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Toro Groundsmaster 4700-D Service Manual
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Toro Groundsmaster 4700-D Service Manual

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Preface
The purpose of this publication is to provide the service
technician with information for troubleshooting, testing
and repair of major systems and components on the
Groundsmaster 4500--D (Model 30857) and 4700--D
(Model 30858).
REFER TO THE TRACTION UNIT AND CUTTING
UNIT OPERATOR'S MANUALS FOR OPERATING,
MAINTENANCE AND ADJUSTMENT INSTRUC-
TIONS. For reference, insert a copy of the Operator's
Manuals and Parts Catalog for your machine into Chap-
ter 2 of this service manual. Additional copies of the Op-
erator's Manuals and Parts Catalog are available on the
internet at www.Toro.com.
The Toro Company reserves the right to change product
specifications or this publication without notice.
Groundsmaster 4700- - D
Groundsmaster
E The Toro Company - - 2009

Service Manual

(Models 30857 and 30858)
R
4500- -D/4700- -D
This safety symbol means DANGER, WARNING
or CAUTION, PERSONAL SAFETY INSTRUC-
TION. When you see this symbol, carefully read
the instructions that follow. Failure to obey the
instructions may result in personal injury.
NOTE: A NOTE will give general information about the
correct operation, maintenance, service, testing or re-
pair of the machine.
IMPORTANT: The IMPORTANT notice will give im-
portant instructions which must be followed to pre-
vent damage to systems or components on the
machine.
Groundsmaster 4500- - D
Part No. 09172SL

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  • Page 1: Service Manual

    IMPORTANT: The IMPORTANT notice will give im- The Toro Company reserves the right to change product portant instructions which must be followed to pre- specifications or this publication without notice. vent damage to systems or components on the machine.
  • Page 2 This page is intentionally blank. Groundsmaster 4500--D/4700--D...

  • Page 3: Table Of Contents

    Table Of Contents Chapter 5 - - Electrical System Chapter 1 - - Safety General Safety Instructions ....1 -- 2 General Information .
  • Page 4 This page is intentionally blank. Groundsmaster 4500--D/4700--D...

  • Page 5: General Safety Instructions 1

    Chapter 1 Safety Table of Contents GENERAL SAFETY INSTRUCTIONS ... . Before Operating ......While Operating .

  • Page 6: General Safety Instructions

    General Safety Instructions The Groundsmaster 4500-D and 4700--D have been tested and certified by TORO for compliance with exist- WARNING ing safety standards and specifications. Although haz- ard control and accident prevention partially are To reduce the potential for injury or death, dependent upon the design and configuration of the ma- comply with the following safety instructions.

  • Page 7: Maintenance And Service

    Toro replacement parts and sult. accessories. Replacement parts and accessories made 7.

  • Page 8: Jacking Instructions

    Jacking Instructions CAUTION When changing attachments, tires or perform- ing other service, use correct jacks and sup- ports. 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.

  • Page 9: Safety And Instruction Decals

    Safety and Instruction Decals Numerous safety and instruction decals are affixed to the Groundsmaster 4500--D and 4700--D. If any decal becomes illegible or damaged, install a new decal. De- cal part numbers are listed in your Parts Catalog. Groundsmaster 4500--D/4700--D Page 1 - - 5 Safety...
  • Page 10 This page is intentionally blank. Safety Page 1 - - 6 Groundsmaster 4500--D/4700--D...

  • Page 11: Product Records

    Chapter 2 Product Records and Maintenance Table of Contents PRODUCT RECORDS ......MAINTENANCE ....... EQUIVALENTS AND CONVERSIONS .

  • Page 12: Equivalents And Conversions

    Equivalents and Conversions 0.09375 Product Records and Maintenance Groundsmaster 4500--D/4700--D Page 2 - - 2...

  • Page 13: Torque Specifications

    For critical applications, as determined reduced by 25% for lubricated fasteners to achieve by Toro, either the recommended torque or a torque that the similar stress as a dry fastener. Torque values may is unique to the application is clearly identified and spe- also have to be reduced when the fastener is threaded cified in this Service Manual.
  • Page 14 Standard Torque for Dry, Zinc Plated and Steel Fasteners (Inch Series) Grade 1, 5 & SAE Grade 1 Bolts, Screws, Studs & SAE Grade 5 Bolts, Screws, Studs & SAE Grade 8 Bolts, Screws, Studs & Thread Size 8 with Thin Sems with Regular Height Nuts Sems with Regular Height Nuts Sems with Regular Height Nuts...
  • Page 15 Standard Torque for Dry, Zinc Plated and Steel Fasteners (Metric Series) Class 8.8 Bolts, Screws and Studs with Class 10.9 Bolts, Screws and Studs with Thread Size Thread Size Regular Height Nuts Regular Height Nuts Regular Height Nuts Regular Height Nuts (Class 8 or Stronger Nuts) (Class 10 or Stronger Nuts) M5 X 0.8...
  • Page 16 Other Torque Specifications SAE Grade 8 Steel Set Screws Wheel Bolts and Lug Nuts Recommended Torque Thread Size Recommended Torque** Thread Size Thread Size Square Head Hex Socket 7/16 -- 20 UNF 65 + 10 ft--lb 88 + 14 N--m Grade 5 1/4 -- 20 UNC 140 + 20 in--lb...

  • Page 17: Specifications

    Chapter 3 Kubota Diesel Engine Table of Contents SPECIFICATIONS ......GENERAL INFORMATION .

  • Page 18: Specifications

    Specifications Item Description Make / Designation Kubota Model V2403--M--T--E3B: 4--Cycle, 4 Cylinder, Water Cooled, Turbocharged, Diesel Engine Bore 3.425” (87.0 mm) Stroke 4.031” (102.4 mm) Total Displacement 148.5 in (2434 cc) Firing Order 1 (closest to gear case end) -- 3 -- 4 (closest to flywheel end) -- 2 Combustion Chamber Spherical Type (E--TVCS) Compression Ratio...

  • Page 19: General Information

    Kubota Workshop Manual, Diesel En- Service and repair parts for Kubota engines are sup- gine, V2403--M--T--E3B that is included at the end of this plied through your Authorized Toro Distributor. If no section. parts list is available, be prepared to provide your distrib- utor with the Toro model and serial number.

  • Page 20: Air Filter System

    Service and Repairs Air Filter System RIGHT 12 to 15 in- -lb FRONT (1.4 to 1.6 N- -m) VACUATOR DIRECTION Figure 1 1. Battery support 11. Air cleaner assembly 20. Flange head screw (4 used) 2. Bracket 12. Service indicator 21.
  • Page 21 Removal (Fig. 1) 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 hood. 3. Remove air cleaner components as needed using Figure 1 as a guide. Installation (Fig.

  • Page 22: Exhaust System

    Exhaust System RIGHT 16 to 22 ft- -lb (21 to 29 N- -m) FRONT 13 ft- -lb (17.6 N- -m) 16 to 22 ft- -lb (21 to 29 N- -m) 16 to 22 ft- -lb (21 to 29 N- -m) 16 to 22 ft- -lb (21 to 29 N- -m) Figure 5...
  • Page 23 Removal (Fig. 5) CAUTION The muffler and exhaust pipe may be hot. To avoid possible burns, allow the engine and ex- haust system to cool before working on the muf- fler. 1. Park machine on a level surface, lower cutting decks, stop engine, engage parking brake and remove key from the ignition switch.

