7 Remove all hydraulic oil from drain pan Make sure that empty drain pan remains under the open fitting of the steering cylinder 8 With the engine off continue turning the steering wheel for a right turn clockwise with the steering cylin der fully extended Observe the open fitting on the steer ing cylinder as the wheel is turned If oil comes outof the fitting while turning the steering wheel to the right the steering cylinder has internal leakage and should be in spected and repaired see Steering Cylinder and Steer ing Cylinder S
273. t trol Manifold Service in this section Refer to Figure 92 edly for lift control manifold cartridge valve installation torque Hydraulic System Page 4 102 Groundsmaster 4300 D Hydraulic System This page is intentionally blank Groundsmaster 4300 D Page 4 103 Hydraulic System Lift Cylinder 67 to 83 ft lb 91 to 112 N m Figure 93 1 Lift cylinder 6 Hydraulic hose 10 Hydraulic hose 2 Pivot shaft 7 O ring 11 Retaining ring 3 Flange head screw 8 90 hydraulic fitting 12 Thrust washer 4 Lift arm 1 shown 9 O ring 13 Cylinder slide pin 5 Flat washer NOTE The procedure for lift cylinder removal and installation is the same for all Groundsmaster 4300 D lift cylinders Figure 93 shows the center front deck 1 lift cylinder Removal Fig 93 GROUNDSMASTER 1 Park the machine on a level surface engage the 4300 D CUTTING parking brake lower the cutting decks and stop the en gine Remove the key from the ignition switch DECK LOCATIONS 2 Read the General Precautions for Removing and Installing Hydraulic System Components at the begin ning of the Service and Repairs section of this chapter Figure 94 Hydraulic System Page 4 104 Groundsmaster 4300 D 3 If lift cylinder for deck or 5 is being removed re move flange nutand carriage screw thatsecure r clamp to lift cylinder Fig 95 4 Label all hydraulic connections for assembly pur poses Thoroughly clean hydraulic c
274. t Drawings 10 Connect wire harness electrical connector to the joystick switch 11 Install control arm covers to machine see Control Arm Assembly in the Service and Repairs section of Chapter 6 Chassis d FRONT Figure 29 1 Joystick 3 Raise switch 2 Lowerswitch Figure 30 3 NC terminal not used 4 Switch lever 1 NO terminal 2 Common terminal Groundsmaster 4300 D Traction Neutral Switch The traction neutral switch is a normally open proximity switch that closes when the traction pedal is in the neu tral position The switch mounts to a bracket on the trac tion pump Fig 31 The sensing plate for the traction neutral switch is the traction lever bracketthatis secured to the pump control arm The neutral switch is used as an input for the TEC controller Testing 1 Before disconnecting the traction neutral switch for testing the switch and its circuit wiring should be tested as a TEC controller input with the Diagnostic Display see Diagnostic Display in the Troubleshooting section of this chapter If the Diagnostic Display verifies thatthe traction neutral switch and circuit wiring are functioning correctly no further switch testing is necessary If how ever the Diagnostic Display determines thatthe traction neutral switch and circuit wiring are not functioning cor rectly proceed with testing procedure 2 Turn ignition switch to the ON position do not start engine and ch
275. t cylinder rod end to lift arm mounting holes B Slide cylinder pin with retaining ring and thrust washer through the lift cylinder and lift arm C Install second thrust washer on pin and secure with second retaining ring D Position r clamp and hydraulic hoses to lift arm Secure r clamp with screw 6 Mountcutting deck to liftarm see Cutting Deck Car rier Frame Installation in the Service and Repairs sec tion of Chapter 7 Cutting Decks 7 Lubricate lift arm and lift cylinder grease fittings Figure 23 1 Liftarm 2 shown 5 Cylinder pin 2 Liftcylinder 6 R clamp 3 Retaining ring 7 Screw 4 Thrust washer Chassis A m i to o This page is intentionally blank Chassis Page 6 26 Groundsmaster 4300 D TORO Table of Contents SPECIFICATIONS ulus iri usss GENERAL INFORMATION Operator s Manual TROUBLESHOOTING Factors That Can Affect Quality of Cut SPECIAL TOOLS ADJUSTMENTS Blade Stopping Time SERVICE AND REPAIRS Blade Spindle Assembly Blade Spindle Service RearRoller Rear Roller Service Front Roller Service Cutting Deck Carrier Frame Groundsmaster 4300 D Page7 1 Chapter 7 Cutting Decks Cutting Decks Specifications MOUNTING All cutting decks are
276. t may interfere with the safe and proper raising of the machine Always chock or block wheels Use jack stands or other ap propriate load holding devices to support the raised machine If the machine is not properly supported the machine may move or fall which may result in personal injury Front End J acking 1 Apply parking brake and chock both rear tires to pre vent the machine from moving 2 Position jack securely under the rectangular pad on the frame axle tube just to the inside of the front wheel Fig 1 3 Jack front of machine off the ground 4 Position jack stands under the frame as close to the wheel as possible to support the machine Rear End J acking 1 Apply parking brake and chock both fronttires to pre vent the machine from moving 2 Place jack securely atthe center of the rear axle un der the axle pivot bracket J ack rear of machine off the ground 3 Position jack stands under the frame to support the machine Groundmaster 4300 D Figure 1 1 Front wheel 2 Frontjacking point Figure 2 3 Jack stand location 1 Rear wheel 2 Rear axle pivot bracket Pagel 5 Safety Safety and Instruction Decals Numerous safety and instruction decals are affixed to the traction unit and cutting units of your Groundsmas ter If any decal becomes illegible or damaged install a new decal Part numbers for decals are listed in your Part Catalog Order replacement decals from your Au tho
