Service Manual
Table Of Contents
- Title Page
- Revision History
- Reader Comments
- NOTES
- Preface
- Table of Contents
- Chapter 1 : Safety
- Chapter 2 : Specifications and Maintenance
- Chapter 3 : Troubleshooting
- GEARS – The Systematic Approach to Defining, Diagnosing and Solving Problems
- General Hydraulic System Problems
- Traction Circuit Problems
- Mow Circuit Problems
- Lift Circuit Problems
- Steering Circuit Problems
- Engine Cooling Fan Circuit Problems
- Operator Advisories
- Fault Codes
- Starting Problems
- General Run and Transport Problems
- Cutting Deck Operating Problems
- Cutting Deck Lift/Lower Problems
- Aftercut Appearance
- Chapter 4 : Yanmar Diesel Engine
- Chapter 5 : Hydraulic System
- General Information
- Hydraulic Schematic
- Hydraulic Flow Diagrams
- Testing
- Precautions for Hydraulic Testing
- Which Hydraulic Tests Are Necessary?
- Traction Circuit Charge Pressure (Using Pressure Gauge)
- Traction Circuit Relief Pressure (Using Pressure Gauge)
- Counterbalance Pressure (Using Pressure Gauge)
- Reverse Traction Circuit Reducing Valve (PR) Pressure (Using Pressure Gauge)
- Rear Traction Circuit Relief Valve (RV) Pressure (Using Pressure Gauge)
- Piston (Traction) Pump Flow Test (Using Tester with Pressure Gauge and Flow Meter)
- Cutting Deck Circuit Pressure (Using Pressure Gauge)
- PTO Relief Pressure (Using Tester with Pressure Gauge and Flow Meter)
- Cutting Deck Motor Case Drain Leakage (Using Tester with Pressure Gauge and Flow Meter)
- Lift/Lower Circuit Relief Pressure (Using Pressure Gauge)
- Steering Circuit Relief Pressure (Using Pressure Gauge)
- Steering Cylinder Internal Leakage
- Engine Cooling Fan Circuit (Using Pressure Gauge and Phototac)
- Engine Cooling Fan Motor Case Drain Leakage Test
- Gear Pump Flow (Using Tester with Pressure Gauge and Flow Meter)
- Adjustments
- Service and Repairs
- General Precautions for Removing and Installing Hydraulic System Components
- Check Hydraulic Lines and Hoses
- Priming Hydraulic Pumps
- Flush Hydraulic System
- Filtering Closed−Loop Traction Circuit
- Charge Hydraulic System
- Hydraulic Reservoir
- Radiator and Oil Cooler Assembly
- Gear Pump
- Gear Pump Service
- Piston (Traction) Pump
- Piston (Traction) Pump Service (For machines serial number below: 400000000)
- Piston (Traction) Pump Service (For machines serial number above: 400000000)
- Rear Axle Motor
- Front Wheel Motors
- Rear Axle and Front Wheel Motor Service
- Rear Traction Manifold
- Rear Traction Manifold Service
- Combination Manifold
- Combination Manifold Service
- Steering Control Valve (For machines serial number below: 400000000)
- Steering Control Valve (For machines serial number above: 400000000)
- Steering Control Valve Service (For machines serial number below: 400000000)
- Steering Control Valve Service (For machines serial number above: 400000000)
- Steering Cylinder
- Steering Cylinder Service
- Engine Cooling Fan Motor
- Engine Cooling Fan Motor Service
- Cutting Deck Motors
- Cutting Deck Motor Service (Sauer−Danfoss)
- Cutting Deck Motor Service (Casappa)
- PTO Manifold
- PTO Manifold Service
- Center Deck Lift Cylinders
- Wing Deck Lift Cylinders
- Lift Cylinder Service
- Chapter 6 : Electrical System
- General Information
- Adjustments
- Electrical System Quick Checks
- Component Testing
- Key Switch
- Fuses
- Operator Cab Fuses (Groundsmaster 4110−D)
- Fusible Link Harness
- PTO Switch
- HI/LOW Speed, Engine Speed and Cutting Deck Lift Switches
- Cruise Control Switch
- Seat Switch
- Parking Brake Switch
- Service Brake Switches
- Headlight Switch (Groundsmaster 4110-D)
- Windshield Wiper/Washer Switch (Groundsmaster 4110-D)
- Air Conditioning Switch (Groundsmaster 4110-D)
- Turn Signal Switch (Groundsmaster 4110−D)
- Flasher Switch (Groundsmaster 4110−D)