  • Page 24: Fuel System

    Fuel System RIGHT FRONT Figure 7 1. Fuel suction tube 10. Cap screw (2 used) 19. Flange nut (2 used) 2. Fuel line clamp (2 used) 11. Clamp (2 used) 20. Fuel/water separator 3. Fuel hose (supply) 12. Flange nut (2 used) 21.

  • Page 25: Check Fuel Lines And Connections

    Fuel Tank Removal (Fig. 7) DANGER 1. Park machine on a level surface, lower cutting decks, stop engine, engage parking brake and remove key from the ignition switch. Because diesel fuel is highly flammable, use cau- tion when storing or handling it. Do not smoke 2.

  • Page 26: Radiator

    Radiator RIGHT FRONT 9 to 11 ft- -lb (12.3 to 14.9 N- -m) Figure 8 1. 90 hydraulic fitting (2 used) 17. Flat washer (8 used) 32. Washer (2 used) 2. Oil cooler 18. Flange head screw (11 used) 33. Oil cooler top bracket 3.
  • Page 27 Removal (Fig. 8) 2. Carefully position radiator and recirculation barriers (items 24 and 25) to the radiator mount. Secure radiator 1. Park machine on a level surface, lower cutting and barriers in place with four (4) flange head screws decks, stop engine, engage parking brake and remove and flange nuts.

  • Page 28: Engine

    Engine RIGHT FRONT Figure 10 1. Muffler 12. Cap screw (4 used) 23. Bolt (5 used) 2. Flange head screw (2 used) 13. RH engine mount 24. LH engine mount 3. Flange head screw (6 used) 14. Engine 25. Exhaust mount 4.

  • Page 29: Engine Removal

    Engine Removal (Fig. 10) 1. Park machine on a level surface, lower cutting decks, stop engine, engage parking brake and remove key from the ignition switch. 2. Remove hood from the machine (see Hood Removal in the Service and Repairs section of Chapter 7 -- Chas- sis).

  • Page 30: Engine Installation

    11. Remove fan motor and fan assembly (Fig. 13). A. To prevent contamination of hydraulic system, thoroughly clean exterior of fan motor and fittings. B. Disconnect hydraulic hoses from cooling fan mo- tor. Put caps or plugs on fittings and hoses to prevent contamination.
  • Page 31 7. Position upper radiator shroud to the radiator. Secu- 12.Using notes taken during engine removal, secure re shroud to the radiator and lower radiator bracket with wires with cable ties in proper locations. removed fasteners (see Radiator Installation in this sec- 13.Install air cleaner assembly to the engine (see Air tion).

  • Page 32: Pump Adapter Plate

    Pump Adapter Plate RIGHT FRONT 29 to 33 ft- -lb Loctite #242 (40 to 44 N- -m) Boss Figure 14 1. Bolt 4. Hardened washer (14 used) 6. Bolt (6 used) 2. Lock washer 5. Spring coupler 7. Cap screw (8 used) 3.
  • Page 33 Coupler Removal (Fig. 14) NOTE: The hydraulic pump assembly needs to be re- moved from engine before coupler can be removed. Engine Side Hydraulic Pump Side 1. If engine is in machine, remove hydraulic pump as- sembly (see Piston (Traction) Pump Removal in the Ser- vice and Repairs section of Chapter 4 -- Hydraulic System).
  • Page 34 This page is intentionally blank. Kubota Diesel Engine Page 3 - - 18 Groundsmaster 4500--D/4700--D...

  • Page 35: Hydraulic Schematics 4

    Chapter 4 Hydraulic System Table of Contents SPECIFICATIONS ......Check Hydraulic Lines and Hoses .
  • Page 36 This page is intentionally blank. Hydraulic System Page 4 - - 2 Groundsmaster 4500--D/4700--D...
  • Page 37 Specifications Item Description Piston (Traction) Pump Eaton variable displacement piston pump (Model 72400) System Relief Pressure: Forward 5000 PSI (345 bar) System Relief Pressure: Reverse 5000 PSI (345 bar) Charge Pressure 207 PSI (14.3 bar) Front Wheel Motors Eaton fixed displacement piston motors (Model 74315) Displacement (per revolution) 2.01 in...

  • Page 38: Towing Traction Unit

    4WD/2WD control manifold test port (G). Toro part numbers 95- -8843 (hydraulic hose), 95- -0985 (coupler fitting) (2 required) and 340- -77 (hydraulic fitting) (2 required) are needed for this connection.

  • Page 39: Relieving Hydraulic System Pressure

    Relieving Hydraulic System Pressure Before disconnecting or performing any work on the hy- System pressure in mow circuit is relieved when the cut- draulic system, all pressure in the hydraulic system ting decks are disengaged (PTO switch in OFF posi- must be relieved.

  • Page 40: Hydraulic Hoses

    Tube Installation in this section). If the hose has an el- bow 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).
  • Page 41 Hydraulic Hose and Tube Installation (O- -Ring Face Seal Fitting) 1. Make sure threads and sealing surfaces of the hose/ C. Use a second wrench to tighten the nut to the cor- tube and the fitting are free of burrs, nicks, scratches or rect Flats From Wrench Resistance (F.F.W.R.).
  • Page 42 Hydraulic Fitting Installation (SAE Straight Thread O- -Ring Fitting into Component Port) Non- -Adjustable Fitting (Fig. 6) 5. If a torque wrench is not available, or if space at the port prevents use of a torque wrench, an alternate meth- 1.
  • Page 43 Adjustable Fitting (Fig. 8) 1. Make sure all threads and sealing surfaces of fitting and component port are free of burrs, nicks, scratches or any foreign material. 2. As a preventative measure against leakage, it is rec- ommended that the O--ring be replaced any time the connection is opened.

  • Page 44: Hydraulic Schematics

    Hydraulic Schematics Hydraulic System Page 4 - - 10 Groundsmaster 4500--D/4700--D...
  • Page 45 Groundsmaster 4500--D/4700--D Page 4 - - 11 Hydraulic System...

  • Page 46: Hydraulic Flow Diagrams

    Hydraulic Flow Diagrams Hydraulic System Page 4 - - 12 Groundsmaster 4500--D/4700--D...

  • Page 47: Traction Circuit: Low Speed (4Wd)

    Traction Circuit: Low Speed (4WD) The traction circuit piston pump is a variable displace- Forward Direction ment pump that is directly coupled to the engine fly- When the Hi--Lo speed control switch is in the low speed wheel. Pushing the traction pedal engages a hydraulic (4WD) position and the traction pedal is pushed in the servo valve which controls the variable displacement forward direction, oil from the piston pump is directed to...
  • Page 48 Hydraulic System Page 4 - - 14 Groundsmaster 4500--D/4700--D...