277. t pin 21 Steering cylinder 36 O ring 7 Thrust washer 22 Ball joint 37 Hydraulic hose 8 Roll pin 23 Ball joint 38 Woodruff key 9 Thrust washer 24 Retaining ring 39 LH drag link 10 J am nut 25 Lock washer 4 used per motor 40 Flange head screw 3 used per link 11 Grease fitting 26 Wheel assembly 41 Flange head screw 12 Wheel motor LH shown 27 Grease fitting 42 Spindle cap 13 Wheel hub assembly 28 Bushing 43 Retaining ring 14 Motor housing 29 Slotted hex nut 44 RH drag link 15 O ring 30 Hydraulic hose 45 Flange bushing 4 used Chassis Page 6 12 Groundsmaster 4300 D Rear Axle Removal Fig 9 1 Park machine on a level surface lower cutting decks stop engine engage parking brake and remove key from the ignition switch 2 Chock front wheels to preventmachine from shifting 3 Remove both rearwheel assemblies see Wheel Re moval in this section Make sure that machine is sup ported with appropriate jack stands 4 Remove cotter pins and slotted hex nuts thatsecure the tie rod ends to the drag links Separate the tie rod ends from the drag links and remove tie rod from axle 5 Remove steering cylinder from rear axle see Steer ing Cylinder R emovalinthe Service and Repairs section of Chapter 4 Hydraulic System 6 Remove wheel motor housings from rear axle see Rear Axle Motor Housing Removal in this section 7 To allow removal of the rear axle pivot pin remove the three 3 cap screws
278. t seal against roller shoulder Fig 14 Make sure that bearing still freely rotates after seal installation D Using the same process install second outer sealmaking sureto notcrush the installed outerseal Again make sure that bearing still freely rotates Cutting Decks 50 to 60 ft Ib 68 to 81 N m Loctite 242 Figure 11 1 Roller tube 5 Outer seal 2 Roller shaft 6 Bearing lock nut 3 Inner seal 7 Setscrew 4 Bearing Page 7 14 Figure 12 1 Roller tube 3 Inner seal tool 2 Inner seal Figure 13 3 Bearing 4 Bearing outer seal tool 1 Roller tube 2 Inner seal Groundsmaster 4300 D 3 From the roller tube end with only the inner seal installed carefully install the roller shaft into the roller tube Make sure thatseals are not damaged as shaftis installed 4 Install new bearing and outer seals into second end of roller tube A Position a second new bearing to roller shaft and tube Position washer see Special Tools in this chapter on bearing to allow pressing on both inner and outer bearing races simultaneously B Use washer and bearing outer seal tool see Special Tools in this chapter with a softface hammer to fully seat bearing Fig 15 After bearing installa tion make sure that shaft
279. t wiring are notfunctioning correctly park machine on level surface lower cutting decks stop engine apply parking brake and remove key from ignition switch 3 To gain access to deck control manifold Fig 46 raise and prop the operator seat Access to the lift con trol manifold Fig 47 can be obtained by removing the operator floor plate 4 Disconnect harness electrical connector from hy draulic solenoid valve coil thatis to be tested Fig 46 or 47 NOTE Prior to taking small resistance readings with a digital multimeter short the meter test leads together The meter may display a small resistance value usually 0 5 ohms or less This resistance is due to the internal resistance ofthe meter and testleads Subtractthis val ue from the measured value of the component you are testing 5 Using a multimeter ohms setting measure resis tance between the two connector terminals on the sole noid valve coil The resistance for the solenoid coils is identified below PRV1 and PRV2 deck 7 1 ohms 7 1 ohms 6 If solenoid coil resistance is incorrect replace sole noid see Hydraulic Solenoid Valve Coil Removal and Installation in the Service and Repairs section of this chapter SV1 and PRV lift S V2 lift Electrical System Page 5 38 NOTE The two 2 solenoid valve coils on the deck control manifold PRV1 and PRV2 are identical Sole noid valve coils SV1 and PRV on the lift control manifold are iden
280. tch to the ON position do not start engine and check LED on cable end of brake switch Fig 32 LED should be illuminated when the parking brake is not applied 3 With the ignition switch still in the ON position do not start engine apply parking brake and check LED on cable end of parking brake switch LED should not be illuminated when the parking brake is applied 4 If the brake switch LED did not function correctly A Make sure that brake switch is properly adjusted see Parking Brake Switch in the Adjustments sec tion of this chapter If necessary adjust switch and return to step 2 above B Make sure ignition switch is OFF and disconnect the parking brake switch connector from the ma chine wire harness C Verify that the machine wire harness connector terminal for black wire is closed continuity to ground Electrical System Page 5 30 D Turn ignition switch to the ON position do not start engine and verify with a multimeter that ma chine wire harness connector terminal for pink wire has system voltage 12 VDC present E If black wire is closed to ground pink wire has system voltage presentand switch LED did not func tion replace parking brake switch Adjust switch af ter installation see Parking Brake Switch in the Adjustments section of this chapter 5 If the parking brake switch tests correctly and a cir cuit problem still exists check wire harness see Electri cal Schematic and Cir
281. tem E b System Diagnostic Display Groundsmaster 4300 D machines are equipped with a TEC controller which controls machine electrical func tions The controller monitors various input switches e g ignition switch seat switch etc and energizes outputs to actuate solenoids or relays forthe requested machine function For the controller to control the machine as desired each of the input switches output solenoids and relays must be connected and functioning properly The Diagnostic Display see Special Tools in this chap ter is a toolto helpthe technician verify correctelectrical functions of the machine IMPORTANT The Diagnostic Display must not be left connected to the machine It is not designed to withstand the environment of the machine s every day use When useofthe Diagnostic Display is com pleted disconnect it from the machine and recon nectloopback connector to harness connector The machine will notoperate withoutthe loopback con nector installed on the harness Store the Diagnos tic Display in a dry secure indoor location not on machine Verify Diagnostic Display Input Functions The interlock switches are for the protection of the operator and bystanders and to ensure cor rect operation of the machine Do not bypass or disconnectswitches Check the operation of the interlock switches daily for properoperation Re place any malfunctioning switches before oper ating the machine 1 Park
