Toro 4300-D User Manual

Part No. 10178SL

Service Manual

Groundsmaster

Preface

The purposeof thispublication isto providethe service technician with information for troubleshooting, testing and repair of major systems and components on the Groundsmaster 4300--D.

REFER TO THEOPERATOR’S MANUALFOROPERATING, MAINTENANCE AND ADJUSTMENT INSTRUCTIONS.Spaceis provided in Chapter2 of this book to insertthe 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.

TheToroCompany reservestherightto changeproduct specifications or this publication without notice.

4300--D

This safety symbol means DANGER, WARNING, or CAUTION, PERSONAL SAFETY INSTRUCTION. When you see this symbol, carefully read the instructions that follow. Failure to obey the instructions may result in personal injury.

NOTE: ANOTE willgive generalinformation about the

correct operation, maintenance, service, testing or repair of the machine.

IMPORTANT: The IMPORTANT notice will give importantinstructionswhichmustbefollowed toprevent damage to systems or components on the machine.

E The Toro Company -- 2010

This page is intentionally blank.

Groundsmaster 4300--D

Chapter 1 -- Safety

Safety Instructions 1 -- 2..........................

Jacking Instructions 1 -- 5.........................

Safety and Instruction Decals 1 -- 6................

Chapter 2 -- Product Records and Maintenance

Product Records 2 -- 1...........................

Maintenance 2 -- 1...............................

Equivalents and Conversions 2 -- 2................

Torque Specifications 2 -- 3.......................

Chapter 3 -- Kubota Diesel Engine

General Information 3 -- 1........................

Specifications 3 -- 2..............................

Adjustments 3 -- 3...............................

Service and Repairs 3 -- 4........................

KUBOTA WORKSHOP MANUAL, DIESEL ENGINE,

05--E3B SERIES

Chapter 4 -- Hydraulic System

Specifications 4 -- 2..............................

General Information 4 -- 3........................

Hydraulic Schematic 4 -- 9........................

Hydraulic Flow Diagrams 4 -- 10...................

Special Tools 4 -- 22.............................

Troubleshooting 4 -- 26...........................

Testing 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

(TC, TB, TE, TJ, TF, TG, TH AND TL SERIES)

SAUER--DANFOSS STEERING UNIT TYPE OSPM

SERVICE MANUAL

SERVICE PROCEDURE

Chapter 5 -- Electrical System

General Information 5 -- 3........................

Special Tools 5 -- 4..............................

Troubleshooting 5 -- 6............................

Electrical System Quick Checks 5 -- 17.............

Adjustments 5 -- 19..............................

Component Testing 5 -- 22........................

Service and Repairs 5 -- 44.......................

Chapter 6 -- Chassis

Specifications 6 -- 2..............................

General Information 6 -- 2........................

Special Tools 6 -- 2..............................

Service and Repairs 6 -- 4........................

Chapter 7 -- Cutting Decks

Specifications 7 -- 2..............................

General Information 7 -- 3........................

Troubleshooting 7 -- 4............................

Special Tools 7 -- 5..............................

Adjustments 7 -- 6...............................

Service and Repairs 7 -- 8........................

Chapter 8 -- Foldout Drawings

Hydraulic Schematic 8 -- 3........................

Electrical Schematic 8 -- 4........................

Wire Harness Drawings 8 -- 6.....................

SafetyProduct Records

and Maintenance

Engine

Kubota Diesel

System

Hydraulic

System

Chassis

Groundsmaster 4300--D

Decks

Cutting Electrical

Foldout

Drawings

This page is intentionally blank.

Groundsmaster 4300--D

Table of Contents

SAFETY INSTRUCTIONS 2......................

Before Operating 2............................

While Operating 3.............................

Maintenance and Service 4....................

JACKING INSTRUCTIONS 5.....................

SAFETY AND INSTRUCTION DECALS 6..........

Chapter 1

Safety

Groundmaster 4300--D Page 1 -- 1 Safety

Safety Instructions

Your Groundsmastermeetsor exceedssafetystandard specifications when weights are installed according to information in the Operator’s Manual. Although hazard control andaccident preventionare partiallydependent uponthe design andconfigurationofthe machine, these factors are also dependent upon the awareness, concern and propertraining ofthe personnelinvolved inthe operation, transport, maintenance and storage of the machine. Improper use or maintenanceof the machine can result in injury or death. To reduce the potential for injury or death,comply with the following safety instructions.

Before Operating

WARNING

To reduce the potentialfor injuryordeath,comply with the following safety instructions.

1. Review and understand the contents of the Operator’ sManual and OperatorTrainingDVD beforestarting and operating the machine. Become familiar with the controls andknow how to stopthe machineand engine quickly. A replacement Operator’s Manual is available on the Internet at www.Toro.com.

2. Keep all shields, safetydevicesand decals inplace. 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).

5. Since dieselfuel is highly flammable, handle itcarefully:

A. Store fuel in containers specifically designed for this purpose.

B. Do not remove machine fuel tank cap while engine is hot or running.

C. Do not smoke while handling fuel. D. Fill fueltank outdoorsandonlytowithinaninchof

the topof the tank, not thefiller neck.Do not overfill. E. After refueling machine, install fuel tank andfuel

container caps. F. Iffuel is spilled,do notattempttostart theengine

but move the machine away from the area of spillage. Avoid creating any source of ignition until fuel vapors have dissipated. Wipe up any spilled fuel.

Groundsmaster 4300--DPage 1 -- 2Safety

While Operating

1. Sit on the seat when starting and operating the machine.

2. Before starting the engine:

A. Apply the parking brake. B. Make sure thetraction pedalis in NEUTRALand

the PTO switch is OFF (disengaged). C. Afterengineisstarted, releaseparking brakeand

keepfoot off tractionpedal. Machinemust 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 Operator’ s Manual).

3. Do not run engine in a confined area without adequate ventilation. Exhaust fumes are hazardous and could possibly be deadly.

4. Do not touch engine, radiator or exhaust system whileengineisrunningor soonafter it is stopped. These areas could be hot enough to cause burns.

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 removekey from ignitionswitch.

6. Anytime the machineis parked (short or long term),

the cuttingdecksshould belowered totheground. This relieves pressurefrom thehydraulic liftcircuit and eliminates the risk of the cutting decks unexpectedly lowering to the ground.

7. Do not parkon slopesunlesswheels arechockedor

blocked.

Safety

Groundmaster 4300--D Page 1 -- 3 Safety

Maintenance and Service

1. Before servicing or making adjustments, lower cutting decks, stop engine, apply parking brake and remove key from the ignition switch.

2. Make suremachineis in safeoperating conditionby keeping all nuts, bolts and screws tight.

3. Never store the machine or fuel container inside wherethereisanopenflame, such asneara waterheater or furnace.

4. Makesure all hydraulic line connectorsare tight,and all hydraulic hoses and lines are in good condition before applying pressure to the hydraulic system.

5. Keepbody andhandsawayfrompinhole leaks inhydrauliclines that ejecthigh pressurehydraulic 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 must be surgically removedwithin a fewhours bya doctor familiar with this form of injury or gangrene may result.

6. Before disconnecting or performing any work on the hydraulicsystem, allpressurein the system must berelieved by using all of the hydraulic controls (seeRelieving Hydraulic Pressure in the General Information section of Chapter 4 -- Hydraulic System).

7. Use care when checking or servicing the cutting decks. Wear gloves 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.

12.Disconnect battery before servicing the machine. Disconnect negative battery cable first and positive cablelast. If batteryvoltage is required for troubleshooting 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 contactwithskin, eyesand 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 asolid level floor such asaconcrete floor. Prior toraising the machine,remove any attachments that may interfere with the safe and proper raising of the machine. Always chock or block wheels. Use jackstandsor appropriate load holdingdevices to support the raised machine. If the machine is not properly supported, the machine may move or fall, whichmay result in personal injury (see JackingInstructions in this section).

16.Ifmajor repairs areever needed or assistance is desired, contact an Authorized Toro Distributor.

17.When welding on machine, disconnect all battery cables toprevent damageto machine electronicequipment. Disconnect negative battery cable first and positive cable last. Also, disconnect the wire harness connector from the machine controller and disconnect the terminalconnectorfrom thealternator.Attach welder ground cableno morethantwo (2)feet (0.61meters) from the welding location.

9. If engine must be runningto performmaintenanceor to make an adjustment, keep hands, feet, clothing and other partsof thebody away fromthe cuttingdecksand other moving parts. Keep bystanders away.

10.Do not overspeed the engine by changing governor setting. T oassuresafetyandaccuracy,check maximum engine speed with a tachometer.

1 1.Shut engine off before checking or adding oil to the crankcase.

18.At the time of manufacture, your Groundsmaster conformed to thesafety standardsforriding mowers.To assure optimum performanceand continuedsafetycertification ofthemachine,usegenuine Tororeplacement parts and accessories. Replacement parts and accessories madeby other manufacturers may result innonconformance with the safety standards, and the warranty may be voided.

Groundsmaster 4300--DPage 1 -- 4Safety

Jacking Instructions

CAUTION

When changing attachments, tiresor performing otherservice, 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 attachments that may interfere with the safe and proper raising of the machine. Always chock or block wheels. Use jack stands or other appropriate load holding devices to support the raised machine. If the machine is not properly supported, the machine may move or fall, which may result in personal injury.

Front End Jacking

1. Applyparking brake and chockboth reartirestoprevent the machine from moving.

2. Position jack securely under the rectangular padon the frame axle tube, just to the inside of the front wheel (Fig. 1).

3. Jack front of machine off the ground.

4. Position jackstands under the frame as close to the wheel as possible to support the machine.

Safety

Figure 1

1. Front wheel 2. Front jacking point

Rear End Jacking

1. Applyparkingbrakeandchockbothfront tires toprevent the machine from moving.

2. Place jacksecurelyat thecenter of the rear axleunder the axle pivot bracket. Jack rear of machine off the ground.

3. Position jack stands under the frame to support the machine.

1. Rear wheel

2. Rear axle pivot bracket

Figure 2

3. Jack stand location

Groundmaster 4300--D Page 1 -- 5 Safety

Safety and Instruction Decals

Numerous safety and instruction decals are affixed to the traction unit and cutting units of your Groundsmaster. If any decal becomes illegible or damaged, installa new decal. Part numbers for decals are listed in your Part Catalog. Order replacement decals from your Authorized Toro Distributor.

Groundsmaster 4300--DPage 1 -- 6Safety

Product Records and Maintenance

Table of Contents

PRODUCT RECORDS 1.........................

MAINTENANCE 1...............................

EQUIVALENTS AND CONVERSIONS 2...........

Decimal and Millimeter Equivalents 2............

U.S. to Metric Conversions 2...................

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 6..........................

Chapter 2

Product Records

and Maintenance

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 installedto your machine, insertthe Installation Instructions, Operator’s Manuals andParts Catalogsfor those options at the end of this chapter.

Maintenance

Maintenanceprocedures andrecommendedservice intervals for your Groundsmaster areidentified in theOperator’s Manual. Refer to that publication when performing regular equipment maintenance.

Groundsmaster 4300--D Page 2 -- 1 Product Records and Maintenance

Equivalents and Conversions

0.09375

Groundsmaster 4300--DPage 2 -- 2Product Records and Maintenance

Torque Specifications

Recommended fastener torque values are listed in the followingtables.Forcriticalapplications,as determined byToro,eitherthe recommended torque oratorque that is unique to theapplication isclearly identifiedand specified in this Service Manual.

These Torque Specifications for the installation and tightening of fasteners shallapply to allfasteners which donot have a specific requirement identified inthis Service 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 ofa prevailing torquefeature (e.g. Nylock nut), hardness of the surface underneath thefastener’sheadorsimilarcondition whichaffectsthe installation.

Fastener Identification

Asnoted inthe followingtables,torquevaluesshouldbe reduced by 25% for lubricated fasteners to achieve the similarstress 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 onthe aluminum or brass material strength, fastener size, length of thread engagement, etc.

The standard method of verifying torque shall be performed by marking a line on the fastener (head or nut) and mating part, then back off fastener 1/4 of a turn. Measurethe torque required to tighten the fasteneruntil the lines match up.

Product Records

and Maintenance

Grade 1 Grade 5 Grade 8

Inch Series Bolts and Screws

Figure 1

Using a Torque Wrench with an Offset Wrench

Useofanoffsetwrench(e.g.crowfootwrench)willaffect torquewrenchcalibration due to the effective change of torquewrench length. When using atorquewrenchwith an offset wrench, multiplythe listed torque recommendation 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 recommendation.

Example: Themeasured effectivelength of the torque wrench (distance from the center of the handle to the center of the square drive) is 18”.

Themeasuredeffectivelengthofthetorquewrenchwith the offset wrench installed (distance from the center of the handle to the center of the offset wrench) is 19”.

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.

(effective length of

torque wrench)

(effective length of torque

wrench + offset wrench)

TORQUE CONVERSION FACTOR = A/ B

Torque wrenchOffset wrench

The calculated torque conversion factor for this torque wrenchwiththisoffsetwrench would be 18 / 19 = 0.947.

Groundsmaster 4300--D Page 2 -- 3 Product Records and Maintenance

Figure 3

Standard Torque for Dry, Zinc Plated and Steel Fasteners (Inch Series)

Thread Size

# 6 -- 32 UNC

# 6 -- 40 UNF

# 8 -- 32 UNC

# 8 -- 36 UNF

#10--24UNC

#10--32UNF

1/4 -- 20 UNC 48 + 7 53 + 7 599 + 79 100 + 10 1130+ 113 140 + 15 1582 + 169

1/4 -- 28 UNF 53 +7 65 + 10 734 + 113 115 + 12 1299 + 136 160+ 17 1808 + 192

5/16 -- 18 UNC 115 + 15 105 +15 1186 + 169 200 + 25 2260 + 282 300 + 30 3390 + 339

5/16 -- 24 UNF 138 +17 128 + 17 1446 + 192 225 +25 2542 + 282 325 + 33 3672 +373

3/8 -- 16 UNC 16 + 2 16 + 2 22 + 3 30 + 3 41 + 4 43 + 5 58 + 7

Grade 1, 5 &

8withThin

Height Nuts

in--lb in--lb N--cm in--lb N--cm in--lb N--cm

10 + 2 13 + 2 147 + 23

13 + 2 25 + 5 282 + 30

18 + 2 30 + 5 339 + 56

ft--lb ft--lb N--m ft--lb N--m ft--lb N--m

SAE Grade 1 Bolts, Screws, Studs &

Sems with Regular Height Nuts

(SAE J995 Grade 2 or Stronger Nuts)

SAE Grade 5 Bolts, Screws, Studs &

Sems with Regular Height Nuts

(SAE J995 Grade 2 or Stronger Nuts)

15 + 2 169 + 23 23 + 3 262 + 34

17 + 2 192 + 23 25 + 3 282 + 34

29 + 3 328 + 34 41 + 5 463 + 56

31 + 4 350 + 45 43 + 5 486 + 56

42 + 5 475 + 56 60 + 6 678 + 68

48 + 5 542 + 56 68 + 7 768 + 79

SAE Grade 8 Bolts, Screws, Studs &

Sems with Regular Height Nuts

(SAE J995 Grade 5 or Stronger Nuts)

3/8 -- 24 UNF 17 +2 18 + 2 24 + 3 35 + 4 47 + 5 50 + 6 68 + 8

7/16 -- 14 UNC 27 + 3 27 + 3 37 + 4 50 + 5 68 + 7 70 + 7 95 + 9

7/16 -- 20 UNF 29 +3 29 + 3 39 + 4 55 + 6 75 + 8 77 + 8 104 + 11

1/2 -- 13 UNC 30 + 3 48 + 7 65 + 9 75 + 8 102 + 11 105 + 11 142+ 15

1/2 -- 20 UNF 32 +4 53 + 7 72 + 9 85 + 9 115 + 12 120 + 12 163 + 16

5/8 -- 11 UNC 65 + 10 88 + 12 119 + 16 150 + 15 203+ 20 210 + 21 285 + 28

5/8 -- 18 UNF 75 +10 95 + 15 129 + 20 170 + 18 230 + 24 240 + 24 325 + 33

3/4 -- 10 UNC 93 + 12 140 + 20 190 + 27 265 + 27 359 + 37 375 + 38 508 + 52

3/4 -- 16 UNF 115 + 15 165 + 25 224 + 34 300 +30 407 + 41 420 + 43 569 + 58

7/8 -- 9 UNC 140 + 20 225 + 25 305 + 34 430 + 45 583 + 61 600 + 60 813 + 81

7/8 -- 14 UNF 155 + 25 260 + 30 353 + 41 475 + 48 644 + 65 667 +66 904 + 89

NOTE: Reduce torque values listed inthe tableabove 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: The nominal torque values listed above for Grade 5 and8 fasteners arebased on 75%of the minimumproofload specified in SAE J429. The toleranceis approximately +

10% of the nominal torquevalue. Thin

height nuts include jam nuts.

NOTE: Torque values may have to be reduced when installing fasteners into threaded aluminum or brass. The specifictorque value should be determined based on the fastener size, the aluminum or base material strength, length of thread engagement, etc.

Groundsmaster 4300--DPage 2 -- 4Product Records and Maintenance

Standard Torque for Dry, Zinc Plated and Steel Fasteners (Metric Series)

Class 8.8 Bolts, Screws and Studs with

Thread Size Regular Height Nuts

(Class 8 or Stronger Nuts)

Class 10.9 Bolts, Screws and Studs with

Regular Height Nuts

(Class 10 or Stronger Nuts)

M5 X 0.8 57 + 6in--lb 644 + 68 N--cm 78 + 8in--lb 881 + 90 N--cm

M6 X 1.0 96 + 10 in--lb 1085 + 113 N- -cm 133 +14 in--lb 1503 + 158 N--cm M8 X 1.25 19 + 2ft--lb 26 + 3N--m 28 + 3ft--lb 38 + 4N--m M10 X 1.5 38 + 4ft--lb 52 + 5N--m 54 + 6ft--lb 73 + 8N--m

M12 X 1.75 66 + 7ft--lb 90 + 10 N--m 93 + 10 ft--lb 126+ 14 N--m

M16 X 2.0 166+ 17 ft--lb 225 + 23 N--m 229 + 23 ft--lb 310 + 31 N--m M20 X 2.5 325 + 33 ft--lb 440 + 45 N--m 450 + 46 ft--lb 610 + 62 N--m

NOTE: The nominal torque values listed above are based on 75% of the minimum proof load specified in SAEJ1199.Thetoleranceisapproximately+ nominal torque value.