  • Page 49: Traction Circuit: High Speed (2Wd)

    Traction Circuit: High Speed (2WD) The traction circuit piston pump is a variable displace- Forward Direction ment pump that is directly coupled to the engine fly- With the Hi--Lo speed control switch is in the high speed wheel. Pushing the traction pedal engages a hydraulic (2WD) position, solenoid valve (SV) in the 4WD/2WD servo valve which controls the variable displacement control manifold is energized.
  • Page 50 Hydraulic System Page 4 - - 16 Groundsmaster 4500--D/4700--D...
  • Page 51 Lower Cutting Decks: Groundsmaster 4500- -D A four section gear pump is coupled to the piston (trac- Counterbalance tion) pump. Gear pump section P3 supplies hydraulic Once the cutting decks are fully lowered, the lift control flow to both the lift control manifold and the steering con- manifold proportional relief valve (TS) maintains back trol valve.
  • Page 52 Hydraulic System Page 4 - - 18 Groundsmaster 4500--D/4700--D...
  • Page 53 Lower Cutting Decks: Groundsmaster 4700- -D A four section gear pump is coupled to the piston (trac- When a deck switch is released, the solenoid valves tion) pump. Gear pump section P3 supplies hydraulic controlled by the switch are de--energized and the lift flow to both the lift control manifold and the steering con- cylinders and cutting decks are held in position.
  • Page 54 Hydraulic System Page 4 - - 20 Groundsmaster 4500--D/4700--D...
  • Page 55 Raise Cutting Decks: Groundsmaster 4500- -D A four section gear pump is coupled to the piston (trac- tion) pump. Gear pump section P3 supplies hydraulic flow to both the lift control manifold and the steering con- trol valve. Hydraulic flow from this pump section is deliv- ered to the circuits through a proportional flow divider located in the fan control manifold.
  • Page 56 Hydraulic System Page 4 - - 22 Groundsmaster 4500--D/4700--D...
  • Page 57 Raise Cutting Decks: Groundsmaster 4700- -D A four section gear pump is coupled to the piston (trac- tion) pump. Gear pump section P3 supplies hydraulic flow to both the lift control manifold and the steering con- trol valve. Hydraulic flow from this pump section is deliv- ered to the circuits through a proportional flow divider located in the fan control manifold.
  • Page 58 Hydraulic System Page 4 - - 24 Groundsmaster 4500--D/4700--D...

  • Page 59: Mow Circuit

    Mow Circuit Hydraulic flow for the mow circuit is supplied by two (2) sections of the gear pump (P1 and P2). Gear pump sec- tion P1 supplies hydraulic flow to decks 5, 3 and 2 (also #4 Deck #1 Deck #5 Deck deck 7 on the GM 4700--D), while gear pump section P2 supplies decks 1 and 4 (also deck 6 on the GM 4700--D).

  • Page 60: Cutting Deck Blade Braking

    Cutting Deck Blade Braking When the operator turns the PTO switch OFF (or if the decks are raised), deck manifold solenoid valves (PRV1, PRV2, SV1 and SV2) are de--energized. The ORIFICE valves will shift to direct oil away from the deck motors and toward the oil cooler and filter.
  • Page 61 This page is intentionally blank. Groundsmaster 4500--D/4700--D Page 4 - - 27 Hydraulic System...
  • Page 62 Hydraulic System Page 4 - - 28 Groundsmaster 4500--D/4700--D...

  • Page 63: Steering Circuit

    Steering Circuit A four section gear pump is coupled to the piston (trac- the cylinder is proportional to the amount of the turning tion) pump. The gear pump section P3 supplies hydrau- on the steering wheel. Fluid leaving the cylinder flows lic flow to the steering control valve and the lift/lower back through the spool valve then through the T port and control valve.
  • Page 64 Hydraulic System Page 4 - - 30 Groundsmaster 4500--D/4700--D...

  • Page 65: Engine Cooling Fan Circuit

    Engine Cooling Fan Circuit A four section gear pump is coupled to the piston (trac- Reverse Direction Fan Operation (Fig. 25) tion) pump. The gear pump section P4 (farthest from the The TEC--5002 controller can reverse the cooling fan to piston pump) supplies hydraulic flow for the hydraulic clean debris from the rear intake screen.

  • Page 66: Special Tools

    Special Tools Order these special tools from your Toro Distributor. Hydraulic Pressure Test Kit Use to take various pressure readings for diagnostic tests. Quick disconnect fittings provided attach directly to mating fittings on machine test ports without tools. A high pressure hose is provided for remote readings.

  • Page 67: Measuring Container

    This kit includes a variety of O--ring Face Seal fittings to enable you to connect test gauges into the system. The kit includes: tee’s, unions, reducers, plugs, caps and male test fittings. Toro Part Number: TOR4079 Figure 28 Measuring Container Use this container for doing hydraulic motor efficiency testing (motors with case drain lines only).
  • Page 68 It is recommended that O--rings be replaced whenever a hydraulic connec- tion is loosened. Toro Part Number: 16- -3799 Figure 31 High Pressure Hydraulic Oil Filter If a component failure occurs in the closed loop traction circuit, contamination from the failed part will remain in the circuit until removed.

  • Page 69: Troubleshooting

    Troubleshooting The charts that follow contain information to assist in hy- Refer to the Testing section of this Chapter for precau- draulic system troubleshooting. There may possibly be tions and specific testing procedures. more than one cause for a machine malfunction. General Hydraulic System Problems Problem Possible Cause...

  • Page 70: Traction Circuit Problems

    Traction Circuit Problems NOTE: When troubleshooting traction circuit problems, ton pump, front wheel motors). If the problem exists in if a problem exists in both low (4WD) and high (2WD) low speed (4WD) but not in high speed (2WD), consider speeds, consider a faulty component that affects the en- a problem in the 4WD traction system (e.g.
  • Page 71 PTO Problems Problem Possible Cause No cutting decks will operate. Decks are not fully lowered to ground. NOTE: Decks have to be fully low- Operator seat is unoccupied. ered and traction speed needs to be Traction system is in high speed (2WD). in low speed (4WD) for decks to op- erate.

  • Page 72: Steering Circuit Problems

    PTO Problems (Continued) Problem Possible Cause All cutting decks operate slowly. Engine RPM is low. Deck motor is damaged. Gear pump section (P1 or P2) is worn or damaged. Cutting deck stops under load. Relief valve in deck control manifold is bypassing. Cutting conditions (e.g.
  • Page 73 Lift/Lower Circuit Problems Problem Possible Cause Cutting decks will not raise. Operator seat is unoccupied. NOTE: Operator must be in seat in Hydraulic oil level in reservoir is low. order to raise the cutting decks. Electrical problem exists that prevents lift control manifold solenoid valve operation (see Chapter 5 -- Electrical System).
  • Page 74 Engine Cooling Fan Circuit Problems Problem Possible Cause Cooling fan runs only in forward di- Fan control manifold solenoid cartridge valve (S1) is faulty. rection (fan does not run in reverse Electrical problem exists that prevents fan control manifold solenoid direction).

  • Page 75: Testing

    Testing The most effective method for isolating problems in the hydraulic system is by using hydraulic test equipment WARNING such as pressure gauges and flow meters in the circuits during various operational checks (See the Special Before disconnecting or performing any work on Tools section in this chapter).