- Traction Pedal Position Sensor
- Relays with Four (4) Terminals
- Relays with Five (5) Terminals
- Toro Electronic Controllers (TEC)
- Hydraulic Solenoid Valve Coils
- Piston (Traction) Pump Control Solenoid Coils
- CAN−bus Termination Resistor
- Diode Assemblies
- Resistor Assembly
- Fuel Sender
- Fuel Pump (Models 30602, 30604 and 30643)
- Fuel Pump (Models 30606, 30608 and 30644)
- Wing Deck Position Switches
- Hydraulic Oil Temperature Sender
- Fan Speed Switch (Machines with Two−Post ROPS Extension Operator Fan Kit)
- Resistor Module (Machines with Two−Post ROPS Extension Operator Fan Kit)
- Audio Alarm
- Service and Repairs
- Chapter 7 : Axles, Planetaries and Brakes
- General Information
- Adjustments
- Service and Repairs
- Brake Assembly
- Brake Inspection and Repair
- Planetary Drive Assembly
- OPH−2 Series Planetary Drive Service
- VA02 Series Planetary Drive Service
- Rear Axle Assembly
- Rear Axle Service
- Bevel Gear Case and Axle Case
- Differential Shafts
- Axle Shafts
- Input Shaft/Pinion Gear
- Differential Gear
- Pinion Gear to Ring Gear Engagement
- Gear Pattern Movement Summary
- Chapter 8 : Chassis
- Chapter 9 : Cutting Decks
- Chapter 10 : Operator Cab (For models 30602 and 30606)
- Chapter 11 : Operator Cab (For models 30643 and 30644)
- General Information
- Service and Repairs
- General Precautions for Removing and Installing the Air Conditioning System Components
- Air Conditioning Compressor
- Roof Assembly
- Heating and Air Conditioning Components
- Air Conditioning Condenser Fan Assembly
- Air Conditioning Condenser Assembly
- Mixing Box Assembly
- Heater and Air Conditioning Evaporator Cores
- Blower Fan
- Windshield Wiper Assembly
- Appendix A: Foldout Drawings
- Electrical Drawing Designations
- Hydraulic Schematic
- Electrical Schematic for Models 30604 and 30602/30643 (For machines serial number below 400000000)
- Electrical Schematic for Models 30604 and 30602/30643 (For machines serial number below 400000000)
- Electrical Schematic for Models 30604 and 30602/30643 (For machines serial number 400000001 to 403450000)
- Electrical Schematic for Models 30604 and 30602/30643 (For machines serial number 400000001 to 403450000)
- Electrical Schematic for Models 30604 and 30602/30643 (For machines serial number 403450001 to 408000000)
- Electrical Schematic for Models 30604 and 30602/30643 (For machines serial number 403450001 to 408000000)
- Electrical Schematic for Models 30604 and 30602/30643 (For machines serial number above 408000000)
- Electrical Schematic for Models 30604 and 30602/30643 (For machines serial number above 408000000)
- Electrical Schematic for Models 30608 and 30606/30644 (For machines serial number below 400000000)
- Electrical Schematic for Models 30608 and 30606/30644 (For machines serial number below 400000000)
- Electrical Schematic for Models 30608 and 30606/30644 (For machines serial numbers 400000001 to 403450000)
- Electrical Schematic for Models 30608 and 30606/30644 (For machines serial numbers 400000001 to 403450000)
- Electrical Schematic for Models 30608 and 30606/30644 (For machines serial numbers 403450001 to 408000000)
- Electrical Schematic for Models 30608 and 30606/30644 (For machines serial numbers 403450001 to 408000000)
- Electrical Schematic for Models 30608 and 30606/30644 (For machines serial numbers above 408000000)
- Electrical Schematic for Models 30608 and 30606/30644 (For machines serial numbers above 408000000)
- Electrical Schematic - Operator Cab (shown with lights for US model)
- Electrical Schematic - International Light Kits
- Platform Wire Harness Diagram (For machines serial number below 400000000)
- Platform Wire Harness Diagram (For machines serial number below 400000000)