10%ofthe

Product Records

and Maintenance

Groundsmaster 4300--D Page 2 -- 5 Product Records and Maintenance

Other Torque Specifications

SAE Grade 8 Steel Set Screws

Recommended Torque

Thread Size

Square Head Hex Socket

1/4 -- 20 UNC 140 + 20 in--lb 73 + 12 in--lb

5/16 -- 18 UNC 215 + 35 in--lb 145 + 20 in--lb

3/8 -- 16 UNC 35 + 10 ft--lb 18 + 3ft--lb 1/2 -- 13 UNC 75 + 15 ft--lb 50 + 10 ft--lb

Thread Cutting Screws

(Zinc Plated Steel)

Type 1, Type 23 or Type F

Thread Size Baseline Torque*

No. 6 -- 32 UNC 20 + 5in--lb

Wheel Bolts and Lug Nuts

Thread Size

7/16 -- 20 UNF

Grade 5

1/2 -- 20 UNF

Grade 5

M12 X 1.25

Class 8.8

M12 X 1.5

Class 8.8

** For steel wheels and non--lubricated fasteners.

Thread Cutting Screws

(Zinc Plated Steel)

Thread

Size

No. 6 18 20 20 + 5in--lb

Threads per Inch Type A Type B

Recommended Torque**

65 + 10 ft--lb 88 + 14 N--m

80 + 10 ft--lb 108 + 14 N--m

Baseline Torque

No. 8 -- 32 UNC 30 + 5in--lb

No. 10 -- 24 UNC 38 + 7in--lb

1/4 -- 20 UNC 85 + 15 in--lb

5/16 -- 18 UNC 110 + 20 in--lb

3/8 -- 16 UNC 200 + 100 in--lb

Conversion Factors

in--lb X 11.2985 = N--cm N--cm X 0.08851 = in--lb

ft--lb X 1.3558 = N--m N--m X 0.7376 = ft--lb

No. 8 15 18 30 + 5in--lb No. 10 12 16 38 + 7in--lb No. 12 11 14 85 + 15 in--lb

*Holesize,materialstrength,materialthicknessandfinish must be considered when determining specific torquevalues. Alltorque values arebasedon non--lubricated fasteners.

Groundsmaster 4300--DPage 2 -- 6Product Records and Maintenance

Table of Contents

Chapter 3

Kubota Diesel Engine

GENERAL INFORMATION 1.....................

Operator’s Manual 1..........................

Stopping the Engine 1.........................

SPECIFICATIONS 2............................

ADJUSTMENTS 3..............................

Adjust Throttle Control 3.......................

General Information

This Chapter gives information about specifications, troubleshooting, testing andrepair 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 useof some specialized test equipment isexplained in theengine workshopmanual included at the endof thischapter. However, the cost of the test equipment and the specialized natureof some repairs may dictate thatthe work be done at an engine repair facility.

SERVICE AND REPAIRS 4......................

Fuel System 4................................

Air Cleaner 6.................................

Exhaust System 8............................

Radiator 10..................................

Engine 12....................................

KUBOTA WORKSHOP MANUAL, DIESEL ENGINE,

05--E3B SERIES

Service and repair parts for Kubota diesel engines are suppliedthroughyour local T oroDistributor.If a parts list is not available, be sure to provide your distributor with the Toro model and serial number.

Engine

Kubota Diesel

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 isturbo--charged. Beforestopping theengine aftermowing or full load operation,cool the turbo-charger by allowing the engine to idle at low speedfor five(5) minutes. Failure to do so may lead to turbo-charger trouble.

Groundsmaster 4300--D Page 3 -- 1 Kubota Diesel Engine

Specifications

Item Description

Make / Designation Kubota V1505--T--E3B, 4--stroke,

Number of Cylinders 4

Bore x Stroke 3.07 in x 3.09 in (78 mm x 78.4 mm)

Total Displacement 91.4 in3(1498 cc)

CompressionRatio 23:1

Firing Order 1 (fan end) -- 3 -- 4 (flywheel end) -- 2

Fuel No. 2--D Diesel Fuel (ASTM D975)

Fuel Injection Pump Bosch MD Type Mini

Fuel Injector Nozzle MiniNozzle (DNOPD)

Fuel Tank Capacity 14 U.S. gallons (53liters)

Governor Centrifugal Mechanical

Low Idle Speed(no load) 1250 to 1350 RPM

High Idle Speed (no load) 3050 to 3250 RPM

Liquid Cooled, OHV, Turbocharged Diesel

Engine Oil API Classification CI--4 or Higher

Oil Pump Gear Driven Trochoid Type

Crankcase Oil Capacity 5.5 U.S. quarts (5.2 liters) with Filter

Cooling System Capacity (including reserve tank) 10 U.S. quarts (9.5 liters)

Starter 12 VDC 1.2 KW

Alternator/Regulator 12 VDC 40 Amp

Engine Dry Weight (approximate) 251 lbs (114 kg)

(see Operator’s Manual for viscosity recommendations)

Groundsmaster 4300--DPage 3 -- 2Kubota Diesel Engine

Adjustments

Adjust Throttle Control

Proper throttle operation is dependent upon proper adjustment of throttle control.

NOTE: The throttle cable swivel should be positioned in the lowest hole in the speed control lever .

1. Move 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 whenthe throttlecontrol lever is in the FAST position.

3. If necessary,throttle controlcanbeadjustedbylooseningcable clampscrew andrepositioning control cable until speed control lever contacts high speed screw when the throttle control lever is in the FAST position. Tighten cable clamp screw after adjustment has been completed.

1. Throttle cable

2. High speed screw

3. Speed control lever

Figure 1

4. Swivel

5. Cable clamp

Engine

Kubota Diesel

Groundsmaster 4300--D Page 3 -- 3 Kubota Diesel Engine

Service and Repairs

Fuel System

RIGHT

FRONT

1. Fuel cap

2. Bushing

3. Washer head screw (2 used)

4. Flange nut (3 used)

5. Clamp (2 used)

6. Returnfitting

7. Suction fitting

8. Hose clamp

9. Hose clamp

10. Fuel tank

11. Grommet

12. Fuel gauge

13. Hose clamp

Figure 2

14. Draincock

15. Fuel supply hose

16. Fuel return hose

17. Bumper

18. Flat washer

19. Cap screw

Groundsmaster 4300--DPage 3 -- 4Kubota Diesel Engine

DANGER

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 tankwhile engineis running, whenengineis hot or when machine is in an enclosed area. Always fill fuel tankoutsideand wipe up any spilled dieselfuelbefore startingtheengine. Store fuel in a clean, safety--approved container and keepcontainer cap inplace.Use dieselfuel for theengine only; not for any other purpose.

3. Opendraincockonbottomoffueltankandallow tank to fully drain. Close draincock.

NOTE: Before removing fuel hoses from tank fittings, label hoses for assembly purposes.

4. Loosenhose clampsanddisconnect fuel hoses from suction (item 7) andreturn (item 6) fittings onthe top of the 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.

Check Fuel Hoses and Connections

Check fuel hoses and connections periodically as recommended in theOperator’s Manual. Checkfuelhoses for deterioration, damage, leakage or loose connections. Replace fuel hoses, clamps and connections as necessary.

Drain and Clean Fuel Tank

Drain and clean the fuel tank periodically as recommendedinthe Operator’sManual. Also,drainandclean the fuel tank if the fuel system becomes contaminated or if the machineis tobestored foran extendedperiod.

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. Placedrainpanunder fueltank. Make sure that drain pan is large enough to hold fuel tank contents (see Specifications in this chapter).

2. Using labels placed during fuel tank removal, correctly 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 thatfuel tank draincock is closed.Fillfuel tank.

Figure 3

1. Fuel supply hose

2. Fuel return hose

3. Fuel gauge

Engine

Kubota Diesel

Groundsmaster 4300--D Page 3 -- 5 Kubota Diesel Engine

Air Cleaner

17 14

Thread Sealant

12 to 15 in--lb

(1.4 to 1.6 N--m)

RIGHT

FRONT

1. Air cleaner assembly

2. Indicator

3. Adapter

4. Spring

5. Hex nut

6. Bolt

7. Hose

Figure 4

8. Hose

9. Mount bracket

10. Air cleaner stand

11. Hose clamp (3 used)

12. Flange nut (8used)

13. Cap screw (2 used)

14. Hose clamp (2 used)

VACUATOR DIRECTION

15. Flange head screw (4 used)

16. Air cleaner mountingband

17. Spacer

18. Hose

19. Hose clamp

20. Flange head screw (2 used)

Groundsmaster 4300--DPage 3 -- 6Kubota Diesel Engine

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 filter system will

allowdirt into engineand will causeseriousengine damage. Make sure that all air cleanercomponents areingood conditionand areproperlysecured during assembly.

1. Assemble air cleaner system using Figure 4 as a guide.

A. If service indicator (item 2) and adapter (item 3) wereremovedfromaircleanerhousing,applythread sealant to adapter threads before installing adapter and indicator to housing. Install adapter so that groovesinadapter hex andadapterfilter elementare installed towardservice indicator (Fig.5).Torque indicator from 12 to 15 in--lb (1.4 to 1.6 N--m).

1. Air cleaner assembly

2. Service indicator

Figure 5

3. Adapter

4. Vacuator valve

Engine

Kubota Diesel

B. Makesurethatvacuator valve ispointeddownafter assembly.

Groundsmaster 4300--D Page 3 -- 7 Kubota Diesel Engine

Exhaust System

RIGHT

FRONT

1. Gasket

2. Lock washer (2 used)

3. Flange nut (4 used)

4. Cap screw (2 used)

5. Carriage screw (4 used)

6. Flange nut (4 used)

7. Muffler support bracket

8. Flange head screw (2 used)

9. Tail pipe bracket

10. Hex nut (2 used)

11. Upper clamp

12. Flange nut (4used)

Figure 6

13. Exhaust header

14. Flange head screw (2 used)

15. Muffler

16. Tail pipe bracket

17. Lower clamp

Groundsmaster 4300--DPage 3 -- 8Kubota Diesel Engine

Removal (Fig. 6)

1. Park machine on a level surface, lower cutting decks, stop engine, engage parking brake and remove key from the ignition switch. Raise and support hood.

CAUTION

The muffler and exhaust pipe may be hot. To avoid possible burns, allow the engine and exhaust system to cool before working on the exhaust system.

2. Remove exhaust system using Figure 6 as a guide.

Installation (Fig. 6) NOTE: Make sure mufflerflange and exhaustmanifold

sealing surfaces arefree of debris or damage that may prevent a tight seal.

1. Place new muffler gasket on the exhaust manifold.

2. If muffler support bracket (item 7) was removed,secure it to engine with removed fasteners.

1 (FIRST)

4 (LAST)

Figure 7

Engine

Kubota Diesel

IMPORTANT: Fingertighten all exhaust systemfastenersbeforetightening so that there is no preload on the exhaust system due to exhaust system assembly.

3. Installexhaust system components to the engineusing Figure 6as aguide. Finger tighten allfasteners until all exhaust system components have been installed.

4. Tightenexhaust systemfastenersinthefollowingorder:

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)toengine flangeusing ordershown in Figure 7.

C. Tighten hex nuts (item10) tosecureupper 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 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

RIGHT

FRONT

45 35

1. Overflow bottle

2. Hose clamp (3 used)

3. Hose

4. Foam seal (2 used)

5. Foam seal (4 used)

6. Mounting bracket (2 used)

7. Oil cooler

8. Pipe plug

9. Hydraulic fitting (2 used)

10. Hose clamp (4 used)

11. Foam seal (2 used)

12. Flange nut (4used)

13. Flange nut (17used)

14. Oil cooler mount plate (2used)

15. Flange head screw (6 used)

16. Hose clamp (4 used)

Figure 8

17. Flange head screw (8 used)

18. Clamp (2 used)

19. Cap screw (2 used)

20. Washer (4 used)

21. Radiator

22. Radiator frame

23. Reservoir bracket

24. Reservoir bracket

25. Upper radiator hose

26. Lower radiator hose

27. Fan shroud

28. Hydraulic hose (2 used)

29. Rivet (2 used)

30. Flange head screw (10 used)

31. Draw latch

32. Washer head screw (6 used)

30 15

33. Flange head screw

34. Lock nut

35. O--ring

36. Screen

37. Intake screen

38. Hose

39. Oil cooler bracket

40. O--ring

41. Hydraulic tube

42. Foam seal

43. Spacer (5 used)

44. Flange head screw (5 used)

45. Hydraulic fitting (2 used)

46. Pin

47. Radiator cap

Groundsmaster 4300--DPage 3 -- 10Kubota Diesel Engine

Removal (Fig. 8)

1. Park machine on a level surface, lower cutting decks, stop engine, apply parking brake and remove key from the ignition switch.

2. Raise and support the hood.

CAUTION

Do not open radiator cap or drain coolant if the radiator or engine is hot. Pressurized, hot coolant can escape and cause burns.

10.Carefully pull radiator assembly from the machine. Plug radiatorand hoseopenings toprevent contamination.

1 1.Inspect all foam seals placed between radiator , fan shroud and radiator frame. Replace damaged foam seals.

Installation (Fig. 8)

1. Remove plugs placedin radiatorand hose openings during the removal procedure.

2. Carefully position radiator assembly to the radiator support. Position fan shroud to the radiator.

Ethylene--glycol antifreeze is poisonous. Disposeof coolant properly, or storeitin aproperly 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 drainpanislargeenough toholdcooling systemcontents (10 U.S. quarts (9.5 liters)).

C. Loosen radiator draincock (threaded in) and allow coolant to drain from radiator.

4. Remove screen from machine.

5. Disconnect radiator hoses (upper and lower) from the radiator.

6. Loosen hose clampand removeoverflowhose from radiator fill opening.

7. Remove two (2)flangehead screwsand flangenuts 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 screwsand flange nuts that secure air intake screen (item 37) to machine. Remove screen and foam seal (item 42). Locate and retrieve five (5) spacers (item 43).

3. Securefanshroudandradiatortoradiatorframe with removed flange head screws and flange nuts. Make sure that atleast 0.250”(6.4mm)clearanceexistsat all 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 (item43) into holes infoam seal(item

42). Position foam seal and air intake screen (item 37) to radiator frame. Secure intakescreen tomachine 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. Makesureradiator draincockisclosed (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 suretoinstallplugonceallairis bled from radiator.

10.After radiator has been properly filled with coolant, install radiator cap.

1 1.Lower and secure hood.

Engine

Kubota Diesel

9. Removeflange head screws and flange nuts thatsecure fanshroud andradiator to radiator frame. Position fan shroud away from the radiator.

Groundsmaster 4300--D Page 3 -- 11 Kubota Diesel Engine

Engine

RIGHT

FRONT

34 to 42 ft--lb

(47to56N--m)

4 22

1. Engine assembly

2. Cap screw (12 used)

3. Temperature sender

4. Engine mount (4 used)

5. Flange head screw (13 used)

6. Snubbing washer (4 used)

7. Cap screw (4 used)

8. Flange nut (4 used)

9. Flange nut (14 used)

10. Fan clutch

11. Stud (4 used)

Figure 9

12. Lock washer

13. Lock washer

14. Pulley

15. V--belt

16. Lock washer (4 used)

17. Cooling fan

18. Flat washer

19. Spring washer

20. Hex nut

21. Cap screw

22. Spacer (4 used)

23. Negative battery cable

24. Air cleaner stand

25. Lock washer (12 used)

26. Fusible link harness

27. Engine mount (4used)

28. Bracket

29. Bracket

30. Hex nut

31. Flange head screw (4 used)

32. Wire harness ground

Groundsmaster 4300--DPage 3 -- 12Kubota Diesel Engine

Removal (Fig. 9)

1. Park machine on a level surface, lower cutting decks, stop engine and remove key from the ignition switch. Chockwheelstokeepthemachinefrommoving.

2. Open and support hood.

3. Disconnect negative (--) cable and then positive (+) cable from the battery.

CAUTION

Do not open radiator cap or drain coolant if the radiator or engine is hot. Pressurized, hot coolant can escape and cause burns.

Ethylene--glycol antifreeze is poisonous. Disposeof coolant properly, or storeitin aproperly 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 Exhaust 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.

1. Throttle cable end

2. Swivel

1. Fuel return hose

2. Fuel supply hose

Figure 10

Figure 11

3. Cable clamp

Engine

Kubota Diesel

3. Fuel/water filter

8. Disconnect hoses from engine:

A. Loosen clamps and remove upper and lower radiator hoses from the engine.

B. At injectorpump, loosenhose clamp anddisconnect 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 disconnectedhoses andengineopeningsto preventleakageand contamination.Positiondisconnected hoses away from engine.

1. Negative battery cable 2. Wire harness ground

Figure 12

Groundsmaster 4300--D Page 3 -- 13 Kubota Diesel Engine

9. Disconnect hydraulic transmission drive shaft from engine (see Hydraulic Transmission Drive Shaft Removal in the Service and Repairs section of Chapter 4

-- Hydraulic System). Support driveshaft away fromengine.

Installation (Fig. 9)

1. Locate machine on alevel surface with cuttingdecks lowered and key removed from the ignition switch. Chock wheels to keep the machine from moving.

10.Disconnectwireharness connectorsfrom thefollowing engine components:

NOTE: Before disconnectingwire harnessconnectors, label all electrical leads for assembly purposes.

A. Alternator connector and stud. B. Oilpressure switchlocatednear theengine oil fil-

ter. C. Connector, fusible link connector and positive

battery cable from the starter motor. D. High temperature shut down switch andtemper-

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.

1 1.Remove engine from machine:

2. Make sure that all parts removed from the engine duringmaintenance or rebuilding are installedtothe engine.

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--lb (47 to 56 N--m).

4. Install engine to machine. A. Attach short sectionof chainbetween 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.

CAUTION

One person should operate hoist or lift while a second person guides the engine into the machine.

A. Attach short sectionof chainbetween lift tabs located 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.

CAUTION

One person should operate hoist or lift while a secondpersonguides theengine out of themachine.