  • Page 76: Hydraulic System

    Traction Circuit Charge Pressure (Using Pressure Gauge) FROM STEERING AND LIFT CIRCUITS (CHARGE CIRCUIT) FORWARD DIRECTION SHOWN PRESSURE GAUGE TO DECK CONTROL MANIFOLD TO DECK CONTROL MANIFOLD TO STEERING AND LIFT CIRCUITS (CHARGE CIRCUIT) TO FAN CIRCUIT Working Pressure Low Pressure Return or Suction FROM DECK MOTORS Flow...
  • Page 77 NOTE: The traction charge circuit is designed to re- 7. Also, with the pressure gauge still connected to the place loss of hydraulic fluid from the closed loop traction charge pressure test port, monitor the gauge reading circuit. while operating the machine in forward and reverse. Start the engine and put throttle at full engine speed Procedure for Traction Circuit Charge Pressure Test (2870 RPM).
  • Page 78 Traction Circuit Relief Pressure (Using Pressure Gauge) FROM STEERING AND LIFT CIRCUITS (CHARGE CIRCUIT) FORWARD DIRECTION TEST SHOWN PRESSURE GAUGE TO DECK CONTROL MANIFOLD TO DECK CONTROL MANIFOLD TO STEERING AND LIFT CIRCUITS (CHARGE CIRCUIT) TO FAN CIRCUIT Working Pressure Low Pressure Return or Suction FROM DECK MOTORS...
  • Page 79 Procedure for Traction Circuit Relief Pressure Test NOTE: Seal leakage across pilot directional valves PD1 and PD2 in 4WD/2WD control manifold can also 1. Make sure hydraulic oil is at normal operating tem- cause low forward traction pressure with reverse pres- perature by operating the machine for approximately ten sure meeting specifications.
  • Page 80 Rear Traction Circuit Relief (RV) Pressure (Using Pressure Gauge) FROM STEERING PRESSURE AND LIFT CIRCUITS (CHARGE CIRCUIT) GAUGE TO DECK CONTROL MANIFOLD TO DECK CONTROL MANIFOLD TO STEERING AND LIFT CIRCUITS (CHARGE CIRCUIT) TO FAN CIRCUIT Working Pressure Low Pressure Return or Suction FROM DECK MOTORS Flow...
  • Page 81 NOTE: Adjustable relief valve (RV) in the 4WD/2WD C. After adjustment is made, recheck relief pressure control manifold reduces rear axle motor pressure and make additional adjustment if necessary. created in down hill, dynamic braking conditions to pre- vent rear wheel lock up. Procedure for Rear Traction Circuit Relief (RV) Pres- RIGHT sure Test...
  • Page 82 Traction Circuit Reducing Valve (PR) Pressure (Using Pressure Gauge) FROM STEERING PRESSURE AND LIFT CIRCUITS (CHARGE CIRCUIT) GAUGE TO DECK CONTROL MANIFOLD TO DECK CONTROL MANIFOLD TO STEERING AND LIFT CIRCUITS (CHARGE CIRCUIT) TO FAN CIRCUIT Working Pressure Low Pressure Return or Suction FROM DECK MOTORS Flow...
  • Page 83 NOTE: When in reverse, pressure reducing valve (PR) B. To decrease pressure setting, remove cap on re- limits the pressure to the rear axle motor to 450 PSI (31 ducing valve and turn the adjustment socket on the bar) so the rear wheels will not scuff the turf. valve in a counterclockwise direction (Fig.
  • Page 84 Cutting Deck Circuit Pressure (Using Pressure Gauge) TEST FOR GM4500- -D DECKS 2, 3 AND 5 SHOWN TO STEERING AND LIFT CIRCUITS FROM FAN CONTROL TO FAN CIRCUIT FROM STEERING CONTROL PRESSURE GAUGE Working Pressure Low Pressure Return or Suction Flow FROM FAN MOTOR Hydraulic System...
  • Page 85 Procedure for Cutting Deck Circuit Pressure Test GM 4500- -D 1. Make sure hydraulic oil is at normal operating tem- perature by operating the machine for approximately ten (10) minutes. Make sure the hydraulic tank is full. 2. Park machine on a level surface with the cutting decks lowered and off.
  • Page 86 Cutting Deck Circuit Relief Pressure (Using Tester with Pressure Gauges and Flow Me- ter) TEST FOR GM4500- -D PUMP SECTION P2 SHOWN TO STEERING AND LIFT CIRCUITS FROM FAN CONTROL TO FAN CIRCUIT FROM STEERING CONTROL Working Pressure Low Pressure Return or Suction Flow TESTER...
  • Page 87 Procedure for Cutting Deck Circuit Relief Pressure 10.Open the tester flow control valve, disengage cutting Test decks and stop the engine. Record test results. 1. Make sure hydraulic oil is at normal operating tem- 11. If specification is not met, make sure that electrical perature by operating the machine for approximately ten connections at deck control manifold are secure and (10) minutes.
  • Page 88 Cutting Deck Motor Case Drain Leakage (Using Tester with Pressure Gauges and Flow Meter) TEST FOR GM4500- -D DECK MOTOR #1 SHOWN TO OIL COOLER Working Pressure Low Pressure Return or Suction Flow TESTER FROM FAN MOTOR STEEL MEASURING CONTAINER Hydraulic System Page 4 - - 54 Groundsmaster 4500--D/4700--D...
  • Page 89 Procedure for Cutting Deck Motor Case Drain Leak- 5. Sit on seat and start the engine. Move throttle to full age Test speed (2870 RPM). Move PTO switch to ON. NOTE: Over a period of time, a deck motor can wear in- 6.
  • Page 90 Gear Pump P1 and P2 Flow (Cutting Deck Circuits) (Using Tester with Pressure Gauges and Flow Meter) TEST FOR GEAR PUMP SECTION P1 SHOWN TO STEERING AND LIFT CIRCUITS TO FAN CIRCUIT FROM STEERING CONTROL FROM DECK CONTROL MANIFOLD TESTER Working Pressure Low Pressure Return or Suction...
  • Page 91 NOTE: Gear pump P1 supplies hydraulic flow to cutting IMPORTANT: Do not fully restrict oil flow through decks 5, 3 and 2 (also deck 7 on the GM 4700--D). Gear tester. In this test, the flow tester is positioned be- pump P2 supplies flow to cutting decks 1 and 4 (also fore the circuit relief valve.
  • Page 92 Steering Circuit Relief Pressure (Using Pressure Gauge) TEST FOR GM4500- -D SHOWN (STEERING WHEEL TURNED FOR RIGHT TURN) PRESSURE GAUGE STEEL Working Pressure Low Pressure Return or Suction Flow Hydraulic System Page 4 - - 58 Groundsmaster 4500--D/4700--D...
  • Page 93 Procedure for Steering Circuit Relief Pressure Test 9. If steering relief pressure is incorrect, inspect steer- ing relief valve located in the steering control valve (see 1. Make sure hydraulic oil is at normal operating tem- Steering Control Valve Service in the Service and Re- perature by operating the machine for approximately ten pairs section of this chapter).
  • Page 94 Lift/Lower Circuit Relief Pressure (Using Pressure Gauge) GM 4500- -D SHOWN PRESSURE GAUGE TO OIL FILTER (CHARGE CIRCUIT) 3 GPM PRIORITY FLOW TO STEERING CONTROL VALVE FROM DECK MOTORS Working Pressure Low Pressure Return or Suction Flow Hydraulic System Page 4 - - 60 Groundsmaster 4500--D/4700--D...
  • Page 95 Procedure for Lift/Lower Circuit Relief Pressure B. If pressure is too low, check for restriction in gear Test pump intake line. Check the lift cylinders for internal leakage. If pump intake line is not restricted and lift 1. Make sure hydraulic oil is at normal operating tem- cylinders are not leaking, remove cap on relief valve perature by operating the machine for approximately ten (Fig.
  • Page 96 Gear Pump P3 Flow (Steering and Lift/Lower Circuits) (Using Tester with Pressure Gauges and Flow Meter) TESTER TO STEERING AND LIFT CIRCUITS TO FAN CIRCUIT FROM STEERING CONTROL FROM DECK CONTROL MANIFOLD Working Pressure Low Pressure Return or Suction Flow Hydraulic System Page 4 - - 62 Groundsmaster 4500--D/4700--D...
  • Page 97 NOTE: Gear Pump P3 supplies oil flow for the steering IMPORTANT: The pump is a positive displacement and lift circuits. type. If pump flow is completely restricted or stopped, damage to the pump, tester or other com- Procedure for Gear Pump P3 Flow Test ponents could occur.
  • Page 98 Cooling Fan Circuit (Using Pressure Gauge and Phototac) GM 4500- -D SHOWN Working Pressure Low Pressure Return or Suction Flow Hydraulic System Page 4 - - 64 Groundsmaster 4500--D/4700--D...
  • Page 99 Procedure for Cooling Fan Circuit Test 1. Make sure hydraulic oil is at normal operating tem- perature by operating the machine for approximately ten (10) minutes. Make sure the hydraulic tank is full. 2. Park machine on a level surface with the cutting decks lowered and off.
  • Page 100 Gear Pump P4 Flow (Cooling Fan Circuit) (Using Tester with Pressure Gauges and Flow Meter) TO STEERING AND LIFT CIRCUITS TESTER TO FAN CIRCUIT FROM STEERING CONTROL FROM DECK CONTROL MANIFOLD Working Pressure Low Pressure Return or Suction Flow Hydraulic System Page 4 - - 66 Groundsmaster 4500--D/4700--D...
  • Page 101 NOTE: Gear Pump P4 supplies oil flow for the engine IMPORTANT: The gear pump is a positive displace- cooling fan circuit. ment type. If pump flow is completely restricted or stopped, damage to the pump, tester or other com- Procedure for Gear Pump P4 Flow Test ponents could occur.