282. the backup gaskets flat side outward between the pressure seals and the grooves in the wear plate 5 Apply alightcoating of petroleum jelly to the exposed side of the front flange 6 Lubricate the drive gear shaftwith clean hydraulic oil Insert the drive end of the drive shaft through the wear plate with the pressure seal side down and the open side of the pressure seal pointing to the inlet side of the mo tor Carefully install shaft into front flange 7 Lubricate the idler gear shaft with clean hydraulic oil Install idler gear shaft into the remaining position in the front wear plate Apply a light coating of clean hydraulic oil to gear faces Hydraulic System Page 4 98 8 Install rear wear plate with pressure seal side up and open side of the pressure seal pointing to the inlet side of the motor 9 Apply a light coating of petroleum jelly to new O rings and O ring grooves in the body Install new O rings to the body 10 Install locating dowels in body Align marker line on the body and front flange IMPORTANT Do not dislodge seals during installa tion 11 Gently slide the body onto the assembly Firm hand pressure should be sufficient to engage the dowels 12 Check to make sure that the surface of the rear wear plate is slightly below the face of the body If the wear plate is not below the body check assembly for a shifted pressure seal backup gasket or O ring Correct before proceeding 13 Applya li
283. the seat cushion approaches the bottom of its travel 7 If seat switch is faulty replace switch see Operator Seat Removal in the Service and Repairs section of Chapter 6 Chassis 8 Ifthe seatswitch tests correctly and a circuit problem still exists check wire harness see Electrical Schemat ic and Circuit Drawings in Chapter 8 Foldout Draw ings 9 Connect wire harness electrical connector to the seat switch electrical lead 1 Seat switch lead 1 Operator seat 2 Seat switch Groundsmaster 4300 D Page 5 27 i ee x WWW Figure 27 2 Electrical connector Figure 28 3 Screw 2 used 4 Seatwire harness Electrical System Electrical Joystick Raise and Lower Switches Two 2 micro switches forthe joystick are located on the lift control that is attached to the control arm The rear switch on the control is used to lower and engage the cutting decks and the front switch to raise and disen gage them These switches are used as inputs for the TEC controller A normally open contact in the switch closes when the joystick is positioned to either lower or raise the cutting decks Each switch has an electrical connector to make sure the normally closed contacton the switch is notused The raise switch has yellow blue and black harness wires connected to it and the lower switch has orange and black harness wires connected to it Testing 1 Before disconnecting the joystic
284. the wheel hub from the wheel motor shaft Toro Part Number TOR6004 Figure 29 Measuring Container Use this graduated container for doing hydraulic motor efficiency testing motors with case drain lines only Measure efficiency ofa hydraulic motor by restricting the outlet flow from the motor and measuring leakage from the case drain line while the motor is pressurized by the hydraulic system The table in Figure 31 provides gallons per minute GPM conversion for measured milliliter or ounce leak age Toro Part Number TOR4077 Figure 30 GPM Milliliters in 15 sec Ounces in 15 sec 4 95 3 2 2 189 6 4 3 284 9 6 4 378 12 8 E 473 16 0 6 568 19 2 7 662 22 4 8 756 25 6 9 852 28 8 10 946 32 0 Figure 31 Groundsmaster 4300 D Page 4 25 Hydraulic System Troubleshooting The cause of an improperly functioning hydraulic sys tem is best diagnosed with the use of proper testing equipment and a thorough understanding of the com plete hydraulic system A hydraulic system with an excessive increase in heat ornoise has a potential forfailure Should either of these conditions be noticed immediately stop the machine turn off the engine locate the cause of the trouble and correctit before allowing the machine to be used again Continued use of an improperly functioning hydraulic system could lead to extensive hydraulic component damage Genera
285. tical and are the same as those used on the deck manifold The remaining lift manifold coil SV2 is different To assistin troubleshooting identical coils can be exchanged If the problem follows the exchanged coil an electrical problem likely exists with the coil Ifthe problem remains unchanged something other than the solenoid coil is the problem source e g switch circuit wiring hydraulic problem 7 Connectwire harness electrical connector to the so lenoid valve coil after testing is completed 8 Lower and secure seat if deck control manifold was accessed Install operator floor plate if lift control man ifold was accessed Figure 46 1 Deck control manifold 2 PRV2 solenoid 3 PRV1 solenoid Figure 47 3 SV2 solenoid 4 PRV solenoid 1 Lift control manifold 2 SV1 solenoid Groundsmaster 4300 D Temperature Sender The temperature sender is attached to the water pump housing on the engine and has a gray wire attached to it Fig 48 The resistance of the temperature sender re duces as the engine coolant temperature increases The changing resistance of the temperature sender sig nals the console temperature gauge to indicate engine coolant temperature level during machine operation When coolant temperature rises to approximately 221 F 105 C temperature sender resistance causes the temperature gauge to provide an input to the TEC controller This controller input causes the high temper ature