IMPORTANT: Make sure to not damage the engine, fuel hoses, hydraulic lines, electrical harness, radiator, battery or other parts while removing the engine.

D. Raise engine and remove toward front of machine.

IMPORTANT: Make sure to not damage the engine, fuel hoses, hydraulic lines, electrical harness, 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, snubbingwasher and then flange nut on four (4) cap screws. Tighten fasteners to secure engine to engine mounts.

5. Connect hydraulic transmissiondrive shaft toengine

(see Hydraulic Transmission Drive Shaft Installation in the Serviceand Repairssectionof Chapter 4 -- Hydraulic System).

6. Connect all wire harness connectors to correct en-

gine components.

12.Ifnecessary, removeengine brackets(item27)from engine.

Groundsmaster 4300--DPage 3 -- 14Kubota Diesel Engine

7. Remove plugs installed in hoses during disassembly. Connect hoses to the engine:

9. Install aircleaner(see Air CleanerInstallationin this section).

A. Connect fuel supply and fuel return hoses to engine fittings (Fig. 11). Secure with hose clamps.

B. Connect upper and lower radiator hoses to the engine. Secure with hose clamps.

8. Connect throttle cable to injector pump (Fig. 10): A. Route throttle cable to injector pump on engine. B. Install the throttle cable end into the swivel in

speed control lever. Secure cable end with cap screw.

C. Position cable under cable clamp. D. Adjust throttle control (see Adjust Throttle Con-

trol in the Adjustments section of this chapter).

10.Install exhaust system to machine (see Exhaust System Installation in this section).

1 1.Makesure radiator draincockisclosed (threaded out fully). Fill radiator with coolant and install radiator cap (see Radiator Installation in this section).

12.Check engine oil level and adjust if needed.

13.Connectpositive(+) batterycable tothebattery and then connect negative (--) cable.

14.Bleed fuel system.

15.Close and secure hood.

Engine

Kubota Diesel

Groundsmaster 4300--D Page 3 -- 15 Kubota Diesel Engine

This page is intentionally blank.

Groundsmaster 4300--DPage 3 -- 16Kubota Diesel Engine

Table of Contents

Chapter 4

Hydraulic System

SPECIFICATIONS 2.............................

GENERAL INFORMATION 3.....................

Operator’s Manual 3..........................

Check Hydraulic Fluid 3.......................

Towing Machine 3.............................

Hydraulic Hoses 4............................

Hydraulic Hose and Tube Installation 5..........

Hydraulic Fitting Installation 6...................

Relieving Hydraulic System Pressure 8..........

Traction Circuit Component Failure 8............

HYDRAULIC SCHEMATIC 9.....................

HYDRAULIC FLOW DIAGRAMS 10...............

Traction Circuit 10.............................

Mow Circuit 12...............................

Mow Circuit Cutting Deck Blade Braking 14.......

Lift Circuit: Raise Cutting Decks 16..............

Lift Circuit: Lower Cutting Decks 18..............

Steering Circuit 20............................

SPECIAL TOOLS 22............................

TROUBLESHOOTING 26........................

General Hydraulic System Problems 26..........

Traction Circuit Problems 27....................

Mow Circuit Problems 28.......................

Lift Circuit Problems 29........................

Steering Circuit Problems 30...................

TESTING 32...................................

Traction Circuit Relief Valve (R3) and (R4)

Pressure Test 34............................

Traction Circuit 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.......

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

Wheel Motors 76........................

Front

Rear Wheel Motors 80.........................

Wheel Motor Service 84.......................

CrossTrax CrossTrax

Deck Control Manifold 90......................

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 104..............................

Lift Cylinder Service 106.......................

Steering Control Valve 108.....................

Steering Control Valve Service 110..............

Steering Cylinder 112..........................

Steering Cylinder Service 114..................

Oil Cooler 116................................

SAUER--DANFOSS LPV CLOSED CIRCUIT AXIAL

PISTON PUMPS REPAIR MANUAL

SAUER--DANFOSS LPV CLOSED CIRCUIT AXIAL

PISTON PUMPS SERVICE INSTRUCTIONS

PARKER TORQMOTOR

(TC, TB, TE, TJ, TF, TG, TH AND TL SERIES)

SAUER--DANFOSS STEERING UNIT TYPE OSPM

SERVICE MANUAL

AWD Manifold 86..................

AWD Manifold Service 88...........

.........................

SERVICE PROCEDURE

System

Hydraulic

Groundsmaster 4300--D Hydraulic SystemPage 4 -- 1

Specifications

Item Description

Piston (Traction) Pump Sauer--Danfoss, LPV Closed Circuit Axial Piston Design

Maximum Pump Displacement (per revolution) 2.14 in

Gear Pump Casappa 4 section, positive displacement gear type pump

Section P1/P2 Displacement (per revolution) 1.03 in Section P3 Displacement (per revolution) 0.37 in Section P4 Displacement (per revolution) 0.24 in

Charge Circuit Relief (R5) Pressure 200 PSI (14 bar)

Traction Circuit Relief Pressure

Forward (R3) 3625 PSI (250 bar) Reverse (R4) 3625PSI (250bar)

Front Wheel Motors Parker orbital rotor motor, TG Series

Displacement (per revolution) 24.7 in

Rear Wheel Motors Parker orbital rotor motor, TL Series

Displacement (per revolution) 18.9 in

Mow Circuit Relief Pressure

Rear Mow Circuit (PRV1) 2500 PSI (175 bar) Front Mow Circuit (PRV2) 3500 PSI (241 bar)

Cutting Deck Motor Casappa gear motor

Displacement (per revolution) 1.05 in Cross Over Relief Valve Pressure 1813 PSI (125 bar)

(35 cc)

(16.84 cc)

(6.1 cc)

(3.9 cc)

(405 cc)

(310 cc)

(17.16 cc)

Steering Valve Sauer--Danfoss Steering Unit, Type OSPMS

Displacement (per revolution) 6.1 in

Steering Circuit Relief (R10)Pressure 1000 PSI (70 bar)

Lift Circuit Relief (PRV)Pressure 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)

(100 cc)

Groundsmaster 4300--DHydraulic System Page 4 -- 2

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 publicationfor additionalinformationwhenservicing the machine.

Check Hydraulic Fluid

The hydraulic system on your Groundsmaster is designedto operate on high qualityhydraulicfluid.Thehydraulic system reservoir holds approximately 14 U.S. gallons (53 liters) of hydraulic fluid. Check level of hy- draulicfluid daily.SeeOperator ’sManualfor fluidlevel checking procedure and hydraulic oil recommendations.

Towing Machine

IMPORTANT: If towing limits are exceeded, severe damage to the piston (traction) pump may occur.

Ifit becomes necessary totoworpush the machine, tow orpushat a speed below 3 mph(4.8kph),andfora very shortdistance. If themachineneedsto be moved a considerabledistance, machine should be transported on a trailer.The piston (traction) pump isequipped with a bypassvalvethatneeds tobeloosenedfortowing orpushing (Fig. 2). Refer to Operator’s Manual for Towing Procedures.

Figure 1

1. Hydraulic reservoir cap

System

Hydraulic

Groundsmaster 4300--D Hydraulic SystemPage 4 -- 3

Figure 2

1. Piston (traction) pump 2. Bypass valve

Hydraulic Hoses

Hydraulichoses are subject to extreme conditions such aspressuredifferentialsduring operation and exposure to weather, sun, chemicals, very warm storage conditionsormishandlingduring operationandmaintenance. These conditions can causehose damageand deterioration. Some hoses are more susceptible to these conditions than others. Inspect all machine hydraulic hoses frequently for signs of deterioration or damage:

WARNING

Beforedisconnectingor performing any work on hydraulic system, relieve all pressure in system (seeRelievingHydraulicSystemPressure in this section).

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 hydraulichose, besure that thehose 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 swivelnut ontothe fittingwith thesecond wrench (see Hydraulic Hose and Tube Installation in this section). 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).

Keepbodyand handsawayfrompinhole leaksor 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 injected into the skin, it must be surgically removed within a few hours by a doctor familiar withthis typeof injury.Gangrenemay resultfrom such an injury.

Groundsmaster 4300--DHydraulic System Page 4 -- 4

Hydraulic Hose and Tube Installation (O--Ring Face Seal Fitting)

1. Makesure threads and sealing surfacesofthehose/ tube and the fittingare freeof burrs,nicks, scratchesor any foreign material.

2. Asa preventative measure against leakage,itisrecommended that the face seal O--ring be replaced any time the connection isopened.Make sure theO--ring is installedandproperly seatedinthefittinggroove.Lightly lubricate the O--ring with clean hydraulic oil.

3. Place the hose/tube against the fitting body so that theflatfaceofthehose/tubesleevefully contactsthe O-ring in the fitting.

4. Thread the swivel nutonto the fittingby 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 affect torque wrench calibration due to the effective length change of the torque wrench. Tightening torque when usingatorquewrenchwithanoffsetwrenchwillbelower than the listed installation torque (see Using a Torque Wrench with anOffsetWrench in theTorque Specificationssectionof Chapter 2 -- Product Records andMaintenance).

C. Useasecond wrench totightenthe nuttothe correct FlatsFrom WrenchResistance (F.F.W.R.). The markingsonthe nutandfittingbodywillverifythatthe connection has been properly tightened.

Siz e F.F.W.R.

4 (1/4 in. nominal hose or tubing) 1/2 to 3/4 6 (3/8 in.) 1/2to 3/4 8 (1/2 in.) 1/2to 3/4 10 (5/8 in.) 1/2 to 3/4 12 (3/4 in.) 1/3 to 1/2 16 (1 in.) 1/3 to1/2

Swivel Nut

Tube or Hose

O--ring

Fitting Body

Figure 3

System

Hydraulic

5. If a torque wrench is not availableor if space at the swivelnut prevents use ofatorquewrench, an alternate method of assembly is the Flats From Wrench Resistance (F.F.W.R.) method (Fig. 4).

Mark Nut

and Fitting

Body

Final

Position

A. Usingawrench,tighten theswivelnut ontothefittinguntillightwrenchresistanceis reached(approxi-

Extend Line

mately 30 in--lb). B. Mark the swivel nut and fitting body. Hold the

hose/tube with a wrench to prevent it from turning.

AT WRENCH RESISTANCE

Figure 4

Fitting Dash Size Hose/Tube Side Thread Size Installation Torque

4 9/16 -- 18 18to22ft--lb(25to29N--m) 6 11/16 - - 16 27to33ft--lb(37to44N--m)

8 13/16 -- 16 37to47ft--lb(51to63N--m) 10 1--14 60 to 74 ft--lb (82 to 100 N--m) 12 13/16--12 85 to 105 ft--lb (116 to 142 N--m)

Initial Position

AFTER TIGHTENING

16 17/16--12 110 to 136 ft--lb (150 to 184 N--m) 20 1 11/16 -- 12 140 to 172 ft--lb (190 to 233 N--m)

Figure 5

Groundsmaster 4300--D Hydraulic SystemPage 4 -- 5

Hydraulic Fitting Installation (SAE Straight Thread O--Ring Fitting into Component Port)

Non--Adjustable Fitting (Fig. 6)

1. Make sure allthreads and sealingsurfaces offitting and component port are free of burrs, nicks, scratches or any foreign material.

2. Asa preventative measure against leakage,itisrecommended that the O--ring be replaced any time the connection is opened.

3. Lightly lubricate the O--ring with clean hydraulic oil. Fittingthreadsshouldbecleanwithnolubricantapplied.

IMPORTANT: Before installing fitting into port, determine port material.If fittingis to beinstalled 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 recommended installation torque shown in Figure 7.

NOTE: Useof an offsetwrench (e.g.crowfoot wrench) will affect torquewrench calibration due tothe effective length change of the torque wrench. Tightening torque when using a torque wrench with an offset wrench will be less than the recommendedinstallation torque. See Using a Torque Wrench with an Offset Wrench in the Torque Specifications section of Chapter 2 -- Product Recordsand Maintenancetodetermine necessaryconversion information.

5. If a torquewrench is not available, or if spaceat the portpreventsuseof atorque wrench,analternate method ofassembly is the Flats From Finger Tight (F.F.F.T.) method.

A. Install thefitting into the port and tighten it down full length until finger tight.

B. If port material is steel, tighten the fitting to the listed F.F.F .T. Ifport material is aluminum,tighten fitting to 60% of listed F.F.F.T.

Siz e F.F.F.T.

4 (1/4 in. nominal hose or tubing) 1.00 + 6(3/8in.) 1.50+ 8(1/2in.) 1.50+ 10 (5/8 in.) 1.50 + 12 (3/4 in.) 1.50 + 16 (1 in.) 1.50 +

Fitting

O--ring

0.25

Figure 6

Fitting

Dash Size

Fitting Port Side

Thread Size

Installation Torque Into

Steel Port

Installation Torque Into

Aluminum Port

4 7/16 -- 20 15to19ft--lb(21to25N--m) 9to11ft--lb(13to15N--m) 5 1/2 -- 20 18to22ft--lb(25to29N--m) 11to15ft--lb(15to20N--m) 6 9/16 -- 18 34to42ft--lb(47to56N--m) 20to26ft--lb(28to35N--m)

8 3/4 -- 16 58to72ft--lb(79to97N--m) 35to43ft--lb(48to58N--m) 10 7/8 -- 14 99 to 121 ft--lb (135 to 164 N--m) 60 to 74 ft--lb (82 to 100 N--m) 12 11/16--12 134 to 164 ft--lb (182 to 222 N--m) 81 to 99 ft--lb (110 to 134 N--m) 14 13/16--12 160 to 196 ft--lb (217 to 265 N--m) 96 to 118 ft--lb (131 to 160 N--m) 16 15/16--12 202 to 248 ft--lb (274 to 336 N--m) 121 to 149 ft--lb (165 to 202 N--m) 20 15/8--12 247 to 303 ft--lb (335 to 410 N--m) 149 to 183 ft--lb (202 to 248 N--m)

Figure 7

Groundsmaster 4300--DHydraulic System Page 4 -- 6

Adjustable Fitting (Fig. 8)

1. Make sure allthreads and sealingsurfaces offitting and component port are free of burrs, nicks, scratches or any foreign material.

2. Asa preventative measure against leakage,itisrecommended that the O--ring be replaced any time the connection is opened.

3. Lightly lubricate the O--ring with clean hydraulic oil. Fittingthreadsshouldbecleanwithnolubricantapplied.

4. Turnback thelock nut asfar aspossible. Makesure the back up washeris notloose and ispushed up asfar as possible (Step 1 in Figure 9).

IMPORTANT: Before installing fitting into port, determine port material.If fittingis to beinstalled into an aluminum port, installation torque is reduced.

Lock Nut

Back--up Washer

O--ring

Figure 8

5. Install the fitting intothe port and tighten finger tight until the washer contactsthe faceof theport ( Step 2 in Figure 9). Make sure that the fitting does not bottomin the port during installation.

6. Toput the fitting in thedesiredposition,unscrew it by the required amount to align fitting with incoming hose or tube, butno more than one fullturn (Step 3 inFigure

9).

7. Hold the fittingin thedesired position with a wrench and use a torque wrench to tighten the lock nut to the recommended installation torque shown in Figure 7. This tighteningprocess willrequire theuse of an offset wrench (e.g. crowfoot wrench). Useof an offset wrench will affect torquewrench calibration due tothe effective length change of the torque wrench. Tightening torque when using a torque wrench with an offset wrench will be lower thanthe listed installation torque (seeUsing a Torque Wrench with an Offset Wrench in the Torque Specifications section of Chapter 2 -- Product Records and Maintenance).

8. If a torquewrench is not available, or if spaceat the portpreventsuseof atorque wrench,analternate method ofassembly is the Flats From Finger Tight (F.F.F.T.) method. Hold the fitting in the desired position with a wrench and, ifport materialis steel, tightenthe lock nut witha second wrench to the listedF.F.F.T (Step 4 in Figure9).Ifportmaterialis aluminum, tighten fitting to 60% of listed F.F.F.T.

Step 3Step 1

Step 2 Step 4

Figure 9

System

Hydraulic

Siz e F.F.F.T.

4 (1/4 in. nominal hose or tubing) 1.00 + 6(3/8in.) 1.50+ 8(1/2in.) 1.50+ 10 (5/8 in.) 1.50 + 12 (3/4 in.) 1.50 + 16 (1 in.) 1.50 +

0.25

Groundsmaster 4300--D Hydraulic SystemPage 4 -- 7

Relieving Hydraulic System Pressure

Beforedisconnectingorperforming any work on the hydraulic system, all pressure in the hydraulic system mustberelieved.Parkmachineonalevel surface,lower cutting decks fully, stop engine and engage parking brake.

To relieve hydraulic pressure in traction circuit, move tractionpedal to both forward and reversedirections.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 machines is a closed loop system that includes the piston (traction) pump and four (4) wheel motors. Ifa componentinthetractioncircuitshouldfail,debrisandcontamination from the failed component will circulate throughout the traction circuit. This contamination can damageother components inthecircuit so itmustbe removed 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) intothe circuit. This filter should be used whenconnecting hydraulic test gauges in order to test tractioncircuit components or after replacing a failed traction circuit component(e.g. traction(piston)pump or wheelmotor). The filter will ensure that contaminates are removed from the closed loop and thus, do notcause additional component damage.

Once the Toro high flow hydraulic filter kit has been placedin the circuit, raise and support the machinewith all wheels off the ground.Then, operate thetraction cir-

To relieve hydraulic pressure in lift circuit, turn ignition switchtoON(do notstartengine) andfullylower thecutting decks. After decks are fully lowered, turn ignition switch to OFF and remove key from the switch.

IMPORTANT: If machinewill be serviced on a lift or atan elevated position,fullylower the cuttingdecks afterthemachine hasbeenraised to ensure that the lift cylinders are fully extended. Pressure will be maintained in the lift cylinders unless they arefully extended.

cuit to allow oil flowthroughout the circuit. The filterwill remove contamination from the traction circuit during operation. Because the Toro high flow filter is bi--directional,the tractioncircuitcan beoperatedin both theforward and reverse direction. The filter should be removed from the machine after contamination has been removed from the traction circuit. See Filtering Closed--LoopTractionCircuitintheServiceandRepairs section of this chapter for additional information on using the Toro high flow hydraulic filter.