  • Page 102: Check Hydraulic Lines And Hoses

    Service and Repairs General Precautions for Removing and Installing Hydraulic System Components Before Repair or Replacement of Components After Repair or Replacement of Components 1. Before removing any parts from the hydraulic sys- 1. Check oil level in the hydraulic reservoir and add cor- tem, park machine on a level surface, engage parking rect oil if necessary.

  • Page 103: Flush Hydraulic System

    Flush Hydraulic System IMPORTANT: Flush the hydraulic system any time 8. Disconnect wire harness connector from engine run there is a severe component failure or the system is solenoid to prevent the engine from starting. contaminated (oil appears milky, black or contains 9.

  • Page 104: Charge Hydraulic System

    Charge Hydraulic System NOTE: When initially starting the hydraulic system with 11. After the hydraulic system starts to show signs of fill, new or rebuilt components such as pumps, motors or lift actuate lift control switch until the lift cylinder rods move cylinders, it is important that the hydraulic system be in and out several times.
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  • Page 106: Gear Pump

    Gear Pump 77 to 93 ft- -lb (105 to 126 N- -m) RIGHT 103 to 118 ft- -lb (140 to 160 N- -m) FRONT Figure 56 1. Flat washer (2 used) 9. Coupler 17. Spacer 2. Cap screw (2 used) 10.
  • Page 107 7. Support gear pump assembly to prevent it from fal- ling. RIGHT 8. Remove two (2) cap screws and washers securing FRONT gear pump to piston pump. Remove gear pump, coupler (item 9), spacer (item 17) and O--rings (item 16) from machine.

  • Page 108: Gear Pump Service

    Gear Pump Service 33 ft- -lb (45 N- -m) Figure 58 1. Dust seal 10. Seal (8 used) 19. Body (section P2) 2. Retaining ring 11. Idler gear 20. Body (section P3) 3. Flange washer 12. Drive shaft 21. Drive gear 4.
  • Page 109 IMPORTANT: Use caution when clamping gear 8. Clean all parts. Check all components for burrs, pump in a vise to avoid distorting any pump compo- scoring, nicks and other damage. nents. 9. Replace the entire pump assembly if parts are ex- 3.

  • Page 110: Piston (Traction) Pump

    Piston (Traction) Pump 77 to 93 ft- -lb (105 to 126 N- -m) 103 to 118 ft- -lb RIGHT (140 to 160 N- -m) FRONT Figure 60 1. Flat washer (2 used) 9. Coupler 17. Spacer 2. Cap screw (2 used) 10.
  • Page 111 7. Remove gear pump from machine (see Gear Pump Removal in this section). 8. Support the piston pump to prevent it from falling while removing two (2) cap screws and washers retain- ing pump assembly to engine adapter plate. Carefully pull pump assembly from adapter plate and raise it out of the machine.

  • Page 112: Piston (Traction) Pump Service

    Piston (Traction) Pump Service 40 to 48 in- -lb 4 to 6 ft- -lb (4.5 to 5.4 N- -m) (5 to 8 N- -m) 100 to 110 ft- -lb 40 to 48 in- -lb 25 to 28 ft- -lb (136 to 149 N- -m) (4.5 to 5.4 N- -m) (34 to 38 N- -m) 27 to 31 ft- -lb...
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  • Page 114 4WD/2WD and Filtration/Charge Control Manifolds RIGHT FRONT Figure 64 1. Flange head screw (2 used) 5. 4WD/2WD control manifold 9. Flat washer (2 used) 2. Filtration manifold bracket 6. Manifold bracket 10. Cap screw (2 used) 3. Filtration/charge control manifold 7.
  • Page 115 Removal (Fig. 64) 75 ft- -lb 25 ft- -lb (101 N- -m) NOTE: The ports on the manifolds are marked for easy (33.9 N- -m) identification of components. Refer to the Hydraulic Schematics in Chapter 9 -- Foldout Drawings to identify the function of the hydraulic lines and cartridge valves at each port.

  • Page 116: Wd/2Wd Control Manifold Service

    4WD/2WD Control Manifold Service 50 ft- -lb (68 N- -m) 15 ft- -lb 25 ft- -lb (20.3 N- -m) (33.9 N- -m) 25 ft- -lb (33.9 N- -m) 9 to 11 ft- -lb (12.3 to 14.9 N- -m) 20 ft- -lb 35 ft- -lb 20 ft- -lb (27.1 N- -m)
  • Page 117 NOTE: The ports on the manifold are marked for easy 5. Visually inspect cartridge valve for damaged sealing identification of components (e.g. P1 is a piston pump surfaces and contamination. connection port and SV is the location for the solenoid A.

  • Page 118: Filtration/Charge Control Manifold Service

    Filtration/Charge Control Manifold Service 25 ft- -lb 25 ft- -lb (33.9 N- -m) (33.9 N- -m) 30 ft- -lb (40.6 N- -m) 30 ft- -lb (40.6 N- -m) 50 ft- -lb (68 N- -m) 25 ft- -lb (33.9 N- -m) Figure 68 1.
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  • Page 120: Rear Axle Motor

    Rear Axle Motor Arrows on side of motor case point up RIGHT FRONT Figure 69 1. Axle motor 5. O- -ring 8. 90 hydraulic fitting 2. O- -ring 6. Hydraulic fitting 9. Cap screw (2 used) 3. Pinion gear 7. O- -ring 10.
  • Page 121 Removal (Fig. 69) Installation (Fig. 69) 1. Park machine on a level surface, lower cutting 1. If fittings were removed from axle motor, lubricate decks, stop engine, engage parking brake and remove and place new O--rings onto fittings. Install fittings into key from the ignition switch.

  • Page 122: Front Wheel Motors

    Front Wheel Motors 23 24 75 to 85 ft- -lb (102 to 115 N- -m) Arrows on side of RIGHT motor case point up FRONT Figure 70 1. Flange head screw (6 per planetary) 10. O- -ring 18. O- -ring 2.
  • Page 123 Removal (Fig. 70) Installation (Fig. 70) 1. Park machine on a level surface, lower cutting 1. If fittings were removed from wheel motor, lubricate decks, stop engine, engage parking brake and remove and place new O--rings onto fittings. Install fittings into key from the ignition switch.