286. tinued The rear cutting decks do not operate Front cutting decks operate Cutting decks are able to raise and lower None of the cutting decks will lower None of the cutting decks will raise One cutting deck will not raise or lower but all other cutting decks will raise and lower Electrical System Page 5 16 Possible Causes Deck control manifold PRV1 solenoid coil or circuit wiring is faulty A hydraulic problem in rear mow circuit exists see Troubleshooting section of Chapter 4 Hydraulic System TEC controller is faulty Mow speed limiter is in the transport position Lower mow switch on joystick or circuit wiring is faulty Mow transport switch or circuit wiring is faulty Lift control manifold P RV solenoid coil or circuit wiring is faulty Lift control manifold S 1 solenoid coil or circuit wiring is faulty A hydraulic problem in cutting deck lift lower circuit exists see Troubleshooting section of Chapter 4 Hydraulic S ystem TEC controller is faulty Raise switch on joystick or circuit wiring is faulty Lift control manifold P RV solenoid coil or circuit wiring is faulty Lift control manifold S2 solenoid coil or circuit wiring is faulty A hydraulic problem in cutting deck lift lower circuit exists see Troubleshooting section of Chapter 4 Hydraulic S ystem TEC controller is faulty A hydraulic problem in cutting deck lift lower circuit exists see Troubleshooting section
287. tion relief valve R3 located in the traction pump Oil flowing from the wheel motors returns to the variable displacement pump and is continuously pumped through the traction circuit as long as the traction pedal is pushed The angle ofthe swash plate determines pump flow and ultimately traction speed When the traction pedalis de pressed a smallamount a small swash plate rotation re sults in low pump outputand lowertraction speed When the traction pedal is depressed fully the pump swash plate rotates fully to provide maximum pump output and traction speed Groundsmaster 4300 D Page 4 11 Gearpump section P 3 supplies oil flow for the steering circuitand also provides a constantsupply of charge oil to the closed loop traction circuit This charge oil pro vides lubrication fortraction circuitcomponents and also replenishes traction circuit oil that is lost due to internal leakage in the traction circuit Gear pump section P3 takes its suction from the hy draulic reservoir Charge pumpflow is directed to the low pressure side of the closed loop traction circuit Charge relief valve R5 located in the traction pump limits the charge relief pressure to 200 PSI 14 bar The piston pump is equipped with a case drain to allow internal leakage to be removed from the pump The case drain is connected to the gear pump inlet The piston pump P5 includes a flushing valve that bleeds off a small amount of hydraulic fluid for
288. to a container gra duated in ounces or milliliters e g Toro TOR4077 and collect hydraulic fluid for 15 seconds After 15 sec onds remove hose end from container Then move the PTO switch to OFF open the tester flow control valve and stop the engine 11 Identify amount of oil collected in the container Re cord test results If flow was greater than 22 4 ounces 662 millili ters 0 7 GPM 2 6 LPM repair or replace the tested deck motor see Cutting Deck Motor Service in the Service and Repairs section of this chapter Ifflow is less than 22 4 ounces 662 milliliters 0 7 GPM 2 6 LPM the tested motor does nothave ex cessive leakage 12 After testing is completed make sure that engine is stopped then relieve hydraulic system pressure see Relieving Hydraulic System Pressure in the General In formation section of this chapter Disconnect tester from motor and return hose Connectreturn hose to the deck motor Remove plug from machine bulkhead fitting and connect case drain hose to the fitting 13 If necessary perform motor efficiency test on other deck motors Figure 50 1 Case drain hose 3 Return hose 2 Bulkhead fitting Hydraulic System Lift Relief Valve PRV Pressure Test TO STEERING CONTROL VALVE TO DECK CONTROL MANIFOLD FRONT CUTTING UNITS lt lt TO DECK CONTROL MANIFOLD REAR CUTTING UNITS a OOOO PUMP P5 INTERNAL 100 MESH CASE A SUCT
289. to steering column with flat washer and lock nut Torque lock nut from 20 to 26 ft Ib 28 to 35 N m 9 BwNp Groundsmaster 4300 D Page 6 7 Ea EIE Install steering wheel cover to steering wheel Washer 2 used Screw 2 used Washer head screw Platform shroud Figure 5 Steering column 7 Pin 8 Universal joint 9 Pin 10 Lock washer 2 used 11 Cylinder 12 Lock nut 2 used Cover plate Bushing 2 used Spacer 2 used Chassis Bolt 2 used Pin Pedal block Pedal cover Pedal Spring Chassis Brake Service RIGHT 70 to 90 ft Ib 315 to 385 ft lb 95 to 122 N m 427 to 521 N m FRONT a Figure 6 1 LH wheel motor 12 Lock nut 4 used per wheel motor 23 Clevis pin 2 used 2 Lug nut 5 used per wheel 13 Cap screw 4 used per wheel motor 24 LH brake assembly 3 Hub 14 Brake bracket 2 used 25 RH brake assembly 4 Wheel assembly 15 Lock nut 2 used per wheel shield 26 Cap screw 4 used per brake assy 5 Hydraulic fitting 2 used per motor 16 RH wheel motor 27 Lock nut 4 used per brake assy 6 Hydraulic tube 17 Lock nut 2 used 28 Square key 7 Hydraulic tube 18 Flat washer 2 used per wheel shield 29 Retum spring 1 used per bracket 8 Cap screw 2 used per wheel shield 19 Brake drum 2 used 30 Brake spring bracket 2 used 9 O ring 20 Front wheel shield LH shown 31 Flange nut 1 used per bracket 10 Hydraulic tube 21 Rear wheel shield LH shown 3
290. ts and powerpoint inoperative as well TEC controller fuses are faulty E F Fusible link harness atthe engine starter motor is faulty Wiring to start circuit components is loose corroded or damaged see Electrical Schematic and Circuit Drawings in Chapter 8 Foldout Drawings High temperature shutdown switch or circuit wiring is faulty Starter solenoid or starter motor is faulty TEC controller is faulty Electrical System General Run and Transport Problems Engine continues to run but should not when the ignition switch is turned off Engine continues to run but should not when the traction pedal is engaged with no operator in the seat The engine stops during operation but is able to restart NOTE Excessive coolant temperature will cause the cutting decks to be disengaged and can lead to engine shutdown If excessive coolant temperature causes en gine shutdown the operator can restart the engine to al low the machine to be moved a short distance Aftera re startin this condition the engine will run for approximate ly ten 10 seconds before the engine shuts down again The engine kills when the traction pedal is depressed Battery does not charge Electrical System Page 5 14 Possible Causes Engine fuel stop solenoid is faulty Ignition switch or circuit wiring is faulty Main power relay or circuit wiring is faulty Seat switch or circuit wiring is faulty Traction neutra