Thealternative tousing theTorohigh flowhydraulicfilter kit after a traction circuit component failure would beto disassemble, drain and thoroughly clean all components, tubes and hoses in the tractioncircuit. If any debris remains in the traction circuit and the machine is operated,thedebriscancauseadditionalcircuit component failure.

NOTE: The traction pump case drain could allow any debrisinthe tractioncircuittocontaminateother hydraulic circuits on the machine.

Groundsmaster 4300--DHydraulic System Page 4 -- 8

Hydraulic Schematic

CYLINDER

STEERING

VALVE

CONTROL

STEERING

LIFT

CONTROL

MANIFOLD

Hydraulic Schematic

Groundsmaster 4300--D

de--energized

All solenoids are shown as

System

Hydraulic

MANIFOLD

CROSSTRAX

VALVE

BYPASS

GEAR

PUMP

PISTON

(TRACTION)

Groundsmaster 4300--D Hydraulic SystemPage 4 -- 9

DECK

CONTROL

MANIFOLD

NOTE: A larger hydraulic schematic is

included in Chapter 8 -- Foldout Drawings

Hydraulic Flow Diagrams

VALVE

CONTROL

STEERING

CYLINDER

STEERING

LIFT

CONTROL

MANIFOLD

Working Pressure

Low Pressure (Charge)

Return or Suction

Flow

Traction Circuit (Forward Shown)

Groundsmaster 4300--D

GEAR

PUMP

BYPASS

MANIFOLD

CROSSTRAX

VALVE

DECK

CONTROL

MANIFOLD

PUMP

PISTON

(TRACTION)

Figure 10

Groundsmaster 4300--DHydraulic System Page 4 -- 10

Traction Circuit

The hydraulic traction circuit consists of a variable displacementpistonpump(P5)connectedinaclosedloop, parallel circuit to four (4) orbital roller vane wheel motors. The traction pump input shaft is rotated by a drive shaft that is driven from the engine flywheel.

Forward traction circuitpressure can bemeasured at a test port located in thehydraulic tube that connects the front wheel motors. Reverse traction circuit pressure can be measuredat test portsin the AWD control manifold.

Forward Direction (Fig. 10)

Pushing the top ofthe tractionpedal anglesthe 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 drivethe wheels inthe forward direction.Traction pump flow isdirected tothe frontwheel motorsand thentotheopposite rearwheelmotors tomaximizetraction. To reduce tire scuffing when turning, traction system pressureis equalized in the AWD control manifold with an orifice and a bi--directional relief valve. Check valvesintheAWDmanifold allow the rear wheel motors toover--runduringtight turns.Forward tractionpressure is limited to 3625 PSI (250 bar) by the forward traction relief valve (R3) located in the traction pump.

Oilflowingfromthe w heel motors returns to the variable displacement pump and is continuously pumped through the tractioncircuit as long as thetraction pedal is pushed.

Theangle of the swash platedeterminespumpflowand ultimatelytractionspeed.Whenthetractionpedalisdepressedasmallamount,asmallswashplaterotationresultsinlowpumpoutputandlowertractionspeed.When the traction pedal is depressed fully, the pump swash platerotatesfullytoprovidemaximumpumpoutputand traction speed.

Gearpump section (P3)suppliesoilflow for thesteering circuitand also provides aconstant supply ofcharge oil to the closed loop traction circuit. This charge oil provideslubricationfortractioncircuitcomponentsandalso replenishes traction circuit oil thatis lost due to internal leakage in the traction circuit.

Gear pump section (P3) takes its suction from the hydraulicreservoir.Chargepumpflowisdirectedtothelow pressure side of theclosed looptraction circuit. Charge relief valve (R5) located in the traction pump limits the charge relief pressure to 200 PSI (14 bar).

The piston pump is equippedwith a casedrain toallow 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 cooling ofthe closedlooptraction circuit.Thechargesystem replenishes oil that is bled from the traction circuit by the flushing valve.

Reverse Direction

The traction circuitoperates essentially the same inreverse as it does in the forward direction. However, the flow through thecircuit isreversed. 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 direction. Reverse traction pressure is limited to 3625 PSI (250bar)bythereversetractionr elief valve(R4) located in the traction pump.

Oil flowing from the wheelmotors returnsto thetraction pump and is continuously pumped through the closed loop traction circuit as long as the traction pedal is pushed.

The charge circuit andflushing valvefunction thesame in reverse as they do in the forwarddirection.

System

Hydraulic

Groundsmaster 4300--D Hydraulic SystemPage 4 -- 11

VALVE

CONTROL

STEERING

CYLINDER

STEERING

LIFT

CONTROL

MANIFOLD

Groundsmaster 4300--D

Working Pressure

Mow Circuit

Low Pressure (Charge)

Return or Suction

Flow

GEAR

PUMP

BYPASS

MANIFOLD

CROSSTRAX

VALVE

DECK

CONTROL

MANIFOLD

PUMP

PISTON

(TRACTION)

Figure 11

Groundsmaster 4300--DHydraulic System Page 4 -- 12

Mow Circuit

A four sectiongear pump is coupled tothe piston(traction) pump. Gear pump sections (P1) and (P2) supply hydraulic flow for the mow circuit. These gear pumps take their suction from the hydraulic reservoir.

Thedeck control manifold contains two (2) independent controlcircuits for the front and rear cuttingdecks.Each circuit is supplied by its own pump section. Pump section (P1) supplies hydraulic power to the rear cutting decks with circuit control by proportional relief valve (PRV1), relief valve (RV1) and logic cartridge (LC1) in the deck control manifold. Pump section (P2) supplies thefrontcutting deckswithcircuitcontrolbyproportional reliefvalve(PRV2),reliefvalve(RV2)andlogiccartridge (LC2) in the deck control manifold. Both circuits share manifoldportT,whichdrainstothe oilcooler,oilfilterand hydraulic reservoir.

Cutting deck motorsare equipped witha cross over relief valve to prevent hydraulic component damage in case a single cutting deck should stall.

The machine controller uses inputs from various machineswitchestodeterminewhenthe solenoids for proportional relief valves (PRV1) and (PRV2) are to be energized. The controller alsoprovides aslight delayin activation of rear cutting decks.

PTO Not Engaged

Whenproportionalreliefvalves (PRV1) and (PRV2) are notenergized (PTOswitchin theOFFpositionor cutting decksraised), flow from pump sections (P1)and (P2) is directedthroughtheunshifted proportionalreliefvalves, out the mowcontrol manifold portT and then returns to thehydraulicreservoir throughtheoilfilterandoilcooler, bypassing the deck motors. The manifold logic cartridges (LC1 and LC2) remain in the unshifted position to prevent any return flow from the deck motors so the motors will not rotate.

amanifold sensingline.This flowpassesthrough anorificewhichcausesapressuredifferentialthat shifts logic cartridge LC1. The shifted LC1allows circuit flow to rotate the rear cutting deck motors. Return oil from the deck motors is directed through the shifted logic cartridge(LC1),manifoldportT,oilcooler,oil filter and then to the reservoir. Deck motorcase drainleakage returns directly to the hydraulic reservoir.

Mow circuit pressure for the rear cutting decks (pump section P1) can be measured at deck control manifold port G1.

The frontcutting deck circuit operates the same as the rear cutting deck circuit. Deck control manifold proportional relief (PRV2), relief valve (RV2) and logic cartridge (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 limitedby the proportional relief valves in the hydraulic control manifold. Thefront deck circuit valve (PRV2) is set at 3500 PSI (241bar) and the rear deck circuit valve (PRV1) is set at 2500 PSI (175 bar).

When increased circuitresistance is met(e.g. a cutting blade should strike an object),the pressure increase is felt at the proportional relief valve. If circuit pressure shouldexceed thereliefsetting, thevalvewillopen toallow circuit flow toreturn to tank throughmanifold portT. When circuit pressure lowers, thevalve closes toallow flow to return to the deck motors.

#4 #1 #5

System

Hydraulic

PTO Engaged (Fig. 11)

When proportional relief valve (PRV1) is energized by thecontroller (PTOswitchin the ONpositionand cutting decks lowered), the proportional relief valve shifts and prevents pump section (P1) flow through the valve. Pump flow that entereddeck controlmanifold port P1is then directed toward the rear cutting deck motors. Because logic cartridge LC1 is unshifted, circuit pressure increases until manifoldrelief valve(RV1) isopened by a manifold pilot piston. The shiftedrelief valve allows a small amount ofhydraulic flow to return totank through

Groundsmaster 4300--D Hydraulic SystemPage 4 -- 13

GROUNDSMASTER

4300--D CUTTING

DECK LOCATIONS

#3#2

Figure 12

Mow Circuit Cutting Deck Blade Braking

When the operator turns the PTO switch OFF or if the decksareraisedwiththePTOswitch ON, the deck control manifold proportional relief valves (PRV1 and PRV2) are de-- energized causing circuit flowto bypass thedeck motors and return to the reservoirout manifold portT(refertoinformationin MowCircuitinthissection). Without circuit flow, the manifold relief valve (RV1 or RV2)returnstoitsneutralpositionwhichcausesthelogic cartridge (LC1 or LC2) to shift to its neutral position, blocking return flow from the deck motors and slowing the cutting blades (Fig. 13).

Theinertiaoftherotatingcutting blades,however,effectively turns the deck motors into pumps causing an increaseinpressure as the flow from themotor 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 allows a small amount of hydraulic flow to return to tank through a manifold sensing line (Fig. 14). This flow causes a pressure differential that shifts the logic cartridge(LC1 or LC2) toonce again allowoil flow fromthe motors (Fig. 15). When return pressure drops below 1500 PSI (105 bar), the relief valve (RV1 or RV2) reseats and causes the logic cartridge (LC1 or LC2) to close again, blocking return flow from the deck motors tofurther slow thecuttingblades. Thisactionof therelief valve opening and the logic cartridge shifting occurs severaltimesina very short time frame as theblades finallycome to astop.Once the bladeshavestopped,the logiccartridge(LC1 or LC2) remains in the neutralposition to keep the deck motors from rotating.

FROM

FROM GEAR

GEAR PUMP

PUMP

TO OIL

OIL COOLER

COOLER

FROM GEAR PUMP

TO OIL COOLER

FROM

FROM FRONT

FRONT MOW

MOW CIRCUIT

CIRCUIT

FROM FRONT MOW CIRCUIT

DECK

DECK CONTROL

CONTROL MANIFOLD

MANIFOLD

Figure 13

ORIFICE

DECK CONTROL MANIFOLD

FROM GEAR PUMP

TO OIL COOLER

FROM FRONT MOW CIRCUIT

Figure 14

ORIFICE

DECK CONTROL MANIFOLD

Figure 15

Groundsmaster 4300--DHydraulic System Page 4 -- 14

This page is intentionally blank.

System

Hydraulic

Groundsmaster 4300--D Hydraulic SystemPage 4 -- 15

VALVE

CONTROL

STEERING

CYLINDER

STEERING

Working Pressure

Low Pressure (Charge)

Return or Suction

LIFT

CONTROL

MANIFOLD

Groundsmaster 4300--D

Lift Circuit: Raise Cutting Decks

Flow

GEAR

PUMP

BYPASS

MANIFOLD

CROSSTRAX

VALVE

DECK

CONTROL

MANIFOLD

PUMP

PISTON

(TRACTION)

Figure 16

Groundsmaster 4300--DHydraulic System Page 4 -- 16

Lift Circuit: Raise Cutting Decks

A four sectiongear pump is coupled tothe piston(traction) pump. Gear pump section (P4) supplies hydraulic flowtotheliftcontrolmanifoldandliftcylinders.Thegear pump takes its suction from the hydraulic reservoir.

The lift control manifold includes three (3) electrically operatedvalves. Solenoidvalve(S1)is used todirectoil flowtoextendthe liftcylinderswhen energizedorretract them when de--energized. Solenoid valve (S2) allows hydraulic flow from the rodend of thelift cylinders when energized and prevents oil passage from the lift cylinders when de--energized. Proportional relief valve (PRV) is used to control the operation of the manifold logiccartridge (LC)andalso actsasa circuitreliefvalve.

While operating the machine during conditions of not raisingor lowering thecuttingdecks(joystickin the neutral (center) position) (Fig. 17), all of the lift manifold valves(S1, S2andPRV)arede--energized.Thede--energizedrelief valve (PRV)allowshydraulicflow to return to tank through the manifold. This flow causes a pressuredifferentialthat shifts the logic cartridge (LC) which allows pump flow to bypass the lift cylinders. Flow returns tothe oil filter and then to the hydraulic reservoir.

LIFT CIRCUIT: NOT RAISING OR LOWERING

S1, S2 AND PRV DE--ENERGIZED

LC SHIFTED

Raise Cutting Decks (Fig. 16)

Whenthejoystickismovedtotheraiseposition,thecontrollerenergizes theproportionalreliefvalve (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, pumpflow is directed to the rod endof all lift cylinders to retract the cylindersand raise allcutting decks. Flowto thelift cylinders bypasses the control manifoldfixed orifices to prevent flow restriction during deck raising.

Whilethe cuttingdecksare beingraised,theproportional reliefvalve (PRV)has a secondary function as a circuit relief to limit lift circuit pressure to 2000 PSI (138 bar). Lift circuit pressurecan be monitoredat liftcontrol manifold port G4.

When the joystick is returned to the neutral (center) position, the proportionalrelief valve(PRV) isde--energized. The de--energized r elief valve (PRV) allows hydraulic flowto returnto tankthrough the manifold. This flow causes a pressure differential that shifts the logic cartridge (LC) whichallows pump flowto bypassthe lift cylinders. All lift cylinders and cutting decks are held in the raised position by de--energized valve S2.

FROM

PUMP P4

TO OIL

FILTER

Figure 17

LIFT CONTROL MANIFOLD

System

Hydraulic

Groundsmaster 4300--D Hydraulic SystemPage 4 -- 17

VALVE

CONTROL

STEERING

CYLINDER

STEERING

Working Pressure

Low Pressure (Charge)

Return or Suction

LIFT

CONTROL

MANIFOLD

Groundsmaster 4300--D

Lift Circuit: Lower Cutting Decks

Flow

GEAR

PUMP

BYPASS

MANIFOLD

CROSSTRAX

VALVE

DECK

CONTROL

MANIFOLD

PUMP

PISTON

(TRACTION)

Figure 18

Groundsmaster 4300--DHydraulic System Page 4 -- 18

Lift Circuit: Lower Cutting Decks

While operating the machine during conditions of not raisingor lowering thecuttingdecks(joystickin the neutral (center) position) (Fig. 19), all of the lift manifold valves(S1, S2andPRV)arede--energized.Thede--energizedrelief valve (PRV)allowshydraulicflow to return to tank through the manifold. This flow causes a pressuredifferentialthat shifts the logic cartridge (LC) which allows pump flow to bypass the lift cylinders. Flow returns tothe oil filter and then to the hydraulic reservoir.

Counterbalance

Once the cutting decks arefully lowered,the lift control manifold proportional relief valve (PRV)maintains back pressure (counterbalance) on the deck lift cylinders. This counterbalance pressure transfers cutting deck weighttothemachinetoimprovetraction.Asetofwires locatedbehindthecontrolarmaccesscover allowcounterbalance pressureto be adjusted to one of three settings.

Apressuretransducerlocatedintheforward tractionhydraulictubeisused bythecontroller asaninput todetermine traction circuit pressure. Based on transducer inputandmachine counterbalance setting, an electrical output from the controller is provided to the lift control manifoldproportional relief valve (PRV)tovary counterbalance pressure. As traction pressure increases (e.g. climbing a hill) the counterbalance pressure also increases to increase the weighton the tiresand improve traction.

LIFT CIRCUIT: NOT RAISING OR LOWERING

NOTE: When the mow speed limiteris inthe transport

position, the cutting decks will not lower.

Lower Cutting Decks (Fig. 18)

When the joystick is moved to the lower position, the controllerenergizes all of theliftmanifold 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 manifoldcartridges in this position, pump flow is directed to the barrel end of alllift cylinderstoextend thecylindersand lowerthecutting decks. Fixed orificesin thelift controlmanifold (C2, C4,C6 and C8) controltheloweringspeed of the cutting decks byproviding a restriction for the return flow from the lift cylinders.

While the cutting decks are being lowered, the proportional relief valve (PRV) has a secondary function as a circuit relief tolimit lift circuitpressure to 2000 PSI (138 bar). Lift circuit pressurecan be monitoredat liftcontrol manifold port G4.

When the joystick is returned to the neutral (center) position, all ofthe liftmanifold valves (S1,S2 andPRV) arede--energized.Thede--energizedreliefvalve(PRV) allows hydraulic flow to returnto tank through themanifold. This flow causes apressure differential thatshifts the logic cartridge (LC) which allows pump flow to bypass the lift cylinders.All lift cylinders andcutting decks are held in position by de--energized valve S2.

FROM

PUMP P4

TO OIL

FILTER

Figure 19

S1, S2 AND PRV DE--ENERGIZED

LC SHIFTED

LIFT CONTROL MANIFOLD

System

Hydraulic

Groundsmaster 4300--D Hydraulic SystemPage 4 -- 19

PISTON

MOVEMENT

Working Pressure

Low Pressure (Charge)

Return or Suction

Flow

LEFT TURN

FROM PUMP (P3)

TO TRACTION

R10

Steering Circuit

Groundsmaster 4300--D

CYLINDER

STEERING

CHARGE CIRCUIT

VALVE

CONTROL

STEERING

PISTON

MOVEMENT

RIGHT TURN

FROM PUMP (P3)

TO TRACTION

R10

CYLINDER

STEERING

VALVE

CONTROL

CHARGE CIRCUIT

STEERING

Figure 20

Groundsmaster 4300--DHydraulic System Page 4 -- 20

Steering Circuit

A four sectiongear pump is coupled tothe piston(traction) pump. Gear pump section P3 supplies hydraulic flow to the steering control valve and for the traction chargecircuit. The gear pump takes its suction fromthe hydraulicreservoir.Steeringcircuitpressureislimited 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 control valve at the P port and goes through the steering controlspool valve,bypassingthe rotarymeter(V1) and steering cylinder.Flow leaves thecontrol valvethrough theTporttothetransmissionoilfilterandtractioncharge circuit.