  • Page 124: Rear Axle And Front Wheel Motor Service

    Rear Axle and Front Wheel Motor Service 15 to 18 ft- -lb (20 to 24 N- -m) FRONT WHEEL MOTOR SHOWN Figure 71 1. Drive shaft 8. Shaft seal (front motor only) 15. Roll pin 2. Backplate 9. Retaining ring 16.

  • Page 125: Cutting Deck Motor

    Cutting Deck Motor The hydraulic motors used on all cutting decks are the same. Removal 1. Park machine on a level surface, lower cutting decks, stop engine, engage parking brake and remove key from the ignition switch. 2. Read the General Precautions for Removing and Installing Hydraulic System Components at the begin- ning of the Service and Repairs section of this chapter.

  • Page 126: Cutting Deck Motor Service

    Cutting Deck Motor Service 33 ft- -lb (45 N- -m) 26 ft- -lb (35 N- -m) 26 ft- -lb (35 N- -m) Figure 74 1. Dust seal 8. Front wear plate 14. Rear wear plate 2. Retaining ring 9. Drive gear 15.
  • Page 127 4. Loosen cap screws from the rear cover. 3. Inspect drive gears and idler gears for the following (Fig. 77): 5. Remove motor from the vise. Turn motor so that the shaft end is facing down. Remove cap screws. A. Gear shafts should be free of rough surfaces and excessive wear at bushing points and sealing areas.
  • Page 128 Assembly (Fig. 74) 9. Apply a light coating of petroleum jelly to new O-- rings and O--ring grooves in the body. Install new O-- NOTE: When assembling the motor, check the marker rings to the body. line on each part to make sure the parts are properly aligned during assembly.
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  • Page 130: Deck Control Manifold

    Deck Control Manifold RIGHT FRONT GROUNDSMASTER 4500- -D SHOWN Figure 78 1. Deck control manifold 4. Hydraulic oil filter 7. Lift control manifold 2. Filter mount bracket 5. Valve mount bracket 8. Flange head screw 3. Filter head 6. Flange head screw (2 used) NOTE: The deck control manifolds used on Ground- smaster 4500--D and 4700--D are different but they mount to the machine in the same location.
  • Page 131 Removal (Fig. 78) 75 ft- -lb 75 ft- -lb 50 ft- -lb (101 N- -m) NOTE: The ports on the manifold are marked for easy (101 N- -m) (68 N- -m) identification of components. Example: P1 is the gear pump connection port (see Hydraulic Schematics in Chapter 9 -- Foldout Drawings to identify the function of the hydraulic lines and cartridge valves at each port).
  • Page 132 Deck Control Manifold Service (GM 4500- -D) 5 ft- -lb (6.8 N- -m) 20 ft- -lb (27.1 N- -m) 25 ft- -lb (33.9 N- -m) 25 ft- -lb (33.9 N- -m) 20 ft- -lb (27.1 N- -m) 25 ft- -lb (33.9 N- -m) 25 ft- -lb (33.9 N- -m)
  • Page 133 For solenoid and control valve service procedures, see 4WD/2WD Control Manifold Service in this section. Re- 20 ft- -lb fer to Figures 81 and 82 for cartridge valve and plug (27.1 N- -m) installation torque. 25 ft- -lb IMPORTANT: A pilot piston (item 6) is placed be- (33.9 N- -m) neath each of the relief valves in deck control man- ifold ports RV8 and RV9.
  • Page 134 Deck Control Manifold Service (GM 4700- -D) 5 ft- -lb (6.8 N- -m) 25 ft- -lb 20 ft- -lb (33.9 N- -m) (27.1 N- -m) 25 ft- -lb 25 ft- -lb (33.9 N- -m) (33.9 N- -m) 5 ft- -lb (6.8 N- -m) 20 ft- -lb 20 ft- -lb...
  • Page 135 For solenoid and control valve service procedures, see 4WD/2WD Control Manifold Service in this section. Re- 20 ft- -lb fer to Figures 83 and 84 for cartridge valve and plug (27.1 N- -m) 20 ft- -lb installation torque. (27.1 N- -m) IMPORTANT: A pilot piston (item 6) is placed be- neath each of the relief valves in deck control man- ifold ports RV8, RV9, RV10 and RV11.

  • Page 136: Steering Control Valve

    Steering Control Valve RIGHT FRONT 20 to 26 ft- -lb (28 to 35 N- -m) Antiseize Lubricant 15 16 7 to 10 ft- -lb (9.5 to 13.5 N- -m) Antiseize Lubricant Figure 85 1. Steering wheel cover 7. Steering column 12.
  • Page 137 7. Position steering column brace (item 12) to machine CAUTION and secure with four (4) flange head screws. 8. Slide rubber bellows to bottom of steering column. Before opening hydraulic system, operate all hy- 9. Position shroud in place and secure with removed draulic controls to relieve system pressure and fasteners (Fig.

  • Page 138: Steering Control Valve Service

    Steering Control Valve Service 20 to 24 ft- -lb (27 to 33 N- -m) Figure 88 1. Relief valve assembly 9. Cross pin 16. Inner gearwheel 2. Dust seal ring 10. Sleeve 17. End cover 3. Steering valve housing 11. Spool 18.
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  • Page 140: Steering Cylinder

    Steering Cylinder RIGHT 100 to 125 ft- -lb FRONT (136 to 169 N- -m) Figure 89 1. Steering cylinder 7. 90 hydraulic fitting 12. Axle washer 2. Ball joint 8. O- -ring 13. Slotted hex nut 3. Ball joint 9. O- -ring 14.
  • Page 141 Removal (Fig. 89) Installation (Fig. 89) 1. Park machine on a level surface, lower cutting 1. If fittings were removed from steering cylinder, lubri- decks, stop engine, engage parking brake and remove cate and place new O--rings onto fittings. Install fittings key from the ignition switch.

  • Page 142: Steering Cylinder Service

    Steering Cylinder Service 30 to 36 ft- -lb (41 to 48 N- -m) Figure 90 1. Tube assembly 6. Piston 10. Head 2. Lock nut 7. O- -ring 11. Wiper 3. Seal 8. Back- -up seal 12. Retaining ring 4. O- -ring 9.
  • Page 143 Disassembly (Fig. 90) Assembly (Fig. 90) 1. Remove oil from steering cylinder into a drain pan by 1. Make sure all cylinder components are clean before slowly pumping the cylinder shaft. Plug both ports and assembly. clean the outside of the cylinder. 2.

  • Page 144: Engine Cooling Fan Motor

    Engine Cooling Fan Motor RIGHT 27 to 33 ft- -lb FRONT (37 to 44 N- -m) 16 17 12 to 14 ft- -lb (17 to 18 N- -m) Figure 91 1. Hydraulic fan motor 8. Washer 15. Hydraulic hose 2. O- -ring 9.
  • Page 145 5. Remove four (4) cap screws and washers used to se- 4. Position fan hub onto motor shaft and secure with cure fan (item 13) to fan hub. Remove fan. washer (item 8) and hex nut (item 9). Torque nut from 27 to 33 ft- -lb (37 to 44 N- -m).

  • Page 146: Engine Cooling Fan Motor Service

    Engine Cooling Fan Motor Service 33 ft- -lb (45 N- -m) Figure 93 1. Flange washer 7. Shaft seal 12. Idler gear 2. O- -ring 8. Backup gasket 13. Cap screw (4 used) 3. Front flange 9. Pressure seal 14. Dowel (2 used) 4.
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  • Page 148: Fan Control Manifold

    Fan Control Manifold RIGHT FRONT Figure 94 1. Fan control manifold 3. Flange head screw (2 used) 5. Bracket 2. Support bracket 4. Battery support 6. Deck manifold (GM 4500- -D shown) Hydraulic System Page 4 - - 114 Groundsmaster 4500--D/4700--D...
  • Page 149 Removal (Fig. 94) 50 ft- -lb NOTE: The ports on the manifold are marked for easy (68 N- -m) identification of components. Example: P1 is the gear pump connection port (see Hydraulic Schematics in Chapter 9 -- Foldout Drawings to identify the function of the hydraulic lines and cartridge valves at each port).