- Platform Wire Harness Diagram (For machines serial number below 400000000)
- Platform Wire Harness Diagram (For machines serial numbers 400000001 to 403450000)
- Platform Wire Harness Diagram (For machines serial numbers 400000001 to 403450000)
- Platform Wire Harness Diagram (For machines serial numbers 400000001 to 403450000)
- Platform Wire Harness Diagram (For machines serial number 403450001 to 408000000)
- Platform Wire Harness Diagram (For machines serial number 403450001 to 408000000)
- Platform Wire Harness Diagram (For machines serial number 403450001 to 408000000)
- Platform Wire Harness Diagram (For machines serial number above 408000000)
- Platform Wire Harness Diagram (For machines serial number above 408000000)
- Platform Wire Harness Diagram (For machines serial number above 408000000)
- Rear Wire Harness Diagram (For machines serial number below 400000000)
- Rear Wire Harness Diagram (For machines serial number below 400000000)
- Rear Wire Harness Diagram (For machines serial number 400000000 to 408000000)
- Rear Wire Harness Diagram (For machines serial number 400000000 to 408000000)
- Rear Wire Harness Diagram (For machines serial numbers above 408000000)
- Rear Wire Harness Diagram (For machines serial numbers above 408000000)
- Engine Wire Harness Drawing for Models 30606, 30608, 30644 (For machines serial number below 400000000)
- Engine Wire Harness Diagram for Models 30606, 30608, 30644 (For machines serial number below 400000000)
- Engine Wire Harness Diagram for Models 30606, 30608, 30644 (For machines serial numbers 400000001 to 403450000)
- Engine Wire Harness Diagram for Models 30606, 30608, 30644 (For machines serial numbers 400000001 to 403450000)
- Engine Wire Harness Diagram for Models 30606, 30608, 30644 (For machines serial number 403450001 to 408000000)
- Engine Wire Harness Diagram for Models 30606, 30608, 30644 (For machines serial number 403450001 to 408000000)
- Engine Wire Harness Diagram for Models 30606, 30608, 30644 (For machines serial number above 408000000)
- Engine Wire Harness Diagram for Models 30606, 30608, 30644 (For machines serial number above 408000000)
- Engine DPF Wire Harness Diagram for Models 30606, 30608, 30644 (For machines serial number above 408000000)
- NO TITLE
- Engine Wire Harness Drawing for Models 30602, 30604, 30643
- Engine Wire Harness Drawing for Models 30602, 30604, 30643
- Operator Cab Wire Harness Diagram (For machines serial number below 400000000)
- Operator Cab Wire Harness Diagram (For machines serial number below 400000000)
- Operator Cab Wire Harness Diagram (For machines serial number above 400000000)
- Operator Cab Wire Harness Diagram (For machines serial number above 400000000)
- Operator Cab Interconnect Wire Harness
- Wire Harness Diagram − Two−Post ROPS Extension (Models 30604 and 30608)
- Wire Harness Diagram − Two−Post ROPS Extension (Models 30604 and 30608)
- Light Kit Wire Harness
- RH Rear Lights Wire Harness
- LH Rear Lights Wire Harness
CounterbalancePressure(UsingPressureGauge)
PRESSURE
GAUGE
S10
RV1
CV1
S2
S4
S5
PRV
P4 CH2 P3
EC
CF
LS
S3
OR1
C3
OR4
.040
S6
OR5
.070
C4 C2 C5
RV2
S7
S9
S8
C6
M1
M2
CH1
CV3
CH4
OR2
.063
OR6
.063
OR3
.070
OR7
.070
T
2SP
CH3
G2
G4
CV4
PR
G1
G3
3250
PSI
1350
PSI
4 PSI
4 PSI
.030
OR9
S1
3300 PSI
RV3
S12
S11
CV2
4 PSI
0.51 CID
1.125” ROD
.030”
80
PSI
60
PSI
310
PSI
2.50” BORE
6.50” STROKE
1.50” BORE
3.08” STROKE
RAM CYLINDERS
CENTER DECK
1.125” ROD
2.50” BORE
6.50” STROKE
GG
COMBINATION MANIFOLD
RIGHT DECK
LEFT DECK
TO FRONT
TO RESERVOIR
TO STEERING
CONTROL VALVE
TO STEERING
CONTROL VALVE
FROM GEAR PUMP
TRACTION
VALVE
TO PISTON
PUMP
TO RESERVOIR
TO WHEEL/AXLE
MOTORS
FROM GEAR PUMP
2500 PSI
g304425
Figure59
Groundsmaster
®
4100-D&4110-D
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HydraulicSystem:Testing
13203SLRevG