Left Turn (Fig. 20)

When a left turn is made with the engine running, the turningof the steering wheel positions thesteering control spool valve so that flow is directed through the bottomofthespool.Flowenteringthesteeringcontrolv alve atthePportgoes through the spool and is routed to two places. First, most of the flow through the valve is bypassed out the T port back to the transmission oil filter andtractionchargecircuit.Second,theremainderofthe flowis directedthroughtherotarymeter (V1)andout the L port. Pressure contracts the steering cylinder piston for a leftturn. The rotary meter ensuresthat the oil flow to the steering cylinderis proportionalto theamount of turningon the steering wheel. Fluidleaving the steering cylinder flows back through the steering control spool valve and thenout of thesteering controlvalve through the T port.

Right Turn (Fig. 20)

When a right turn is made with the engine running,the turningof the steering wheel positions thesteering control spool valve so that flow is directed through the top of the spool. Flow enteringthe 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 valveisbypassed outtheTportbacktothetransmission oil filter and traction charge circuit. Also like a left turn, the remainder ofthe flow isdirected throughrotary meter(V1) butgoesoutport R.Pressureextendsthe steering cylinder piston for a right turn. The rotary meter ensures that the oil flow to the steering cylinder is proportional 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.

Thesteeringcontrolvalvereturnstothe neutral position when turning is completed.

System

Hydraulic

Thesteeringcontrolvalvereturnstothe neutral position when turning is completed.

Groundsmaster 4300--D Hydraulic SystemPage 4 -- 21

Special Tools

Order Special Tools from your Toro Distributor.

Hydraulic Pressure Test Kit

Use to take various pressure readings for diagnostic tests. Quickdisconnect fittings provided attach directly to mating fittings on machine test ports without tools. A high pressure hoseis 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: TOR47009

15 GPM Hydraulic Tester Kit (Pressure and Flow)

Figure 21

Use to test hydraulic circuits and components for flow andpressurecapacitiesas recommendedintheTesting sectionofthischapter.Thistesterincludesthefollowing:

1. INLET HOSE: Hoseconnected fromthe system circuit 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 5000PSI gauge to provide operating circuit pressure.

4. FLOWMETER: This metermeasures actualoil flow in the operating circuit with a gauge rated from 1 to 15 GPM(5to55LPM).

5. OUTLET HOSE: A hose from the outlet side of the hydraulictesterconnectsto thehydraulicsystemcircuit.

6. FITTINGS:An assortmentofhydraulic fittings areincluded with this kit.

Toro Part Number: TOR214678

Figure 22

Groundsmaster 4300--DHydraulic System Page 4 -- 22

40 GPM Hydraulic Tester (Pressure and Flow)

Use to test hydraulic circuits and components for flow andpressurecapacitiesas recommendedintheTesting sectionofthischapter.Thistesterincludesthefollowing:

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 5000PSI gauge to provide operating circuit pressure.

3. FLOWMETER: This metermeasures actualoil flow in the operating circuit with a gauge rated from 4 to 40 GPM (20 to 150 LPM).

Toro Part Number: AT40002 NOTE: Thistesterdoesnotincludehoses(seeHydrau-

lic Hose Kit TOR6007 below).

Hydraulic Hose Kit

Thiskitincludesfittingsandhosesneededtoconnect40 GPM hydraulic tester (AT40002) or high flow hydraulic filterkit(TOR6011)tomachinehydraulic tractionsystem components.

Toro Part Number: TOR6007

O --Ring Kit

Figure 23

Figure 24

System

Hydraulic

The O--ring kit includes O--rings in avariety ofsizes for face sealand port seal hydraulic connections. It is recommended that O--rings be replaced whenever a hydraulic connection is loosened.

Toro Part Number: 117--2727

Groundsmaster 4300--D Hydraulic SystemPage 4 -- 23

Figure 25

High Flow Hydraulic Filter Kit

The high flow hydraulic filter kit is designed with large flow (40 GPM/150 LPM) and high pressure (5000 PSI/345 bar) capabilities. This kitprovides for bi--directionalfiltration which prevents filtereddebris frombeing allowedback into the circuit regardless offlowdirection.

If a component failureoccurs inthe closedloop traction circuit, contaminationfrom the failed part will remain in the circuit until removed. When connecting hydraulic test gauges in order to test traction circuit components orafterreplacing afailedtractioncircuitcomponent(e.g. hydrostat or wheel motor), the high flow hydraulic filter can be installed in the traction circuit. The filter will ensure that contaminates are removed from the closed loopandthus,donotcause additional component damage.

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 part number

TOR6012. Filter element cannister tightening torque is 25 ft--lb (34 N--m).

Figure 26

Hydraulic Test Fitting Kit

This kitincludes avariety ofO--ring face seal fittings to enable connection of test gauges to the system.

The kit includes: tee’s, unions, reducers, plugs, caps and male test fittings.

Toro Part Number: TOR4079

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

TORO TEST FITTING KIT (TOR4079)

Figure 27

Figure 28

Groundsmaster 4300--DHydraulic System Page 4 -- 24

Wheel Hub Puller

The wheel hub puller allows safe removal of the wheel hub from the wheel motor shaft.

Toro Part Number: TOR6004

Measuring Container

Use this graduated containerfor doinghydraulic motor efficiency testing (motors with case drain lines only). Measureefficiencyofahydraulicmotorbyrestrictingthe outlet flow fromthe motor and measuring leakagefrom thecase drain line whilethe motor ispressurized by the hydraulic system.

Figure 29

The table in Figure 31 provides gallons per minute (GPM)conversion for measured milliliter or ounceleakage.

Toro Part Number: TOR4077

Figure 30

Figure 31

System

Hydraulic

Groundsmaster 4300--D Hydraulic SystemPage 4 -- 25

Troubleshooting

The cause of an improperly functioning hydraulic system is best diagnosed with the use of proper testing equipment and a thorough understanding of the complete hydraulic system.

A hydraulic system with an excessive increase in heat ornoise hasapotential forfailure. Shouldeitherofthese conditions be noticed, immediately stop the machine, turn off the engine, locate the cause of the trouble and correct it before allowing themachine tobe used again. Continued use of an improperly functioning hydraulic system could lead to extensive hydraulic component damage.

The charts that follow contain information to assist in troubleshooting. There maypossibly bemore than one cause for a machine malfunction.

Review the hydraulicschematic and informationon hydraulic system operation in the Hydraulic Flow Diagrams section of this chapter. This information will be useful during the hydraulic troubleshooting process.

Refer to the Testing section of this chapter for precautions and specific hydraulic test procedures.

General Hydraulic System Problems

Problem Possible Causes

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 damage, it is possible that other traction circuit components are also damaged).

Groundsmaster 4300--DHydraulic System Page 4 -- 26

Traction Circuit Problems

Problem Possible Causes

Neutral is difficult to find or machine operates in one direction only

Traction response is sluggish Hydraulic oil is very cold.

No traction in either direction Parking brake is applied, dragging or binding.

Traction control linkage is misadjusted, disconnected, binding or damaged.

Piston (traction) pump check relief valve is not seating or is damaged (NOTE: Piston (traction) pump check relief valves for forward and reverse are identical and can be reversed for testing purposes).

Piston (traction) pump is worn or damaged.

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.

System

Hydraulic

Single wheel motor turns while unloaded, but slows down or stops when load is applied

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 seating 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).

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).

Groundsmaster 4300--D Hydraulic SystemPage 4 -- 27

Traction Circuit Problems (Continued)

Problem Possible Causes

Wheel motor will not turn Brakes are binding.

Wheel motor is worn or damaged (NOTE: If a traction circuit component has internal wear or damage, it is possible that other traction circuit components are also damaged).

Wheel motors will not hold load when traction pedal is in neutral

Charge pressure is low. 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 circuit components are also damaged).

Mow Circuit Problems

Problem Possible Causes

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

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 (P2) 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).

Single cutting deck motor will not operate or rotates slowly

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 (P1) 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.

Groundsmaster 4300--DHydraulic System Page 4 -- 28

Lift Circuit Problems

Problem Possible Causes

Single cutting deck raises slowly or not at all

Cutting decks raise, but will not remain in the raised position

NOTE: Lift cylinders and control manifold cartridge valves cannot provide an absolutely perfect seal. The cutting decks will eventually lower if left in the raised position.

None of the cutting decks will raise or lower

NOTE: Mow speed limiter must be in mow speed position in order to lower the cutting decks.

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. Lift circuit hydraulic lines or fittings are leaking. Air exists in lift circuit. Lift cylinder leaks internally. Solenoid valve (S2) in lift control manifold leaks.

Oil level in hydraulic reservoir is low (other hydraulic systems are affected as well).

An electrical problem exists that prevents lift control manifold solenoid valve operation (see Troubleshooting in Chapter 5 -- Electrical System).

Solenoid valve PRV in lift control manifold is faulty. Logic cartridge LC in lift control manifold is faulty.

System

Hydraulic

Neither of the rear cutting decks will raise or lower but the front cutting decks will raise and lower

Single cutting deck lowers very slowly or not at all

Solenoid valve S2 in lift control manifold is faulty. Gear pump section (P4) is worn or damaged.

Flow control orifice in lift control manifold for the rear cutting decks (port C8) is plugged, stuck or damaged.

Lift arm or lift cylinder is binding. Lift cylinder is damaged. Flow control orifice in lift control manifold for the affected cutting deck is

plugged, stuck or damaged.

Groundsmaster 4300--D Hydraulic SystemPage 4 -- 29

Steering Circuit Problems

Problem Possible Causes

Steering inoperative or sluggish Steering components (e.g. tie rods, steering cylinder ends) are worn or

binding. Steering cylinder is binding. Oil level in hydraulic reservoir is low (other hydraulic systems are

affected as well). Steering relief valve (R10) in steering control valve is stuck or

damaged. Steering cylinder leaks internally. Steering control valve is worn or damaged. Gear pump section (P3) is worn or damaged (NOTE: A w orn or

damaged gear pump section (P3) will also affect the traction (charge) circuit).

Groundsmaster 4300--DHydraulic System Page 4 -- 30

This page is intentionally blank.

System

Hydraulic

Groundsmaster 4300--D Hydraulic SystemPage 4 -- 31

Testing

The most effectivemethod for isolating problems in the hydraulic system is by using hydraulic test equipment suchaspressuregauges 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 improper adjustments must be checked before assuming that a hydraulic component is thesource of a problem.

Precautions for Hydraulic Testing

CAUTION

Failure to use gauges with expected pressure (psi/bar)ratingaslistedintestprocedurescould result indamage tothe gauge and possiblepersonal injury from leaking hot oil.

CAUTION

All testing should be performed by two (2) people.One personshouldbe inthe seat tooperate the machine and the other should read and record test results.

2. Review all test steps before starting the test procedure.

3. Beforetesting, check all controllinkages for improper adjustment, binding or broken parts.

4. Allhydraulic tests should be made with thehydraulic oil at normal operating temperature.

WARNING

Beforedisconnecting orperformingany workon the hydraulic system, all pressure in the system must be relieved. See Relieving Hydraulic System Pressure in theGeneral Informationsection of this chapter.

5. Put metal caps or plugs on any hydraulic lines left open or exposedduring testing orcomponent removal.

6. Whenusing 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. Installhydraulicfittings finger tight and far enough to makesurethattheyarenotcross--threadedbeforetightening them with a wrench.

8. Position tester hoses to prevent rotating machine partsfrom contacting anddamagingthehoses or tester.

WARNING

Keep body and handsaway frompin holeleaks or nozzles that eject hydraulic fluid under high pressure. Do not use hands tosearch for leaks; use paper or cardboard. Hydraulic fluid escaping under pressure can have sufficient force to penetrate the skin and cause serious injury. If fluidisinjectedintotheskin,it mustbesurgicallyremovedwithin a few hours by a doctor familiar with this typeof injury. Gangrene may result from such an injury.

1. Clean machine thoroughly before disconnecting or disassemblingany hydraulic components. Alwayskeep in mind the need for cleanliness when working on hydraulicequipment. Contamination can cause excessive wear or binding of hydraulic components.

9. After connecting test equipment, check oil level in the hydraulictank to make sure that oil level is correct.

10.When using hydraulic tester (pressure and flow), opentesterloadvalvecompletelybeforestartingengine to minimize the possibility of damaging components.

11.Theenginemustbeingoodoperating 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 hydraulic flow tests.

12.After hydraulic test procedures have been completed,checkoillevelin the hydraulic tank to make sure that oil level is correct.

Groundsmaster 4300--DHydraulic System Page 4 -- 32

Which Hydraulic Tests Are Necessary?

Before beginning any hydraulictest, identify if theproblemis related tothetraction circuit,cutting(mow) circuit, lift circuit or steeringcircuit. Once thefaulty systemhas been identified, perform tests that relate to that circuit.

1. Ifa traction circuit problem exists,consider performing 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 chapterfor information regarding theimportanceof removing contamination from the traction circuit.

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 (P1) and (P2) Flow and/or Deck Motor Efficiency Tests.

3. If a lift circuit problem exists, consider performing oneormoreofthefollowingtests:LiftReliefValve(PRV) Pressure, Gear Pump(P4) Flowand/or Lift CylinderInternal Leakage Tests.

4. Ifa steeringcircuitproblem exists,considerperforming one or more of the following tests: Steering Relief Valve (R10) Pressure, SteeringCylinder Internal Leakage and/or Gear Pump (P3) Flow Tests.

System

Hydraulic

Groundsmaster 4300--D Hydraulic SystemPage 4 -- 33

Traction Circuit Relief Valve (R3) and (R4) Pressure Test

TO STEERING CONTROL VALVEAND CHARGE CIRCUIT

TO MOW CONTROL

(FRONT CUTTING UNITS)

TO MOW CONTROL (REAR CUTTING UNITS)

TO LIFT CONTROL MANIFOLD

PISTON

(TRACTION)

PUMP

GEAR PUMP

BYPASS

VALVE

Figure 32

FORWARD (R3) RELIEF

VALVE TEST SHOWN

CROSSTRAX

MANIFOLD

GAUGE

PRESSURE

FROM STEERING CONTROL VALVE

The traction circuit relief pressure test should be performed to make sure that forward and reverse traction circuit relief pressures are correct.

Procedure for Traction Circuit ReliefValve(R3) (R4) Pressure

Test

and

1. Make sure hydraulic oil is at normal operating temperature 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 section.

CAUTION

Beforeopening hydraulic system, operate all hydraulic controls to relieve system pressure and avoid injury from pressurized hydraulic oil. See RelievingHydraulic System Pressureinthe General Information section of this chapter.

4. Locate traction circuit test port for direction to be tested.Forwardtestportislocated onhydraulictube between front wheels ( Fig. 33). Reverse test ports are located on AWD hydraulic manifold(Fig. 34). Thoroughly clean test port.

Groundsmaster 4300--DHydraulic System Page 4 -- 34

5. Connecta5000PSI(350bar) pressuregaugeto test port.

6. Afterinstalling pressure gauge, startengine and run atidlespeed.Check for any hydraulic leakage from test connections and correct before proceeding with test.

7. Move throttle to full speed (3200 RPM).

8. Sit on seat, andwith brakes applied,slowly depress the traction pedal in the direction to be tested (forward orreverse).Whilepushingtractionpedaldown,carefully watch the pressure gaugeneedle. As the traction relief 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 reverse (R4)

NOTE: If traction pedal continues to be pressed after

the relief valve has opened, system pressure can increase higher than relief pressure.

9. Release traction pedal, stop engine and record test results.

NOTE: Forward(R3) and reverse (R4)reliefvalvesare identical.Relief valves can beswitchedin 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 theproblem changes to the otherdirection. Clean or replacevalves as necessary.Thesecartridge type valves are factory set,and arenot adjustable.If pressureis incorrect and relief valves are in good condition, traction pumpand/orwheelmotors shouldbesuspectedofwear and inefficiency.

Figure 33

1. Lower hydraulic tube 2. Forward test port

Figure 34

1. AWD hydraulic manifold 2. Reverse test port

System

Hydraulic

11.After testing is completed, make sure that engine is stopped and then relieve hydraulic system pressure (seeRelievingHydraulicSystemPressureintheGeneralInformationsectionofthischapter). Removepressure gauge from machine.

1. Piston (traction) pump

2. Reverse relief valve (R4)

Groundsmaster 4300--D Hydraulic SystemPage 4 -- 35

RIGHT FRONT

Figure 35

3. Forward relief valve (R3)

Traction Circuit Charge Pressure Test

TO MOW CONTROL

(FRONT CUTTING UNITS)

TO MOW CONTROL (REAR CUTTING UNITS)

GEAR PUMP

TO STEERING CONTROL VALVEAND CHARGE CIRCUIT

TO LIFT CONTROL MANIFOLD

BYPASS

VALVE

CROSSTRAX

MANIFOLD

PISTON

(TRACTION)

PUMP

PRESSURE

GAUGE

OIL FILTER

REMOVED

Figure 36

The traction circuitcharge pressure testshould be performed to make sure that the traction charge circuit is functioning correctly.

ProcedureforTractionCircuitChargePressure

Test

1. Make sure hydraulic oil is at normal operating temperature by operating the machine under load for approximately ten (10) minutes.

2. Park machine on a level surface with the cutting deckslowered and PTO switch off. Make sure engine is off. Apply the parking brake.

FROM STEERING CONTROL VALVE

3. Read Precautions For Hydraulic Testing in this section.

CAUTION

Groundsmaster 4300--DHydraulic System Page 4 -- 36

4. Raise and support operator seat to allow access to hydraulic pump assembly.

NOTE: If gear pump (P3) is worn or damaged, both charge circuit and steering circuit will be affected.

5. Thoroughly clean ends of hydraulic tubes that connecttothe oil filter (Fig. 37). Disconnect hydraulic tubes from oil filter adapter. Remove two (2) flange head screwsthatsecureoil filteradapter toframeand remove oil filter and adapter assembly from machine.

6. Install tee fitting with 1000 PSI (70 bar) pressure gaugeinplaceoftheremovedhydraulicfilterassembly.

7. Makesure that traction pedalis inneutral, the steering wheel is stationary and parking brake is engaged.

8. Startengine and run at idlespeed.Checkforanyhydraulic leakage from test connections and correct before proceeding with test.