291. ttery Care 1 Battery electrolyte level must be properly main tained The top of the battery must be kept clean If the machine is stored in a location where temperatures are extremely high the battery will discharge more rapidly than ifthe machine is stored in a location where temper atures are cool Wear safety goggles and rubber gloves when working with electrolyte Charge battery in a well ventilated place so gasses produced while charging can dissipate Since the gases are explosive keep open flames and electrical sparks away from the battery do not smoke Nausea may resultifthe gases are inhaled Un plug charger from electrical outlet before con necting or disconnecting charger leads to or from battery posts IMPORTANT Do not remove battery fill caps while cleaning 2 Check battery condition weekly or after every 50 hours of operation Keep terminals and entire battery case clean because a dirty battery will discharge slowly A Clean battery by washing entire case with a solu tion ofbaking soda and water R inse with clear water B Coat battery posts and cable connectors with Battery Terminal Protector Toro PartNo 107 0392 or petroleum jelly to prevent corrosion Electrical System Page 5 44 4 Store battery in a cool atmosphere to avoid quick de terioration of the battery charge 5 To help preventthe battery from freezing make sure itis fully charged see Battery Service in this section
292. ublication for additional information when servicing the machine Check Hydraulic Fluid The hydraulic system on your Groundsmaster is de signed to operate on high quality hydraulic fluid The hy draulic system reservoir holds approximately 14 U S gallons 53 liters of hydraulic fluid Check level of hy draulic fluid daily S ee O perator s Manual for fluid level checking procedure and hydraulic oil recommenda tions Towing Machine IMPORTANT If towing limits are exceeded severe damage to the piston traction pump may occur If it becomes necessary to tow or push the machine tow or push ata speed below 3 mph 4 8 kph and for a very short distance Ifthe machine needs to be moved a con siderable distance machine should be transported ona trailer The piston traction pump is equipped with a by pass valve thatneeds to be loosened for towing or push ing Fig 2 Refer to Operator s Manual for Towing Procedures Figure 1 1 Hydraulic reservoir cap Figure 2 1 Piston traction pump 2 Bypass valve Groundsmaster 4300 D Page 4 3 Hydraulic System Hydraulic Hoses Hydraulic hoses are subject to extreme conditions such as pressure differentials during operation and exposure to weather sun chemicals very warm storage condi tions or mishandling during operation and maintenance These conditions can cause hose damage and deterio ration Some hoses are more susceptible to these conditions than others
293. ubota Diesel Engine This page is intentionally blank Kubota Diesel Engine Page 3 16 Groundsmaster 4300 D TORO Table of Contents SPECIFICATIONS eet Sekar eae 2 GENERAL INFORMATION 3 Operator s Manual 3 Check Hydraulic Fluid 3 Towing Machine 3 Hydraulic HOSES 4 Hydraulic Hose and Tube Installation 5 Hydraulic Fitting Installation 6 Relieving Hydraulic System Pressure 8 Traction Circuit Component Failure 8 HYDRAULIC SCHEMATIC 9 HYDRAULIC FLOW DIAGRAMS 10 Traction Circuit s s eum toe ts 10 MOW CIFCUIE testes carn eae ete RET ee d 12 Mow Circuit Cutting Deck Blade Braking 14 Lift Circuit Raise Cutting Decks 16 Lift Circuit Lower Cutting Decks 18 Steering Circuit 20 SPEGIAL TOOLS 5 enr foe ica eens Gee ace 22 TROUBLESHOOTING 26 General Hydraulic System Problems 26 Traction Circuit Problems 27 Mow Circuit Problems 28 Lift Circuit Problems 29 Steering Circuit Problems 30 RESTING cue Pepa n p ha aa Le ate det daa 32 Traction Circuit Relief Valve R3 and R4 Pressure Test 34 Traction Circuit
294. ure that clearance be tween head of parking brake switch and tab on the park ing brake detent has not changed 3 Afteradjustmentto the parking brake switch use the Diagnostic Display see Special Tools in this chapter to verify that parking brake switch and circuit wiring are functioning correctly see Parking Brake S witch in the Component Testing section of this chapter Figure 16 1 Parking brake switch 4 Parking brake detent 2 Lock washer 2 used 5 Brake pedal 3 Jam nut 2 used Electrical System Page 5 20 Groundsmaster 4300 D Mow Transport Switch The mow transport switch is a normally closed proximity switch thatopens when the mow speed limiter is placed in the transport position The switch mounts to a bracket on the footrest platform Fig 17 The sensing plate for the mow transportswitch is a tab on the mow speed lim iter Adjustment 1 The gap between the mow transport switch and the mow speed limiter should be from 0 070 to 0 100 1 8 to 2 5 mm 2 Ifgapis incorrect loosen jam nuts thatsecure switch to footrest platform P osition switch with jam nuts to al low correct gap between switch and mow speed limiter Tighten jam nuts to secure adjustment J am nuts should be torqued from 162 to 198 in Ib 18 4 to 22 4 N m After jam nuts are tightened make sure that clearance between head of mow transport switch and the mow speed limiter has not changed 3 After adjustment to the mow transport sw
295. ury or death To reduce the potential for injury or death comply with the following safety instruc tions Before Operating 1 Review and understand the contents of the Opera tor s Manual and Operator Training DVD before starting and operating the machine Become familiar with the controls and know how to stop the machine and engine quickly A replacement Operator s Manual is available on the Internet at www Toro com 2 Keep allshields safety devices and decals in place If a shield safety device or decal is defective illegible or damaged repair or replace it before operating the machine 3 Tighten any loose nuts bolts or screws to ensure machine is in safe operating condition 4 Assure interlock switches are adjusted correctly so engine cannot be started unless traction pedal is in NEUTRAL and PTO switch is OFF disengaged Safety Pagel 2 A WARNING To reduce the potential for injury or death com ply with the following safety instructions 5 Since diesel fuel is highly flammable handle it care fully A Store fuel in containers specifically designed for this purpose B Do not remove machine fuel tank cap while en gine is hot or running C Do not smoke while handling fuel D Fill fuel tank outdoors and only to within an inch of the top of the tank not the filler neck Do not overfill E After refueling machine install fuel tank and fuel container caps F Iffuelis spilled do not att