  • Page 150: Fan Control Manifold Service

    Fan Control Manifold Service 5 ft- -lb 5 ft- -lb 50 ft- -lb (6.8 N- -m) (6.8 N- -m) (68 N- -m) 25 ft- -lb (33.9 N- -m) 25 ft- -lb (33.9 N- -m) 25 ft- -lb (33.9 N- -m) 25 ft- -lb (33.9 N- -m) 20 ft- -lb...
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  • Page 152: Lift Control Manifold

    Lift Control Manifold RIGHT FRONT GROUNDSMASTER 4500- -D SHOWN Figure 97 1. Lift control manifold 4. Hydraulic oil filter 6. Flange head screw (2 used) 2. Filter mount bracket 5. Valve mount bracket 7. Deck control manifold 3. Filter head NOTE: The lift control manifolds used on Groundsmas- IMPORTANT: To prevent unexpected deck lower- ter 4500--D and 4700--D machines are different but they...
  • Page 153 WARNING GROUNDSMASTER 4500- -D Make sure that cutting decks are fully lowered before loosening hydraulic lines from lift man- ifold. If decks are raised as hydraulic lines are 50 ft- -lb loosened, decks may drop unexpectedly. (68 N- -m) 6. Disconnect hydraulic lines from manifold and put caps or plugs on open hydraulic lines and fittings.
  • Page 154 Lift Control Manifold Service (GM 4500- -D) 5 ft- -lb (6.8 N- -m) 5 ft- -lb (6.8 N- -m) 25 ft- -lb (33.9 N- -m) 20 ft- -lb (27.1 N- -m) 25 ft- -lb (33.9 N- -m) 20 ft- -lb (27.1 N- -m) 20 ft- -lb (27.1 N- -m)
  • Page 155 IMPORTANT: A flow control orifice (item 6) is placed beneath the hydraulic fitting in lift control manifold WARNING port C2. If this fitting is removed from the manifold, make sure to remove orifice and label its position for assembly purposes. Also note location of If lift manifold is attached to machine, make sure groove in orifice for assembly purposes.
  • Page 156 Lift Control Manifold Service (GM 4700- -D) 20 ft- -lb (27.1 N- -m) 25 ft- -lb 5 ft- -lb (33.9 N- -m) (6.8 N- -m) 20 ft- -lb (27.1 N- -m) 20 ft- -lb (27.1 N- -m) 5 ft- -lb (6.8 N- -m) 25 ft- -lb (33.9 N- -m)
  • Page 157 25 ft- -lb 25 ft- -lb WARNING 20 ft- -lb (33.9 N- -m) (33.9 N- -m) (27.1 N- -m) If lift manifold is attached to machine, make sure that cutting decks are fully lowered before loos- ening hydraulic lines, cartridge valves or plugs from lift manifold.

  • Page 158: Lift Circuit Junction Manifold

    Lift Circuit Junction Manifold RIGHT FRONT Figure 103 1. Flange head screw (2 used) 5. 4WD/2WD control manifold 9. Flat washer (2 used) 2. Filter manifold bracket 6. Manifold bracket 10. Cap screw (2 used) 3. Filtration and charge control manifold 7.
  • Page 159 Removal (Fig. 103) 1. If fittings were removed from junction manifold, lubri- cate and place new O--rings onto fittings. Install fittings NOTE: The ports on the lift circuit junction manifold are into manifold openings making sure that orifice is cor- marked for easy identification of components (e.g.
  • Page 160 Lift Cylinders: Decks #1, #4 and #5 RIGHT FRONT Figure 105 1. Lift arm (deck #4) 6. O- -ring 10. Lift cylinder (deck #4) 2. Flange nut 7. 90 hydraulic fitting 11. Lift cylinder (deck #1) 3. Lift arm (deck #1) 8.
  • Page 161 Removal (Fig. 105) Installation (Fig. 105) 1. Park machine on a level surface, lower cutting 1. If fittings were removed from lift cylinder, lubricate decks, stop engine, engage parking brake and remove and place new O--rings onto fittings. Install fittings into key from the ignition switch.
  • Page 162 Lift Cylinders: Decks #2 and #3 RIGHT FRONT Figure 107 1. Lift arm (deck #2 shown) 6. O- -ring 11. Lift cylinder 2. Cylinder pin 7. Retaining ring 12. Flange nut 3. Flange head screw 8. Cylinder pin 13. Rotation stop 4.
  • Page 163 Removal (Fig. 107) 2. Position cylinder barrel clevis to frame and insert cyl- inder pin (item 8) with one (1) retaining ring installed 1. Park machine on a level surface, lower cutting through the frame and cylinder clevis. Secure pin with decks, stop engine, engage parking brake and remove second retaining ring.
  • Page 164 Lift Cylinders: Decks #6 and #7 (GM 4700- -D) RIGHT FRONT Figure 109 1. Retaining ring 7. Plastic roller 12. O- -ring 2. Cylinder pin 8. Rear link 13. Grease fitting 3. Thrust washer 9. Lock nut 14. O- -ring 4.
  • Page 165 Removal (Fig. 109) 2. Position cylinder barrel clevis to support frame and insert cylinder pin (item 2) into frame and clevis. Secure 1. Park machine on a level surface, lower cutting pin with retaining ring. decks, stop engine, engage parking brake and remove key from the ignition switch.

  • Page 166: Lift Cylinder Service

    Lift Cylinder Service See text for torque specification Figure 111 1. Tube assembly 6. O- -ring 11. Head 2. Lock nut 7. O- -ring 12. Wiper 3. Wear ring 8. Back- -up ring 13. Rod assembly 4. Seal 9. Seal 14.
  • Page 167 Disassembly (Fig. 111) Assembly (Fig. 111) 1. Remove oil from lift cylinder into a drain pan by slowly 1. Make sure all cylinder components are clean before pumping the cylinder shaft. Plug both ports and clean assembly. the outside of the cylinder. 2.

  • Page 168: Hydraulic Reservoir

    Hydraulic Reservoir RIGHT FRONT 68 to 75 ft- -lb (93 to 101 N- -m) 154 to 170 ft- -lb (209 to 230 N- -m) 36 to 40 ft- -lb (49 to 54 N- -m) Figure 112 1. Plug 14. Screen filter 27.
  • Page 169 Removal (Fig. 112) Inspection 1. Park machine on a level surface, lower cutting 1. Clean hydraulic reservoir and suction strainer with decks, stop engine, engage parking brake and remove solvent. key from the ignition switch. 2. Inspect reservoir for leaks, cracks or other damage. 2.

  • Page 170: Hydraulic Oil Cooler

    Hydraulic Oil Cooler RIGHT FRONT Figure 113 1. Oil cooler 7. Plenum 12. Hydraulic hose (2 used) 2. Mount plate (2 used) 8. Flange nut (4 used) 13. Cap screw (2 used) 3. Flange head screw (8 used) 9. O- -ring 14.
  • Page 171 Removal (Fig. 113) 2. Install oil cooler using Figures 113, 114 and 115 as guides (see Hydraulic Hose and Tube Installation in the General Information section of this chapter). CAUTION 3. Fill reservoir with hydraulic fluid as required. The radiator and oil cooler may be hot. To avoid possible burns, allow the engine and cooling systems to cool before working on the oil cooler.
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  • Page 173: Electrical Drawings 5

    Engine Cooling Fan Switch ....Toro Electronic Controllers (TEC) ....