9. Place throttle to full speed (3200 RPM) and monitor pressure gauge on tester.

GAUGEREADINGTOBEapproximately 200 to

250 PSI (13.8 to 17.2 bar)

10.Next, determinechargepressure undertractionload byoperatingthemachineinadirect forwardand reverse direction (not steering). Make sure that engine is running at full speed (3200 RPM). Apply the brakes and pressthetractionpedal intheforwarddirectionand then to reverse while monitoring the pressure gauge. Stop engine and record test results.

GAUGEREADINGTOBEapproximately 150 to

250 PSI (13.8 to 17.2 bar)

11.Compare measured charge pressure from step 9 with pressure from step 10:

A. Ifcharge pressure is goodundernoload(step 9), but drops below specification when under traction load(step 10), the piston pump should besuspected of wear and inefficiency. Whenthe pump is worn or damaged,thechargesystemisnotable toreplenish losttractioncircuitoil duetoexcessiveleakagein the worn pump.

12.After charge pressure testing is completed, make surethat engine is notrunning and thenrelieve hydraulic system pressure (See Relieving Hydraulic System Pressure in the General Information section 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

2. Oil filter / filter adapter

4 5

3. Hydraulic tube

RIGHT FRONT

System

Hydraulic

B. Ifthere is no chargepressure, or pressureis low, checkfor restrictioningear pump intakeline.Inspect charge relief valve and valve seat in the traction pump(see TractionPumpServicein theServiceand Repairs section of this chapter). Also, consider a

1. Traction pump

2. Plug

3. O--ring

worn ordamaged gear pump (P3) (see Gear Pump (P3) Flow Test in this section).

Groundsmaster 4300--D Hydraulic SystemPage 4 -- 37

Figure 38

4. Shim kit

5. Spring

6. Charge relief poppet

Gear Pump (P3) Flow Test (Using Tester with Pressure Gauges and Flow Meter)

TO STEERING CONTROL VALVEAND CHARGE CIRCUIT

TO MOW CONTROL (FRONT CUTTING UNITS)

TO LIFT CONTROL MANIFOLD

TO MOW CONTROL (REAR CUTTING UNITS)

GEAR PUMP

BYPASS

VALVE

CROSSTRAX

MANIFOLD

PISTON

(TRACTION)

PUMP

OIL FILTER AND TUBE REMOVED

Figure 39

The gear pump (P3) flow test should be performed to make sure that the traction charge circuit and steering circuit have adequate hydraulic flow.

Procedure for Gear Pump (P3) Flow

Test

1. Make sure hydraulic oil is at normal operating temperature by operating the machine under load for approximately ten (10) minutes.

TESTER

FROM STEERING CONTROL VALVE

2. Park machine on a level surface with the cutting deckslowered and PTO switch off. Make sure engine is off. Apply the parking brake.

3. Read Precautions For Hydraulic Testing in this section.

Groundsmaster 4300--DHydraulic System Page 4 -- 38

CAUTION

FLOW TESTER READING TOBE: Apump in good condition should have a flow of approximately 4.9 GPM (18.5 LPM) at 800 PSI (55 bar).

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 tractionpump inlet. Remove two (2) flangeheadscrews 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 testerand into the traction pump.

6. Installtesterwith pressure gauges and flowmeter 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 fitting.Make sure theflowcontrol valve ontester is ful-

ly open.

11.Open the tester flow control valve, stop engine and record test results.

12.If flowislessthan4.4 GPM (16.6 LPM) or apressure of 800 PSI(55 bar)cannot beobtained, consider thata pump problem exists. Check for restriction in pump intake 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 chapter).

NOTE: Iftheflowfromgearpump(P3)islow,theoperationof both the charge circuit and the steering circuitwill be affected.

13.After testing is completed, make sure that engine is stopped, then relieve hydraulic system pressure (see RelievingHydraulic System Pressure in the General Information section of this chapter). Remove tester and then install oilfilter assembly and hydraulic tubeto machine.

14.Lower and secure operator seat.

System

Hydraulic

7. Make sure that the traction pedal is in neutral, the steeringwheelisstationaryandtheparkingbrake is engaged.

8. Startengine and run at idlespeed.Checkforanyhydraulic leakage from test connections and correct before proceeding with test.

9. Move throttle to full speed (3200 RPM).Usea tachometer to verify that engine speed is correct.

IMPORTANT: The gear pumpis a positivedisplacement type. If pump flow is completely restricted or stopped, damage to the pump,tester or other components could occur.

10.While watching pressure gauges, slowly close the tester flow control valve until 800 PSI (55 bar) is obtained on gauge.

1. Hydraulic tube

2. Oil filter / filter adapter

Figure 40

3. Hydraulic tube

4. Gear Pump (P3)

Groundsmaster 4300--D Hydraulic SystemPage 4 -- 39

Front Wheel Motor Efficiency Test

TO MOW CONTROL (FRONT CUTTING UNITS)

TO MOW CONTROL (REAR CUTTING UNITS)

TO STEERING CONTROL VALVEAND CHARGE CIRCUIT

TO LIFT CONTROL MANIFOLD

GEAR PUMP

BYPASS

VALVE

CROSSTRAX

MANIFOLD

TESTER

CAP

PISTON

(TRACTION)

PUMP

FROM STEERING CONTROL VALVE

Figure 41

Procedure for Front Wheel Motor Efficiency Test NOTE: Over a period of time, a wheel motor can wear

internally. A worn motormay bypass oil internally,causing the motorto be lessefficient. Eventually, enough oil losswill cause the wheelmotortostall under heavy load conditions. Continued operation with aworn, inefficient motor can generate excessive heat, cause damage to sealsandother componentsinthehydraulicsystemand affect overall machine performance.

IMPORTANT: Refer to Traction Circuit Component Failure in the General Information section of this chapterfor information regarding theimportanceof removing contamination from the traction circuit.

CAP

RH FRONT WHEEL

MOTOR EFFICIENCY

TEST SHOWN

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 temperature by operating the machine under load for approximately ten (10) minutes.

2. Makesure that tractionpedal isadjusted tothe neutral position (see Operator’s Manual).

3. Park machine on a level surface with the cutting decks lowered andPTO switch off.Shut engineoff and apply the parking brake.

4. Read Precautions For Hydraulic Testing in this section.

Groundsmaster 4300--DHydraulic System Page 4 -- 40

14.To test individual front wheel motors:

CAUTION

5. Attachaheavychaintotherearofthemachineframe and an immovable object to prevent the machine from moving during testing.

6. Chock front wheelsto 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 elbowfitting on bottomof traction pump(Fig.

42). 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 thepump, through the tester and into the disconnected hydraulic hose.

9. Installtesterwith pressure gauges and flowmeter in series with the traction pump and the disconnected hose.Make sure the testerflow control valve isfully open.

A. Removefrontwheel from wheel motor that is not being tested. Remove wheel shield to allow access to hydraulic tubes and fittings on wheel motor. Remove fasteners that secure front hydraulic tube r-clamps to frame.

B. Onthefrontwheelmotorthatis not being tested, thoroughlycleanjunctionofbothhydraulictubesand wheelmotor fittings. Disconnect both hydraulic lines from wheel motor that is not being tested. Cap disconnected hydraulic lines and wheel motor fittings.

C. Use the procedure described in steps 8 to 11 above to identify individual front wheel motor leakage. Individual motorinternal leakagewill beshown on flow meter in GPM (LPM). Flow should be less than 1.5 GPM (5.7 LPM)for the testedwheel motor.

D. If other front wheel motor requires testing, complete steps A, B and C for remaining wheel motor.

15.After testing is completed, stopengine and then relievehydraulicsystempressure(seeRelievingHydraulic System Pressure in the General Information section of this chapter). Disconnect tester from hydraulicfitting andhose.Connecthoseto pump elbow fitting. Remove capsfrom hydraulic tubesandreconnecttubes towheel motor.Securehydraulictubes tomachine withr--clamps and removed fasteners. Install wheel shield and wheel(s) (see Wheels in the Service and Repairs section of Chapter 6 -- Chassis).

System

Hydraulic

10.Start engine and move throttle to full speed (3200 RPM).

CAUTION

Use extreme caution when performing test. The front tires on the ground will be trying to move themachineforward.

11.Slowly pushtraction pedal inforward direction until 1000 PSI (70 bar) is displayed on the tester pressure

gauge. Make sure that frontwheels 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--thirdturn and retest.Testingof wheel motor leakagein three(3) different wheel positions will providethemostaccuratetestresults.Ifleakagespecifications are notmet, individual front wheel motorsneed to be tested.

RIGHT FRONT

1. Traction pump

2. RH elbow fitting

3. Hyd hose (forward)

Figure 42

4. LH elbow fitting

5. Hyd hose (reverse)

Groundsmaster 4300--D Hydraulic SystemPage 4 -- 41

Piston (Traction) Pump Flow Test (Using Tester with Flow Meter and Pressure Gauge)

TO STEERING CONTROL VALVEAND CHARGE CIRCUIT

TO MOW CONTROL

(FRONT CUTTING UNITS)

TO MOW CONTROL (REAR CUTTING UNITS)

GEAR PUMP

BYPASS

VALVE

TO LIFT CONTROL MANIFOLD

CROSSTRAX

MANIFOLD

TESTER

PISTON

(TRACTION)

PUMP

Figure 43

Procedure for Piston (Traction) Pump Flow

Test

Thistest 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 (113.5LPM).Use40GPM HydraulicTester#AT40002 (pressure and flow) for this test (see Special Tools in this chapter).

1. Make sure hydraulic oil is at normal operating temperature by operating the machine under load for approximately ten (10)minutes. Makesure thehydraulic tank is full.

FROM STEERING CONTROL VALVE

2. Park machine on a level surface with the cutting deckslowered 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 section.

CAUTION

Groundsmaster 4300--DHydraulic System Page 4 -- 42

4. Makesure that tractionpedal isadjusted tothe neutral position. Also, ensure that traction pump is at full stroke when traction pedal is pushed into fully forward position.

5. Raise and support machineso allwheels are off the ground(see Jacking Instructions in Chapter 1 --Safety).

6. Thoroughly clean junction of hydraulic hose and right side fitting on bottom of traction pump (Fig. 44). Disconnect hose from right side pump fitting.

IMPORTANT: Make sure that the oil flow indicator arrow on the flow meter is showing that the oil will flow from thepump, 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 allowflow from tractionpump to tester. Use hydraulichosekit(seeSpecialToolsinthischapter)toconnect testerto machine.Make sure that fitting and hose connectionsareproperlytightened. Also,make surethe flow control valve on tester is fully open.

12.Observe flow gauge. Flow indication should be approximately 28 GPM (106 LPM).

13.Release traction pedalto the neutral position, open flow control valveon testerand shutoffengine. 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 rotated fully (e.g. traction pedal linkage may need adjustment, mow speed limiter is not in the transport position).

B. The piston(traction) pump needs to berepaired or replaced as necessary.

C. Make necessary repairsbefore performing additional tests.

15.When testing is complete, disconnect tester and hose kit from pump fittingand machinehydraulic hose. Reconnect hose to pump fitting.

CAUTION

Allwheels willbeoff thegroundand rotatingduring this test. Make suremachine is supported so itwill notmove andaccidentallyfall toprevent injuring anyone near the machine.

8. Startengine and run at idlespeed.Checkforanyhydraulic leakage fromtester andhose connections.Correct any leaks before proceeding.

9. Movethrottle so engine is runningat high idlespeed (3200 RPM).

10.Slowly push traction pedal to fully forward position. Keep pedal fully depressed in the forward position.

11.Have secondperson w atch pressuregauge ontester carefully while slowly closing the flow control valve until 1000 PSI (69 bar) is obtained. Verify with a phototac that the engine speed is still 3200 RPM.

RIGHT FRONT

1. Traction pump

2. RH elbow fitting

Figure 44

3. Hyd hose (forward)

System

Hydraulic

Groundsmaster 4300--D Hydraulic SystemPage 4 -- 43

Relief Valve (PRV1) and (PRV2) Pressure Test

PISTON

(TRACTION)

PUMP

TO STEERING CONTROL VALVEAND CHARGE CIRCUIT

TO LIFT CONTROL MANIFOLD

GEAR PUMP

BYPASS

VALVE

CROSSTRAX

MANIFOLD

FROM STEERING CONTROL VALVE

TESTER

ROTATION

DIRECTION

MOTOR

INLET

MOTOR

OUTLET

CASE DRAIN

DECK CONTROL MANIFOLD

FROM LIFT CONTROL MANIFOLD

Figure 45

The relief valve (PRV1) and (PRV2) pressure test should be performed tomake surethat thecutting deck circuit relief pressures are correct.

NOTE: Thefrontcuttingdeckcircuitis protectedbyproportional relief valve (PRV2) in the deck control manifold. The rear cutting deck circuit is protected by proportional relief valve (PRV1) (see Hydraulic Flow Diagrams in this chapter).

RELIEF VALV E (PRV1)

TEST SHOWN

Procedure for ReliefValve (PRV1) and (PRV2)

Test

sure

Pres-

1. Make sure hydraulic oil is at normal operating temperature by operating the machine under load for approximately ten (10) minutes.

2. Park machine on a level surface with the cutting deckslowered and PTO switch off. Make sure engine is off and mowspeed limiteris in the mow position.Apply the parking brake.

Groundsmaster 4300--DHydraulic System Page 4 -- 44

3. Read Precautions For Hydraulic Testing in this section.

10.Watchpressuregaugecarefully while slowly closing the tester flow control valve.As the relief valve lifts,the pressure gauge needle will momentarily stop.

CAUTION

4. Raise and support operator seat to allow access to hydraulic deck control manifold.

5. Thoroughlycleanjunctionofhydraulicinlet hoseand deck motor fitting on left side cutting deck for the relief valvetobetested.Disconnecthosefromdeckmotorfitting (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 flowfrom thedisconnectedhose, throughthe 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.

NOTE: Oncethe relief valve hasopened, systempres-

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.Open thetesterflow control valve,disengagecutting decks and stop the engine.

13.If pressure is incorrect, remove PRV valve on mow manifold andclean or replace valve (see Deck Control Manifold Service in the Service and Repairs section of this chapter). Also, if pressure isstill low aftervalve service, check for restriction in pump intake line. Gear pump (P2) (front cutting deck circuit) and/orpump (P1) (rear cutting deck circuit) could also be suspected of wear,damage orinefficiency (see GearPump (P1) and (P2) Flow Test in this section).

14.After testing is completed, make sure that engine is stopped, then relieve hydraulic system pressure (see RelievingHydraulic System Pressure in the General Information section of this chapter). Remove tester from machine and connect hydraulic hose to deck motor fitting.

System

Hydraulic

7. After installing tester, start engine and run at idle speed. Check for any hydraulic leakage from test connections and correct before proceeding with test.

8. Move throttle to full speed (3200 RPM).

CAUTION

Keepawayfromcuttingdecks during test toprevent personal injury from rotating blades.

9. Have a second person occupy seat, press PTO switchto ONandthen movejoysticklever forwardtoengage cutting decks.

IMPORTANT: When performing this test, do not hold over relief any longer than necessary toobtain pressure reading.

15.Lower and secure operator seat.

FRONT OF MACHINE

Figure 46

1. Cutting deck motor (#2 shown)

2. Deck motor inlet hose

Groundsmaster 4300--D Hydraulic SystemPage 4 -- 45

Gear Pump (P1) and (P2) Flow Test (Using Tester with Pressure and Flow Capabilities)

TO STEERING CONTROL VALVEAND CHARGE CIRCUIT

TO LIFT CONTROL MANIFOLD

TESTER

GEAR PUMP

BYPASS

VALVE

PISTON

(TRACTION)

PUMP

FROM STEERING CONTROL VALVE

CROSSTRAX

MANIFOLD

GEAR PUMP (P1)

FLOW TEST SHOWN

DECK CONTROL MANIFOLD

FROM LIFT CONTROL MANIFOLD

Figure 47

Over aperiod of time, the gears and wear plates in the gear pump can wear. A worn pump will by-pass oil and makethe pumplessefficient.Eventually, enoughoilcan by-passtocausethedecks to stall in heavy cutting conditions. Continued operation with a worn, inefficient pump can generate excessiveheat and cause damage to seals and othercomponents inthe hydraulicsystem.

Procedure for Gear Pump (P1) and (P2) Flow

Test

1. Make sure hydraulic oil is at normal operating temperature by operating the machine under load for approximately ten (10) minutes.

2. Park machine on a level surface with the cutting deckslowered and PTO switch off. Make sure engine is off. Apply the parking brake.

Groundsmaster 4300--DHydraulic System Page 4 -- 46

3. Read Precautions For Hydraulic Testing in this section.

CAUTION

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 ofgear pump fitting and hydraulic outlet hose. Disconnect hose frompump fitting:

Pump section (P1) for rear cutting decks Pump section (P2) for front cutting decks

11.If flow is less than 12.1 GPM (45.8 LPM) or a pressureof1500PSI(103bar) cannotbeobtained,consider that a pump problem exists. Check for restriction in pumpintake line. If intake isnot restricted, removegear pump and repair or replace pump as necessary (see Gear Pump andGear Pump Servicein the Serviceand Repairs section of this chapter).

12.After testing is completed, make sure that engine is stopped, then relieve hydraulic system pressure (see RelievingHydraulic System Pressure in the General Information section of this chapter). Remove tester from machine and connect hydraulic hose to gear pump fitting.

13.Lower and secure operator seat.

IMPORTANT: Make sure that the oil flow indicator arrow onthe flow gauge is showing that the oil will flowfrom thegearpump, throughthe tester andinto the hose.

6. Installtesterwith pressure gauges and flowmeter in series between disconnected hose and gear pump fitting.Make sure theflowcontrol valve ontester is ful-

ly open.

7. After installing tester, start engine and run at idle speed. Check for any hydraulic leakage from test connections 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 pumpis a positivedisplacement type. If pump flow is completely restricted or stopped, damage to the pump,tester or other components could occur.

9. While watching pressure gauges, slowly close the tester flowcontrol valveuntil 1500 PSI (103 bar) is obtained on gauge.