296. usible link harness After testing is complete make sure that fusible link is securely attached to starter B terminal and machine wire harness Connect positive battery cable to bat tery terminal firstand then connectnegative cable to battery Groundsmaster 4300 D Page 5 37 Figure 44 2 Fusible link harness FUSIBLE LINK FUSIBLE LINK A 7 J1 STARTER B TO MAIN HARNESS M FUSIBLE LINK Figure 45 Electrical System E b u Hydraulic Solenoid Valve Coil The Groundsmaster 4300 D hydraulic system uses several hydraulic solenoid valve coils forsystem control The deck control manifold includes two 2 solenoid valves Fig 46 and the lift control manifold includes three 3 solenoid valves Fig 47 When the solenoid coils are energized hydraulic valve shift occurs to con trol hydraulic flow Testing of the coils can be done with the coil installed on the hydraulic valve Testing 1 Before disconnecting solenoid valve coils test the solenoids and their circuit wiring as TEC controller out puts with the Diagnostic Display see Diagnostic Display in the Troubleshooting section of this chapter If the Diagnostic Display verifies thatsolenoid coils and circuit wiring are functioning correctly no further testing is nec essary 2 If the Diagnostic Display determines that coils and circui
297. ust be surgically re moved within a few hours by a doctor familiar with this type of injury Gangrene may resultfrom such an injury Groundsmaster 4300 D Hydraulic Hose and Tube Installation O Ring Face Seal Fitting 1 Make sure threads and sealing surfaces ofthe hose C Useasecond wrench to tighten the nutto the cor tube and the fitting are free of burrs nicks scratches or rect Flats From Wrench Resistance F F W R The any foreign material markings on the nutand fitting body will verify thatthe connection has been properly tightened 2 As a preventative measure againstleakage itis rec ommended that the face seal O ring be replaced any Size F F W R time the connection is opened Make sure the O ring is ae 4 1 4 Ih tub 1 2 to 3 4 installed and properly seated in the fitting groove Lightly 6 c oo ip y i Y lubricate the O ring with clean hydraulic oil 8 1 2 in 1 2 to 3 4 10 5 8 in 1 2 to 3 4 i Wn 12 3 4 in 1 3 to 1 2 3 Place the hose tube against the fitting body so that 16 1 in 18 5 12 the flatface ofthe hose tube sleeve fully contacts the O ring in the fitting Swivel Nut I Fitting Body 4 Thread the swivel nut onto the fitting by hand While holding the hose tube with a wrench use a torque wrench to tighten the swivel nut to the recommended installation torque shown in Figure 5 This tightening process will require the use of an offset wrench e g crowfoot wrench Use of an offset wrench will af
298. values are listed in the following tables F or critical applications as determined by Toro either the recommended torque ora torque that is unique to the application is clearly identified and spe cified in this Service Manual These Torque Specifications for the installation and tightening of fasteners shall apply to all fasteners which do not have a specific requirementidentified in this S er vice Manual The following factors shall be considered when applying torque cleanliness of the fastener use of a thread sealant e g Loctite degree of lubrication on the fastener presence of a prevailing torque feature e g Nylock nut hardness of the surface underneath the fastener s head orsimilar condition which affects the installation Fastener Identification Grade 1 Grade 5 Inch Series Bolts and Screws Figure 1 Using a Torque Wrench with an Offset Wrench Use ofan offsetwrench e g crowfootwrench will affect torque wrench calibration due to the effective change of torque wrench length When using a torque wrench with an offset wrench multiply the listed torque recommen dation by the calculated torque conversion factor Fig 3 to determine proper tightening torque Tightening torque when using a torque wrench with an offset wrench will be lower than the listed torque recommen dation Example The measured effective length of the torque wrench distance from the center of the handle to the center of the square drive is
299. ve brack et and two 2 flat washers from gear pump 13 If necessary remove hydraulic fittings from pumps Note orientation of fittings for assembly purposes 14 Remove and discard all O rings from removed hy draulic lines and fittings Installation Fig 67 1 Iffittings were removed from pumps lightly lubricate new fitting O rings with clean hydraulic oil Install fittings with O rings to the pumps see Hydraulic Fitting Instal lation in the General Information section ofthis chapter Orientate fittings as noted during removal 2 Assemble traction and gear pumps Fig 70 A Lubricate and position new O ring between pumps B Position gear pump to traction pump and secure with two 2 socket head screws lock washers and flat washers C If pump support bracket was removed from gear pump fit flat washers and bracketto gear pump and secure with two 2 lock nuts IMPORTANT Make sure to not damage machine components while installing the pump assembly 3 Carefully lower pump assembly to machine frame 4 Secure pump assembly to machine frame with two 2 flange screws and flange nuts Hydraulic System Page 4 70 Figure 70 1 Traction pump 6 Gear pump 2 O ring 7 Flat washer 2 used 3 Flat washer 2 used 8 Pump support bracket 4 Lock washer 2 used 9 Lock nut 2 used 5 Socket screw 2 used 5 Secure pump support bracket to inside of frame bracket with two 2 carriage screws item 12
300. ve throttle so engine is running athigh idle speed 3200 RPM 10 Slowly push traction pedal to fully forward position Keep pedal fully depressed in the forward position 11 Have second person watch pressure gauge on test er carefully while slowly closing the flow control valve until 1000 PSI 69 bar is obtained Verify with a photo tac that the engine speed is still 3300 RPM Groundsmaster 4300 D Page 4 43 12 0bserve flow gauge Flow indication should be approximately 28 GPM 106 LPM 13 Release traction pedal to the neutral position open flow control valve on tester and shut off engine Record test results 14 If flow is less than 25 GPM 95 LPM consider the following A The traction pump swash plate is not being ro tated fully e g traction pedal linkage may need ad justment mow speed limiter is not in the transport position B The piston traction pump needs to be repaired or replaced as necessary C Make necessary repairs before performing addi tional tests 15 When testing is complete disconnect tester and hose kitfrom pump fitting and machine hydraulic hose Reconnect hose to pump fitting Figure 44 3 Hyd hose forward 1 Traction pump 2 RHelbow fitting Hydraulic System Relief Valve PRV1 and PRV2 Pressure Test TO STEERING CONTROL VALVE AND CHARGE CIRCUIT DIRECTION ROTATION 47 BYPASS VALVE TO LIFT CONTROL MANIFOLD RIGH
301. vice in this section R efer to Figure 78 for CrossTrax AWD control manifold cartridge valve installation torque NOTE Adjustment of Bi Directional R elief Valve item 12 is NOT recommended Hydraulic System Page 4 88 NOTE The CrossTrax AWD control manifold uses several zero leak plugs These plugs have a tapered sealing surface on the plug head that is designed to re sist vibration induced plug loosening The zero leak plugs also have an O ring to provide a secondary seal If zero leak plug removal is necessary lightly rap the plug head using a punch and hammer before using an allen wrench to remove the plug the impact will allow plug removal with less chance of damage to the socket head of the plug When installing plugs into the control manifold torque plugs to the values identified in Figures 78 Groundsmaster 4300 D Hydraulic System This page is intentionally blank Groundsmaster 4300 D Page 4 89 Hydraulic System Deck Control Manifold Figure 79 1 Deck control manifold 6 O ring 10 Flange head screw 3 used 2 O ring 7 Hydraulic hose 11 Hydraulic tube 3 Diagnostic fitting 8 O ring 12 Hydraulic tube 4 Dustcap 9 Hydraulic tube 13 Hydraulic tube 5 Hydraulic tube Hydraulic System Page 4 90 Groundsmaster 4300 D Removal Fig 79 1 Park the machine on a level surface engage parking brake lower cutting decks and stop engine Remove key from the ignition switch 2 Read the Ge
302. ving contamination from the traction circuit Hydraulic System Page 4 40 NOTE This test procedure includes steps to test both front wheel efficiency together before testing individual front wheel motors 1 Make sure hydraulic oil is at normal operating tem perature by operating the machine under load for approximately ten 10 minutes 2 Make sure that traction pedal is adjusted to the neu tral position see Operator s Manual 3 Park machine on a level surface with the cutting decks lowered and PTO switch off Shut engine off and apply the parking brake 4 Read Precautions For Hydraulic Testing in this sec tion Groundsmaster 4300 D Before opening hydraulic system operate all hy draulic controls to relieve system pressure and avoid injury from pressurized hydraulic oil See Relieving Hydraulic System Pressure in the Gen eral Information section of this chapter 5 Attacha heavy chain to the rear of the machine frame and an immovable object to prevent the machine from moving during testing 6 Chock front wheels to prevent wheel rotation Make sure parking brake is applied 7 Jack up and support the rear wheels off the ground to allow flow through the rear wheel motors 8 Thoroughly clean junction of hydraulic hose and right side elbow fitting on bottom of traction pump Fig 42 Disconnect hose from right side pump fitting IMPORTANT Make sure that the oil flow indicator arrow on the flow meter
303. wheel motorto preventhydraulic system contamination 13 Label hydraulic connections at wheel motor for as sembly purposes 14 Disconnecthydraulic lines from fittings on wheel mo tor Allow lines to drain into a suitable container 15 Putcaps or plugs on disconnected lines and fittings to prevent contamination 16 Support wheel motor to prevent it from falling Re move four 4 lock nuts from cap screws thatsecure mo tor and brake bracket to frame 17 Remove four 4 cap screws brake assembly with brake bracket item 14 and brake spring bracket item 30 from wheel motor and frame 18 Remove wheel motor from machine 19 Ifhydraulic fittings are to be removed from wheel mo tor mark fitting orientation to allow correct assembly Remove fittings from motor and discard O rings Installation Fig 74 IMPORTANT Because of internal differences in front wheel motors DO NOT interchange front wheel motors on machine i e do not put right side motor on left side of machine The left side wheel motor has a yellow identification mark on the motor housing If necessary use parts catalog and part number on wheel motor to identify RH and LH mo tors 1 If fittings were removed from wheel motor lubricate and place new O rings to fittings Install fittings into mo tor ports using marks made during the removal process to properly orientate fittings see Hydraulic Fitting Instal lation in the General Information section of this c
304. wipe up any spilled die sel fuel before starting the engine Store fuel in a clean safety approved container and keep con tainer cap in place Use diesel fuel for the engine only not for any other purpose Check Fuel Hoses and Connections Check fuel hoses and connections periodically as rec ommended in the Operator s Manual Check fuel hoses for deterioration damage leakage or loose connec tions Replace fuel hoses clamps and connections as necessary Drain and Clean Fuel Tank Drain and clean the fuel tank periodically as recom mended in the Operator s Manual Also drain and clean the fuel tank if the fuel system becomes contaminated or ifthe machine is to be stored for an extended period To clean fuel tank flush tank out with clean diesel fuel Make sure tank is free of all contaminates and debris Fuel Tank Removal Fig 2 1 Park machine on a level surface lower cutting decks stop engine apply parking brake and remove key from the ignition switch 2 Placedrain pan underfueltank Make sure thatdrain pan is large enough to hold fuel tank contents see Specifications in this chapter Groundsmaster 4300 D Page3 5 3 Opendraincock on bottom of fuel tank and allow tank to fully drain Close draincock NOTE Before removing fuel hoses from tank fittings label hoses for assembly purposes 4 Loosen hose clamps and disconnectfuel hoses from suction item 7 and return item 6 fittings on the top of the