1. Gear pump assembly

2. Pump P1 outlet hose

Figure 48

3. Pump P2 outlet hose

System

Hydraulic

FLOW TESTER READING TOBE: Apump in good condition should have a flow of approximately 13.6 GPM (51.2 LPM) at 1500 PSI (103 bar).

10.Open the tester flow control valve and stop the engine. Record test results.

Groundsmaster 4300--D Hydraulic SystemPage 4 -- 47

Deck Motor Efficiency Test (Using Tester with Pressure Gauges and Flow Meter)

ROTATION

DIRECTION

Install tester in series between fitting and return hose at motor outlet.

TESTER

CAP

MEASURING CONTAINER

Disconnect case drain hose at traction deck bulkhead

MOTOR

INLET

CASE DRAIN

#5(RHFRONT)DECKMOTOR

EFFICIENCY TEST SHOWN

MOTOR

OUTLET

TO RESERVOIR

MOW CONTROL

MANIFOLD

Figure 49

NOTE: Overaperiodoftime, adeckmotor canwearinternally. 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, causedamage tosealsand othercomponentsin thehydraulic system 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 faultymotor willrun slowerthan other motors,producefewerclippingsand may cause clip marks (a choppy appearance) on the turf.

Procedure for Deck Motor Efficiency

Test

1. Make sure hydraulic oil is at normal operating temperature 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 deckslowered and PTO switch off. Make sure engine is off and mowspeed limiteris in the mow position.Apply the parking brake.

4. Read Precautions For Hydraulic Testing in this section.

Groundsmaster 4300--DHydraulic System Page 4 -- 48

CAUTION

9. While watching pressure gauges, slowly close flow control valve on testeruntil apressure of1200 PSI (83

bar) is obtained.

NOTE: The deck motors are connected in series. To

isolate a faulty motor, all motorsin the circuitmay have to be tested by starting with the upstream motor first.

5. For deck motor to be tested, thoroughlyclean junction of the motorcase drainhose (smalldiameter hose) where it connects to traction unit bulkhead (not at the motor)(Fig.50).Disconnectthe casedrain hoseandput a steel cap on the 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 onthe flow gauge is showing that the oil will flow from the deck motor, through the tester and into the return hose.

6. On deck motor to be tested, thoroughly clean junction of hydraulic returnhose anddeck motorfitting (Fig.

50).Disconnectreturnhosefromthemotor.Installtester with pressuregauges and flow meter in series with the motor and disconnected return hose. Make sure the

flow control valve on tester is fully open.

10.After achieving 1200 PSI (83 bar), place disconnected motor case drain hose into a container graduatedin ouncesormilliliters (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.Record 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 (seeCutting Deck Motor Service in the Service and Repairs section of this chapter).

Ifflow is less than 22.4ounces (662 milliliters) (0.7 GPM/2.6 LPM),the testedmotor doesnot haveexcessive leakage.

12.After testing is completed, make sure that engine is stopped, then relieve hydraulic system pressure (see RelievingHydraulic System Pressure in the General Information section of this chapter). Disconnect tester from motor and returnhose. Connect returnhose to the deckmotor.Remove plug frommachine bulkhead fitting and connect case drain hose to the fitting.

13.If necessary, perform motor efficiency test on other deck motors.

System

Hydraulic

NOTE: Use a graduated container, special tool

TOR4077, to measure case drain leakage (Fig. 49).

7. Startengine and run at idlespeed.Checkforanyhydraulic leakage from test connections and correct before proceeding with test.

CAUTION

Cutting deck bladeswill rotate whenperforming themotorefficiencytest.K eep awayfromcutting decksduring testtoprevent personalinjuryfrom rotating blades. Do not stand in front of the machine.

8. Sit on seat and move throttle to full speed (3200 RPM).PressPTOswitch to ON. Move joystick leverfor-

ward to engage cutting decks.

1. Case drain hose

2. Bulkhead fitting

Figure 50

3. Return hose

Groundsmaster 4300--D Hydraulic SystemPage 4 -- 49

Lift Relief Valve (PRV) Pressure Test

TO STEERING

CONTROL VALVE

TO DECK CONTROL MANIFOLD

(FRONT CUTTING UNITS)

TO DECK CONTROL MANIFOLD (REAR CUTTING UNITS)

PUMP (P5) INTERNAL

CASE

DRAIN

FROM MOW CONTROL MANIFOLD

GEAR PUMP

PRESSURE

GAUGE

LIFT CONTROL MANIFOLD

Figure 51

The lift relief valve (PRV) pressure test should be performed to make surethat the liftcircuit reliefpressure is correct.

Procedure for Lift Relief Valve (PRV) Pressure

Test

1. Make sure hydraulic oil is at normal operating temperature by operating the machine under load for approximately ten (10) minutes.

2. Park machine on a level surface with the cutting deckslowered and PTO switch off. Make sure engine is off. Apply the parking brake.

3. Read Precautions For Hydraulic Testing in this section.

CAUTION

4. Gain access to hydraulic lift control manifold by removing the operator floorplate. The liftcontrol manifold is attached to a framebracket under thefloor plate (Fig.

52).

Groundsmaster 4300--DHydraulic System Page 4 -- 50

5. Thoroughlycleantest port (G4) on bottom oflift control manifold. Connect a 5000 PSI (350 bar) pressure gauge to test port.

6. After installing pressure gaugeto manifold testport, startengineandrunatidlespeed.Checkforanyhydraulicleakagefromtestconnectionsandcorrectbeforeproceeding with test.

7. Move throttle to full speed (3200 RPM).

IMPORTANT: Do not allow pressureto exceed2500 PSI (172 bar).

IMPORTANT: While performing this test, hold joystick lever in the raise position only long enough to get a system pressure reading. Holding the lever in raise for an extended period may damage system components.

8. MakesurethatPTOswitch isOFFandthenpull joystickleverrearwardtopressurizeliftcircuit.Whileholding lever in the raise (rearward) position, watch pressure gauge carefully.As the cuttingdecks fully raiseand 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 reducingvalve(PRV)fromliftcontrolmanifoldandclean orreplace valve (see Lift ControlManifoldServiceinthe Service and Repairs section of this chapter). Also, iflift circuitpressure islow,checkforrestriction ingearpump intake line. Internal lift cylinder leakage would also cause low lift circuit pressure(see Lift Cylinder Internal LeakageTestinthissection).Gearpump(P4)c ouldalso besuspected of wear,damage orinefficiency(see Gear Pump (P4) Flow Test in this section).

FRONT

1. Lift control manifold

2. SV1 solenoid

Figure 52

3. SV2 solenoid

4. PRV solenoid

System

Hydraulic

11.After testing is completed, make sure that engine is stopped, then relieve hydraulic system pressure (see RelievingHydraulic System Pressure in the General Information section ofthis chapter). Disconnectpressure gauge from lift control manifold test port.

Groundsmaster 4300--D Hydraulic SystemPage 4 -- 51

Gear Pump (P4) Flow Test (Using Tester with Pressure Gauges and Flow Meter)

TO STEERING

CONTROL VALVE

TO DECK CONTROL MANIFOLD

(FRONT CUTTING UNITS)

TO DECK CONTROL MANIFOLD

(REAR CUTTING UNITS)

PUMP (P5)

INTERNAL

CASE

DRAIN

GEAR PUMP

TESTER

FROM MOW CONTROL MANIFOLD

Figure 53

The gear pump (P4) flow test should be performed to make sure thatthe cuttingdeck liftcircuit has adequate hydraulic flow.

Procedure for Gear Pump (P4) Flow

Test

1. Make sure hydraulic oil is at normal operating temperature by operating the machine under load for approximately ten (10) minutes.

2. Park machine on a level surface with the cutting deckslowered and PTO switch off. Make sure engine is off. Apply the parking brake.

LIFT CONTROL MANIFOLD

3. Read Precautions For Hydraulic Testing in this section.

CAUTION

Groundsmaster 4300--DHydraulic System Page 4 -- 52

4. Raise and support operator seat to allow access to hydraulic pump.

5. Thoroughly clean both ends of the hydraulic hose that connects gear pump (P4) outlet (Fig. 54) and lift control manifold P4 port. Remove hydraulic hose. Access to hydraulic hose atlift control manifoldcan be obtained from below the machine.

IMPORTANT: Make sure that the oil flow indicator arrow on the flow meter is showing that the oil will flow from pump (P4), through the tester and to the lift control manifold.

6. Installtesterwith pressure gauges and flowmeter in placeofthe removed hydraulic hose. Connect testerinlet 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. Makesure thatthetraction pedalisin neutralandthe parking brake is engaged.

8. Startengine and run at idlespeed.Checkforanyhydraulic leakage from test connections and correct before proceeding with test.

9. Move throttle to full speed (3200 RPM).Usea tachometer to verify that engine speed is correct.

IMPORTANT: The gear pumpis a positivedisplacement type. If pump flow is completely restricted or stopped, damage to the pump,tester or other components could occur.

13.After testing is completed, make sure that engine is stopped, then relieve hydraulic system pressure (see RelievingHydraulic System Pressure in the General Information section of this chapter). Remove tester and connectremoved hydraulic hosetogear pump (P4)outlet and lift control manifold P port.

14.Lower and secure operator seat.

Figure 54

1. Gear pump (P4) 2. Hydraulic hose

System

Hydraulic

10.While carefully watching pressure gauges, slowly closethetesterflowcontrolvalve until1000 PSI(70bar) is obtained on gauge.

FLOW TESTER READING TOBE: Apump 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.If flowislessthan2.8 GPM (10.6 LPM) or apressure of 1000 PSI (70 bar) cannot be obtained, considerthat apump problem exists. Check for restriction in pump intake 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 chapter).

NOTE: Iftheflowfromgearpump(P4)islow,theoperation of all lift cylinders will be affected.

Groundsmaster 4300--D Hydraulic SystemPage 4 -- 53

Lift Cylinder Internal Leakage Test

TO DECK CONTROL MANIFOLD

(FRONT CUTTING UNITS)

TO STEERING

CONTROL VALVE

TO DECK CONTROL MANIFOLD (REAR CUTTING UNITS)

PUMP (P5) INTERNAL

CASE

DRAIN

FROM MOW CONTROL MANIFOLD

GEAR PUMP

(PARTIALL Y RAISED)

PLUG CAP

CHECK FOR

CYLINDER

EXTENDING

LIFT CONTROL MANIFOLD

Figure 55

The lift cylinder internal leakage test should be performedifacuttingdeckraiseandlowerproblemisidentified. This test will determine if a lift cylinder is faulty.

NOTE: Cuttingdeckraise/lowercircuitoperation willbe affected by lift cylinderbinding, extra weighton the cutting decks and/or bindingof lift components. Makesure that these items are checkedbefore proceedingwith lift cylinder internal leakage test.

Procedure for Lift Cylinder Internal Leakage

Test:

NOTE: When performing the lift cylinder internal leak-

age test, thecutting decks should be attachedto the lift arms.

LEFT FRONT (#4) LIFT CYLINDER TEST SHOWN

1. Parkmachine on a level surface withthePTOswitch OFF.Positionthecuttingdecksintheturn--aroundposition 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. Thiswill removethe load from the lift cylinder and relieve lift cylinder hydraulic pressure. Leave thejack under thelift arm tosupport the lift arm and to prevent the lift arm from lowering.

NOTE: If either ofthe rear lift cylindersis beingtested, both rear lift arms need to be supported.

3. Thoroughlyclean the area aroundthe endof the hydraulichoseatthe rodendofthelift cylinder.Disconnect the hydraulic hose from the lift cylinder rod end fitting (Fig. 56).

Groundsmaster 4300--DHydraulic System Page 4 -- 54

IMPORTANT: When capping lift cylinder fitting and hydraulic hose end, use a steel cap and plug to ensure that fluid leakage will not occur. Plastic plugs will not hold hydraulic pressure that will be developed during this test procedure.

4. Place a steel cap on the open lift cylinder fitting to sealthe lift cylinder.Also, install a steel plugin theopen endofthedisconnectedhoseto preventleakage orcontamination.

5. Slowly lower the jack and remove it from under the lift arm. Thecutting deck should settle slightlyand then be supported by the capped lift cylinder.

6. Markthepositionoftheliftcylinderrod attheliftcylinder head with a piece of tape (Fig. 57).

7. Leave the machine parked for two (2) hours and monitor the lift cylinder. The weight of the cutting deck may cause the lift cylinderto 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” (31.7mm)aftertwo(2)hours,makesurethat thecutting deck hasnot settled tothe ground. Ifthe cutting deckis still suspended aftertwo(2)hoursand lift cylinder 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 willshow minimal movement.

B. Rodmovement in excess of 1.250”(31.7mm)after two (2) hours indicates that the lift cylinder may have internal seal damage or excessive wear. Remove and inspect the lift cylinder (see Lift Cylinder and Lift CylinderService in the Service andRepairs section of this chapter).

Figure 56

1. Lift cylinder (#5 shown)

2. Cylinder rod end fitting

Figure 57

1. Lift cylinder rod

2. Lift cylinder head

3. Hydraulic hose

3. Tape (initial position)

System

Hydraulic

8. Once lift cylinder condition has been determined, use a jackto raisethe lift armslightly whichwill remove the load from the lift cylinder. Leave the jack to support the lift armand to prevent it from lowering. Remove the cap from the cylinder fitting and the plug from the hydraulichose.Connect the hydraulic hose to the lift cylinder fitting.

9. Carefully remove jack from under the lift arm. Start engineandoperateliftcylindersthroughseveral up and down cycles. Stop the engine and check for any leakage.

10.If needed, repeat steps2 through 10 forother lift cylinders.

1. Tape (after 2 hours) 2. Cylinder rod movement

11.After testingis complete, check oil levelin hydraulic reservoir and adjust if necessary.

Groundsmaster 4300--D Hydraulic SystemPage 4 -- 55

Figure 58

Steering Relief Valve (R10) Pressure Test

TO DECK CONTROL MANIFOLD

(FRONT CUTTING UNITS)

TO DECK CONTROL MANIFOLD (REAR CUTTING UNITS)

PUMP (P5) INTERNAL

CASE

DRAIN

TO LIFT CONTROL MANIFOLD

GEAR PUMP

TO TRACTION CHARGE CIRCUIT

OUT IN

STEERING WHEEL TURNED

FOR RIGHT TURN

Figure 59

STEERING

CONTROL

VALVE

R10

PRESSURE

GAUGE

STEERING CYLINDER

Groundsmaster 4300--DHydraulic System Page 4 -- 56

The s teering relief v alve (R10) pressuretest shouldbe performed to make sure that the steering circuit relief pressure is correct.

12.If specification is not met, inspect steering control valve(seeSteeringControlValveServiceintheService and Repairs section of this chapter).

Procedure for Steering Relief Valve Pressure

1. Make sure hydraulic oil is at normal operating temperature by operating the machine under load for approximately ten (10) minutes.

2. Park machine on a level surface with the cutting deckslowered and PTO switch off. Make sure engine is off. Apply the parking brake.

3. Read Precautions For Hydraulic Testing in this section.

Test:

CAUTION

4. Thoroughlycleantheareaaroundthehydraulichose 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.

13.After testing is completed, make sure that engine is stopped, then relieve hydraulic system pressure (see RelievingHydraulic System Pressure in the General Information section of this chapter). Remove tee fitting and pressure gauge from hydraulic hose and steering cylinder.Connect hydraulic hose to steering cylinderfitting.

Figure 60

1. Steering cylinder 2. Rod end fitting

System

Hydraulic

6. Installatee fittingbetween thedisconnectedhydraulic hose and the steering cylinder fitting. Install a 5000 PSI (350 bar) pressure gauge to the tee fitting.

7. Afterinstalling pressure gauge, startengine and run atidlespeed.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 lefthand turn (counter--clockwise) and holding.

10.System pressure should be approximately 1000 PSI (70bar) as the relief valve lifts. Return steering wheel to the neutral position.

11.Shut off engine. Record test results.

Groundsmaster 4300--D Hydraulic SystemPage 4 -- 57

Steering Cylinder Internal Leakage Test

STEERING WHEEL

TURNED FOR

RIGHT TURN

R10

STEERING

CONTROL

VALVE

STEERING CYLINDER

(FULLYEXTENDED)

Figure 61

The steering cylinder internal leakage test should be performed if a steering problem is identified. This test will determine if the steering cylinder is faulty.

CAP

LOOK FOR LEAKAGE

NOTE: Steering circuit operation will be affected by

rear tire pressure, steering cylinder binding, extra weightonthevehicleand/orbindingofrearaxlesteering components. Make sure that these items are checked before proceeding with steering cylinder internal leakage test.

Groundsmaster 4300--DHydraulic System Page 4 -- 58

Procedure for Steering Cylinder Internal Leakage Test:

1. Make sure hydraulic oil is at normal operating temperature.

2. Park machine on a level surface with the cutting deckslowered and PTO switch off. Make sure engine is off. Apply the parking brake.

3. Read Precautions For Hydraulic Testing.

CAUTION

4. Turnthesteering wheelforarightturn (clockwise)so the steering cylinder rod is fully extended.

5. Thoroughlycleantheareaaroundthehydraulichose at the rod end of the steering cylinder (Fig. 62).

6. Place a drain pan under the steering cylinder. Removehydraulichosefromthefittingontherodendofthe 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.

Figure 62

1. Steering cylinder 2. Rod end fitting

System

Hydraulic

8. With the engine off, continue turning the steering wheelfor a right turn(clockwise) with thesteering cylinderfully extended.Observe theopenfitting onthesteeringcylinder as the wheelisturned.If oil comes outofthe fitting while turning the steering wheel to the right, the steeringcylinder has internal leakageand should beinspectedandrepaired(seeSteeringCylinderandSteering Cylinder Servicein theService andRepairs section of this chapter). Checkdrain pan for anyevidence of oil that would indicate internal cylinder leakage.

9. Removeplugfromthehydraulichose. Connecthose to the steering cylinder fitting.

10.If a steering problem existsand the steering cylinder tested acceptably, the steering control valve requires service (see Steering Control Valve and Steering Control ValveService in the Service andRepairs section of this chapter).

11.Check oil level in hydraulic reservoir and adjust if needed.

Groundsmaster 4300--D Hydraulic SystemPage 4 -- 59

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 system, park machine on a level surface, engage parking brake, lower cutting decks and stop engine. Remove key from the ignition switch.