305. wo 2 rubber bushings and spacers 6 Slide rubber bellows up steering column to allow ac cess to fasteners that secure steering column to ma chine 7 Support steering control valve to prevent it from fal ling during steering column removal 8 Loosen and remove four 4 socket head screws item 6 that secure steering control valve to steering column 9 Loosen and remove four 4 socket head screws item 17 and flange nuts item 7 that secure steering column to machine 10 Slide steering column assembly from steering con trol valve and machine 11 Disassemble steering column assembly as needed using Figure 5 as a guide Installation Fig 3 1 Apply antiseize lubricant to input shaft of steering control valve 2 Slide steering column onto steering control valve Secure steering column in place with four 4 socket head screws item 17 and flange nuts item 7 3 Secure steering control valve to steering column with four 4 socket head screws item 6 4 Slide rubber bellows to bottom of steering column 5 Place rubber bushings and spacers into holes of platform shroud Fig 4 Position shroud in place and secure with removed fasteners 6 Thoroughly clean tapered surfaces of steering wheel and steering column 7 Apply antiseize lubricant to splines of steering col umn taking care to keep antiseize lubricant from column taper Slide steering wheel onto steering column 8 Secure steering wheel
306. ydraulic System Steering Circuit Problems Steering inoperative or sluggish Steering components e g tie rods steering cylinder ends are worn or binding Steering cylinder is binding Oil level in hydraulic reservoir is low other hydraulic systems are affected as well Steering relief valve R10 in steering control valve is stuck or damaged Steering cylinder leaks internally Steering control valve is worn or damaged Gear pump section P 3 is worn or damaged NOTE A worn or damaged gear pump section P 3 will also affect the traction charge circuit Hydraulic System Page 4 30 Groundsmaster 4300 D Hydraulic System This page is intentionally blank Groundsmaster 4300 D Page 4 31 Hydraulic System Testing The most effective method for isolating problems in the hydraulic system is by using hydraulic test equipment such as pressure gauges and flow meters in the circuits during various operational checks see the Special Tools section in this chapter Before Performing Hydraulic Tests IMPORTANT All obvious areas such as oil supply oil filter binding linkages loose fasteners or im proper adjustments must be checked before as suming thata hydraulic componentis the source of a problem Precautions for Hydraulic Testing Failure to use gauges with expected pressure psi bar rating as listed in test procedures could result in damage to the gauge and possible per sonal injury from leaking
307. ydraulic System Pressure in the Gen eral Information section of this chapter Groundsmaster 4300 D 4 Make sure thattraction pedal is adjusted to the neu tral position Also ensure that traction pump is at full stroke when traction pedal is pushed into fully forward position 5 Raise and support machine so all wheels are off the ground see J acking Instructions in Chapter 1 Safety 6 Thoroughly clean junction of hydraulic hose and right side fitting on bottom of traction pump Fig 44 Disconnect hose from right side pump fitting IMPORTANT Make sure that the oil flow indicator arrow on the flow meter is showing that the oil will flow from the pump through the tester and into the disconnected hydraulic hose 7 Install tester with pressure gauge and flow meter in series between traction pump fitting and disconnected hose to allow flow from traction pump to tester Use hy draulic hose kit see S pecialTools in this chapter to con necttester to machine Make sure that fitting and hose connections are properly tightened Also make sure the flow control valve on tester is fully open All wheels will be offthe ground and rotating dur ing this test Make sure machine is supported so it will notmove and accidentally fall to preventin juring anyone near the machine 8 Startengine and run atidle speed Check for any hy draulic leakage from tester and hose connections Cor rect any leaks before proceeding 9 Mo
308. zed Solenoid valve S2 allows hydraulic flow from the rod end of the lift cylinders when energized and prevents oil passage from the lift cylin ders when de energized Proportional relief valve PRV is used to control the operation of the manifold logic cartridge LC and also acts as a circuit relief valve While operating the machine during conditions of not raising or lowering the cutting decks joystick in the neu tral center position Fig 19 all of the lift manifold valves 1 S2 and PRV are de energized The de en ergized relief valve PRV allows hydraulic flow to return to tank through the manifold This flow causes a pres sure differential thatshifts the logic cartridge LC which allows pump flow to bypass the lift cylinders Flow re turns to the oil filter and then to the hydraulic reservoir NOTE When the mow speed limiter is in the transport position the cutting decks will not lower Lower Cutting Decks Fig 18 When the joystick is moved to the lower position the controller energizes all ofthe lift manifold valves S1 S2 and PRV The energized relief valve PRV prevents flow through the valve which returns logic cartridge LC to the unshifted position With lift manifold cartridges in this position pump flow is directed to the barrel end of allliftcylinders to extend the cylinders and lowerthe cut ting decks Fixed orifices in the lift control manifold C2 C4 C6 and C8 control the lowering speed ofthe

10178SL - Toro Media

Contents

Download Pdf Manuals

Related Search

Related Contents