2. Thoroughlyclean machinebeforedisconnecting, removing or disassembling any hydraulic components. Make sure hydraulic components, hose connections andfittingsare thoroughlycleaned.Alwayskeepinmind the need for cleanliness when working on hydraulic components.

CAUTION

Before loosening any hydrauliccomponent, operate all hydraulic controls to relieve system pressure and avoid injury from pressurized hydraulicoil. SeeRelievingHydraulic System Pressure in the General Information section of this chapter.

3. Operateallhydraulic controlstorelievesystempressure before loosening any hydraulic connection (see RelievingHydraulic System Pressure in the General Information section).

4. Putcapsor plugsonanyhydrauliclines,hydraulicfittings or components left open or exposed to prevent contamination.

After Repair or Replacement of Components

1. If a component failure occurred in the closed loop traction circuit (e.g. piston pump or wheelmotor), filtering the traction circuit is recommended (see Filtering Closed--Loop Traction Circuit in this section).

2. Ifcomponent failure issevere orhydraulic systemis contaminated, flush hydraulic system (see Flush Hydraulic System in this section).

3. Lubricate O--rings andseals withclean hydraulic oil before installing hydraulic components.

4. Make sure all caps or plugs are removed from hydraulic tubes, hydraulicfittings and componentsbefore reconnecting.

5. Use proper tightening methods when installing hydraulichoses and fittings (see Hydraulic FittingInstallation inthe General Information section of this chapter).

6. After repairs, check control linkages and cables for proper adjustment, binding or broken parts.

7. Afterrepairs are completed, clean hydrauliccomponents, hose connections and fittings to prevent future accumulation of dirt and debris on hydraulic components.

8. After disconnecting or replacing anyhydraulic components, operate machine functions slowly until air is outofsystem(seeHydraulicSystemStartUpinthissection).

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 elbow fittings) on hydraulic components before removal. Mark parts if necessaryto make surethat fittingswill be aligned properlywhen reinstalling hydraulic hoses and tubes.

9. Checkfor hydraulic oil leaks. If any leaks are discovered, shut off engine and correct leaks.

10.Check oil level in hydraulic reservoir and addcorrect oil if necessary.

Groundsmaster 4300--DHydraulic System Page 4 -- 60

Check Hydraulic Lines and Hoses

CAUTION

Keep body and hands away from pin hole leaks or nozzles that eject hydraulic fluid under high pressure. Use paperor 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 injected into the skin, it must be surgically removed within a few hours by a doctor familiar withthistypeofinjury. Gangrenemay resultfrom such an injury.

Flush Hydraulic System

Check hydraulic lines and hosesdaily forleaks, kinked lines, loose mounting supports, wear, loose fittings or deterioration.Make allnecessaryrepairs beforeoperating the machine.

IMPORTANT: Flush the hydraulic system any time thereis 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 failureoccurred in the closed loop traction circuit (e.g. piston pump or wheel motor), filtering the traction circuit isrecommended.SeeFiltering Closed--LoopTractionCircuit in this section.

1. Park machine on a level surface. Lower cutting decks, stop engine, engage parkingbrake andremove key from ignition switch.

2. Drain hydraulic reservoir. Remove suction screen fromreservoirandclean thoroughly.Considerremoving and cleaning reservoir if necessary.

3. Clean area around the mounting areas of the hydraulic filters. Remove and discard hydraulic filters.

4. Drainentire hydraulicsystem.Drainall hoses,tubes andcomponents while thesystemiswarm. Flush hoses and tubes to remove any contamination.

7. Disconnect wire harness electrical connector from theenginefuelstop solenoid to prevent the engine from starting.

8. Make sure traction pedal is in neutral and the PTO switch isOFF. 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.Startengineand letit idleatlowspeedfor aminimum of two (2) minutes.

11.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.Move PTOswitch toONto engagecuttingdecksand let them run for several minutes. Move PTO switch to OFF.

System

Hydraulic

5. Makesure the mounting surfaces of the hydraulic filtersareclean. Applyclean hydraulicoiltogasketonnew 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’sManual.Other fluidscouldcausesystem damage.

6. Fill hydraulic reservoir with new hydraulic oil.

Groundsmaster 4300--D Hydraulic SystemPage 4 -- 61

14.Shut off engine and check for hydraulic oil leaks. Check oil level inhydraulic reservoir andadd correctoil if necessary.

15.Operate the machine fortwo (2) hoursunder normal operating conditions.

16.Checkconditionofhydraulicoil.Ifthefluidshowsany signsofcontamination,repeatsteps 1through14again.

17.Resume normal operation andfollowrecommended maintenance intervals.

Filtering Closed--Loop Traction Circuit

Filteringof a closed--loophydraulicsystemafter a major component failure (e.g.traction (piston) pump orwheel motor)is a requirement to preventdebris from transmitting throughout the system. If a closed--loop hydraulic systemfilteringtoolisnotusedtoensuresystemcleanliness, repeat failures, aswell assubsequent damage to other hydraulic components in theaffected system,will occur. To effectively remove contamination from closed--looptraction circuit, useoftheTorohighflow hydraulic filter and hydraulic hose kits are recommended (see Special Tools in this chapter).

1. Parkmachineonalevelsurfacewithenginestopped and key removed from ignition switch.

2. Raise and support machineso allwheels are off the ground(see Jacking Instructions in Chapter 1 --Safety).

NOTE: Ifwheel motorwasreplaced,installhigh flow filter to the inletof the new motorinstead ofto the traction pump fitting. This will prevent system contamination from entering and damaging the new wheel motor.

3. Thoroughlyclean junction of hydraulic hoseand 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 betweentraction pump fitting and disconnected hose. Use hydraulic hosekit (see Special Tools in this chapter) to connectfiltertomachine.Makesurethatfittingandhose connections are properly tightened.

IMPORTANT: Use only hydraulic fluids specified in Operator’sManual.Other fluidscouldcausesystem damage.

5. Afterinstalling high flowfilter tomachine, checkand fillhydraulic reservoir with new hydraulic oilasrequired.

7. With engine running atlow idle speed, slowly move the traction pedal to the forward direction to allow flow throughthe tractioncircuit andhighflow filter.Keeptraction circuit engaged for five (5) minutes while gradually increasing both forwardpressure on traction pedal and engine speed. Monitor filterindicator to make sure that green color is showing during operation.

8. With engine running at high idle speed and traction pedalmoved 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: Ifusing a filterthat is nottheTorohigh flow filter that is bi--directional, do not press the traction pedal in the reverse direction. If flow is reversed when using afilter thatis not bi--directional, debris from the filter will re--enter the traction circuit.

9. With engine running at high idle speed, alternately movetractionpedalfromforwardtoreverse.Whilemonitoring filter indicator, continuethis processfor an additional five (5) minutes.

10.Shut engine off and remove key from ignition switch.

11.Remove high flow hydraulic filter and hydraulichose kit from machine. Connect hydraulic hose to left side tractionpump fitting. Make sure to properly tightenhose (seeHydraulic Hose and TubeInstallationintheGeneral Information section of this chapter).

12.Lower machine to ground.

13.Check oil level in hydraulic reservoir and addcorrect oil if necessary.

6. Startengine and run at idlespeed.Checkforanyhydraulic leakage from filter and hose connections. Correct any leaks before proceeding.

CAUTION

Allwheels willbeoff thegroundand rotatingduring 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 filter. If the indicator should show red, either reduce pressure on the traction pedal or reduce engine speed to decrease hydraulic flow through the filter.

RIGHT

FRONT

1. Traction pump

2. RH elbow fitting

3. Hyd hose (forward)

Figure 63

4. LH elbow fitting

5. Hyd hose (reverse)

Groundsmaster 4300--DHydraulic System Page 4 -- 62

Hydraulic System Start--up

NOTE: Wheninitially startingthehydraulicsystemwith

new or rebuilt components such as pumps, wheel motors or lift cylinders,it is importantthat thisstart--up procedure be used.This procedure reducesthe chance of damaging the systemor its components from notpurging the system of air.

1. After the hydraulic system components have been properly installed and ifthe traction pumpwas rebuilt or replaced, make sure traction pump housing is at least half full of clean hydraulic oil.

2. Makesureallhydraulicconnectionsandlinesaresecured tightly.

3. Drain, flush and refill hydraulic system and change hydraulic oil filters if component failure was severe or systemiscontaminated(seeFlushHydraulicSystemin this section).

4. Make sure hydraulic reservoir is full.Add correctoil if necessary.

5. Checkcontrol linkageforproper adjustment,binding or broken parts.

6. Disconnect wire harness electrical connector from theenginefuelstop solenoid to prevent the engine from starting.

7. Make sure traction pedal is in neutral and the PTO switch isOFF. 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 chargepump shouldpickup oilandfill thehydraulicsystem. If thereis no indicationof fill inthirty (30) seconds, stop the engine and determine the cause.

10.If the tractionpump was replaced or rebuilt, run the traction unit so thewheels turnslowly forten (10)minutes.

11.Operate the traction unit(including steering and cutting deck lift/lower) by gradually increasing the work load to full over a ten (10) minute period.

12.Stop themachine. Check oillevel in hydraulicreservoir and add correct oil if necessary. Check hydraulic components for leaks and tighten any loose connections.

System

Hydraulic

Groundsmaster 4300--D Hydraulic SystemPage 4 -- 63

Hydraulic Reservoir

26 to 32 ft--lb

(36to43N--m)

RIGHT

105 to 115 ft--lb

(143 to 155 N--m)

FRONT

1. Suction strainer

2. Tank cap

3. Hydraulic reservoir

4. Adapter

5. Manifold

6. O--ring

7. Hydraulic hose

8. O--ring

9. Cap screw

Figure 64

10. Flat washer

11. Bumper

12. Washer head screw (2 used)

13. Clamp (2 used)

14. Flange nut

15. Flange head screw(2 used)

16. O--ring

17. Hose clamp (2 used)

18. Hydraulic hose

19. Oil filter

20. Filter head

21. Hydraulic hose

22. O--ring

23. 90

hydraulic fitting

24. O--ring

25. Screen filter

26. Hydraulic fitting

Groundsmaster 4300--DHydraulic System Page 4 -- 64

Removal (Fig. 64)

Installation (Fig. 64)

1. Parkthemachineona levelsurface,engage parking brake, lower cutting decks and stop engine. Remove key from the ignition switch.

2. Thoroughlycleanhydraulic hoseendsandfittingson hydraulic reservoir to prevent hydraulic system contamination. Label hydraulichoses toassist ininstallation.

3. Disconnect hydraulic hose (item 7) from adapterfittingon bottom of reservoir to allow draining ofreservoir. Drain reservoir into a suitable container.

4. Disconnect remaining hydraulic hoses from reservoir.Allowhydrauliclines todrain intoasuitablecontainer.Plugorcapopeningsofreservoir andlinestoprevent contamination.

5. Remove hydraulic reservoir using Figure 64 as a guide.

6. Remove suction strainerfrom reservoir. DiscardO-ring.

7. Ifhydraulicfittings are to be removedfrom reservoir, mark fitting orientation to allow correct assembly. Remove fittings from reservoir and discard O--rings.

Inspection (Fig. 64)

1. Clean hydraulic reservoir and suction strainer with clean solvent.

1. Iffittingswere removed from reservoir,lubricateand placenew O--rings ontofittings.Install fittingsintoreservoir openings using marks made during the removal process to properly orientate fittings. Tighten fittings (see Hydraulic Fitting Installation in the General Information section of this chapter).

2. Lubricate new suction strainer O--ring and install ontostrainer.Thread suction strainer intohydraulic reservoir andtorque strainer 105 to 115 ft--lb (143 to 155 N--m).

3. Position hydraulic reservoir to machine. Secure reservoir 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 inhoses and fittings during the removal process.

5. Install hydraulic hoses to fittings on hydraulic reservoir 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 hydrauliclines and fittings forleaks.Tightenanylooseconnections.Checkhydraulic oil level and adjust if necessary.

System

Hydraulic

2. Inspecthydraulic reservoir for leaks,cracks orother damage.

Groundsmaster 4300--D Hydraulic SystemPage 4 -- 65

Hydraulic Pump Drive Shaft

RIGHT

FRONT

Permatex

Threadlocker

34 to 42 ft--lb

(46to56N--m)

Antiseize

Lubricant

1. Piston (traction) pump

2. Flange nut (2 used)

3. Flange head screw (2 used)

4. Guard hoop

Figure 65

5. Cap screw (2 used)

6. Engine flywheel

7. Cap screw (6 used)

8. Drive shaft assembly

9. Flange nut (4 used)

10. Flange head screw(2 used)

Groundsmaster 4300--DHydraulic System Page 4 -- 66

Removal (Fig. 65)

Installation (Fig. 65)

1. Parkthemachineona levelsurface,engage parking brake, lower cutting decks and stop engine. Remove key from the ignition switch.

2. Removetwo(2) flange head screws andflange nuts that secure drive shaft guard hoop (item4) to machine frame. Remove guard.

3. Removetwo (2) cap screws (item5) and flange nuts (item9)thatsecuredrive shaftyoketopistonpumpinput shaft.

4. Removesix (6) capscrews(item7) that secure 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 removing and installing bearings toprevent 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. Applyacoatingofgreaseto bearing bores in end

yoke and shaft yoke.

1. Applyantiseizelubricanttotractionpump inputshaft.

2. Positiondriveshaft assemblytoengineandpumpinput shaft.

3. Apply Permatex Blue Gel Threadlocker (or equivalent) to threadsof capscrews (item 7)that securedrive shaft flange to engine flywheel. Secure drive shaft flange to flywheel with six (6) cap screws (item 7). Torque cap screwsfrom 34 to42 ft--lb (46 t o 56 N--m).

4. Slidedrive shaftyoke on pump input shaft so yoke is flush with end of input shaft. Securedrive 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 headscrews andflange nuts.

6. Lubricate grease fittings on drive shaft.

System

Hydraulic

B. Press one bearing partially into yoke. C. Insert cross into yoke and bearing. D. Holdcrossinalignment and press bearinginuntil

it hits the yoke. E. Install snap ring into yoke groove to secure

installed bearing. F. Place second bearing into yoke bore and onto

crossshaft.Pressbearing into yoke and secure with snap ring.

G. Repeat procedure for other yoke. H. Greasecross untilgreasecomesoutofallfour(4)

cups.

4. Makesurethatassembled joint moves without bind-

ing. Slight binding can usually be eliminated by lightly rapping the yoke lugswith a soft facedhammer. If binding continues, disassemble joint to identify source of binding.

1. End yoke

2. Cross and bearing kit

Figure 66

3. Snap ring (4 used)

4. Shaft yoke

Groundsmaster 4300--D Hydraulic SystemPage 4 -- 67

Hydraulic Pump Assembly

Antiseize

Lubricant

RIGHT

FRONT

1. Drive shaft assembly

2. Cap screw (2 used)

3. Flange head screw (2 used)

4. Hydraulic pump assembly

5. O--ring

6. 90

hydraulic fitting (2 used)

7. Hydraulic hose (2 used)

8. Pump support bracket

9. Flange nut (2 used)

10. Traction cable bracket

11. Flange head screw (2 used)

12. Carriage screw (2 used)

13. Hydraulic hose

Figure 67

14. Guard hoop

15. Flange nut (6 used)

16. Manifold

17. Hose clamp (2 used)

18. Hydraulic hose

19. Hydraulic fitting

20. Neutral switch

21. O--ring

hydraulic fitting

22. 90

23. O--ring

24. Hydraulic tube

25. O--ring

26. Hydraulic fitting

27. Hydraulic hose

28. Hydraulic hose

29. Frame bracket

30. Flange head screw(2 used)

31. Hydraulic tube

32. O--ring

33. O--ring

34. Flat washer (2 used)

35. Lock nut (2 used)

36. O--ring

37. Hydraulic fitting (2 used)

38. Hydraulic fitting

39. Hydraulic fitting

Groundsmaster 4300--DHydraulic System Page 4 -- 68

Toro 4300-D User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Preface

Table Of Contents

Safety Instructions

Before Operating

While Operating

Maintenance and Service

Jacking Instructions

Safety and Instruction Decals

Product Records

Maintenance

Equivalents and Conversions

Torque Specifications

Fastener Identification

Using a Torque Wrench with an Offset Wrench

Standard Torque for Dry, Zinc Plated and Steel Fasteners (Inch Series)

Standard Torque for Dry, Zinc Plated and Steel Fasteners (Metric Series)

Other Torque Specifications

Conversion Factors

General Information

Operator’s Manual

Stopping the Engine

Specifications

Adjustments

Adjust Throttle Control

Service and Repairs

Fuel System

Air Cleaner

Exhaust System

Radiator

Engine

Specifications

General Information

Operator’s Manual

Check Hydraulic Fluid

Towing Machine

Hydraulic Hoses

Hydraulic Hose and Tube Installation (O--Ring Face Seal Fitting)

Hydraulic Fitting Installation (SAE Straight Thread O--Ring Fitting into Component Port)

Relieving Hydraulic System Pressure

Traction Circuit Component Failure

Hydraulic Schematic

Hydraulic Flow Diagrams

Mow Circuit

Mow Circuit Cutting Deck Blade Braking

Lift Circuit: Raise Cutting Decks

Lift Circuit: Lower Cutting Decks

Steering Circuit

Special Tools

Troubleshooting

General Hydraulic System Problems

Traction Circuit Problems

Mow Circuit Problems

Lift Circuit Problems

Steering Circuit Problems

Testing

Traction Circuit Relief Valve (R3) and (R4) Pressure Test

Traction Circuit Charge Pressure Test

Front Wheel Motor Efficiency Test

Relief Valve (PRV1) and (PRV2) Pressure Test

Lift Relief Valve (PRV) Pressure Test

Lift Cylinder Internal Leakage Test

Steering Relief Valve (R10) Pressure Test

Steering Cylinder Internal Leakage Test

Service and Repairs

General Precautions for Removing and Installing Hydraulic System Components

Check Hydraulic Lines and Hoses

Flush Hydraulic System

Filtering Closed--Loop Traction Circuit

Hydraulic System Start--up

Hydraulic Reservoir

Hydraulic Pump Drive Shaft

Hydraulic Pump Assembly