  • Page 174: General Information

    4700--D is provided with a CAN--bus system (see be- low). Figure 1 Because of the solid state circuitry built into the Toro 1. Toro Electronic Controller (GM 4500- -D shown) Electronic Controller (TEC), there is no method to test CAN- -bus Communications (Groundsmaster 4700- -D) The two (2) TEC controllers (TEC--5002 and Two (2) specially designed, twisted cables form the bus.

  • Page 175: Electrical Drawings

    Electrical Drawings The electrical schematics and other electrical drawings for the Groundsmaster 4500--D and Groundsmaster 4700--D are located in Chapter 9 -- Foldout Drawings. Groundsmaster 4500--D/4700--D Page 5 - - 3 Electrical System...

  • Page 176: Special Tools

    The multimeter can test electrical components and cir- cuits for current (amps), resistance (ohms) or voltage. Obtain this tool locally. NOTE: Toro recommends the use of a DIGITAL Volt-- Ohm--Amp multimeter when testing electrical circuits. The high impedance (internal resistance) of a digital me- ter in the voltage mode will make sure that excess cur- rent is not allowed through the meter.

  • Page 177: Diagnostic Display

    Toro Electronic Controllers (TEC) inputs and outputs can be checked using the Diagnostic Display. Toro Part Number for Diagnostic Display: 85- -4750 Toro Part Number for Overlay (English): TEC--5002 (GM4500--D / GM4700--D): 117- -4795...

  • Page 178: Troubleshooting

    (GM 4500--D) or two (GM 4700--D) 1. Park machine on a level surface, lower the cutting Toro Electronic Controllers (TEC) which control ma- decks, stop the engine and apply the parking brake. chine electrical functions. The controllers monitor vari- ous input switches (e.g.
  • Page 179 5. The “inputs displayed” LED, on lower right column of the Diagnostic Display, should be illuminated. If “outputs TEC- -5002 displayed” LED is illuminated, press the toggle button on OVERLAY the Diagnostic Display to change to “inputs displayed” (BOTH LED. GM4500- -D 6.
  • Page 180 Diagnostic Display Inputs Diagnostic Display LED Operation P BRAKE OFF Parking brake released: LED ON Parking brake applied: LED OFF DECKS DOWN Main 5 (center) cutting decks lowered: LED ON Main 5 (center) cutting decks raised: LED OFF NEUTRAL Traction pedal in neutral: LED ON Traction pedal in forward or reverse: LED OFF SEAT SWITCH Operator seat occupied: LED ON...

  • Page 181: Verify Diagnostic Display Output Functions

    LED’s are not decks, stop the engine and engage the parking brake. correctly illuminated, this indicates a TEC controller problem. If this occurs, contact your Toro Distributor 2. Remove plate in front of seat to allow access to wire for assistance.

  • Page 182: Starting Problems

    Starting Problems Problem Possible Causes No electrical power to machine (including gauges). Battery is discharged. Battery cables are loose or corroded. Ground connection on machine is loose or corroded. The ignition switch or circuit wiring is faulty. Starter solenoid clicks, but starter will not crank. Battery is discharged.
  • Page 183 Starting Problems (continued) Problem Possible Causes Engine cranks, but does not start. Fuel tank is empty. Engine is not cranking fast enough. Engine and/or fuel may be too cold. Fuse F5--1 (40 amp) is faulty (open). Glow relay, glow plugs or fuse M1 (60 amp) are faulty. Engine run solenoid or circuit wiring is faulty.

  • Page 184: Cutting Deck Operating Problems

    Cutting Deck Operating Problems Cutting decks run, but should not, when raised. Decks The cutting deck position switch or circuit wiring is shut off with PTO switch. faulty. Wire harness connections are incorrectly connected to hydraulic solenoid valve coils on hydraulic deck control manifold.

  • Page 185: Electrical System Quick Checks

    Electrical System Quick Checks Battery Test (Open Circuit Test) Use a multimeter to measure the voltage between the Voltage Measured Battery Charge Level battery terminals. 12.68 V (or higher) Fully charged (100%) Set multimeter to the DC volts setting. The battery 12.45 V 75% charged should be at a temperature of 60...

  • Page 186: Check Operation Of Interlock Switches

    Replace any malfunctioning switches before op- NOTE: Use the Diagnostic Display (see Special Tools erating the machine. in this chapter) to test Toro Electronic Controller inputs and outputs before further troubleshooting of an electri- cal problem on your Groundsmaster. Electrical System...

  • Page 187: Component Testing

    Component Testing For accurate resistance and/or continuity checks, elec- trically disconnect the component being tested from the CAUTION circuit (e.g. unplug the ignition switch connector before checking continuity on the switch terminals). When testing electrical components for continu- NOTE: For engine component testing information, see ity with a multimeter (ohms setting), make sure the Kubota Workshop Manual, Diesel Engine, that power to the circuit has been disconnected.

  • Page 188: Fuses

    Fuses Groundsmaster 4500--D and 4700--D use numerous Fuse Testing fuses for circuit protection. The fuses are located in two 1. Make sure that ignition switch is OFF and key is re- (2) areas of the machine. Most of the fuses reside in the moved from switch.

  • Page 189: Indicator Lights

    Indicator Lights Charge Indicator Light The charge indicator light should come on when the igni- tion switch is in ON with the engine not running or with an improperly operating charging circuit while the en- gine is running. To test the charge indicator light and circuit wiring, ground the white wire attached to alternator.

  • Page 190: Pto Switch

    PTO Switch The PTO switch is located on the console arm (Fig. 18). 7. After testing is completed, connect the wire harness The PTO switch is pulled up to engage the PTO and connector to the PTO switch. pushed in to disengage the PTO. 8.

  • Page 191: Cutting Deck Lift Switches

    Cutting Deck Lift Switches The cutting deck lift switches are used as inputs for the 7. After testing is completed, connect wire harness TEC controller to raise or lower the cutting decks. When connector to the lift switch. the front of a lift switch is depressed and held, the con- 8.
  • Page 192 Hi- -Low Speed and Headlight Switches The Hi--Low speed switch is located on the console arm (Fig. 23). This two position rocker switch allows the trac- tion speed to be set to high speed (transport) or low speed (mow). The headlight switch is located on the operator side of the console arm (Fig.

  • Page 193: Engine Cooling Fan Switch

    Engine Cooling Fan Switch The engine cooling fan switch is located on the outside of the console arm (Fig. 25). This two position rocker switch allows the engine cooling fan to run in the normal, automatic mode or in the manual reverse (momentary) direction.

  • Page 194: Seat Switch

    Seat Switch The seat switch is normally open and closes when the operator is on the seat. The seat switch and its electrical connector are located in the seat assembly. If the trac- tion system or PTO switch is engaged when the operator raises out of the seat, the engine will stop.

  • Page 195: Parking Brake Switch

    Parking Brake Switch The parking brake switch is a normally open proximity switch. The parking brake switch is attached to the bot- tom of the RH brake pedal (Fig. 28). When the parking brake is not applied, the parking brake detent is positioned near the target end of the parking brake switch so the switch is closed.

  • Page 196: Cutting Deck Position Switch

    Cutting Deck Position Switch The cutting deck position switch is a normally open prox- imity switch that is located on the traction unit frame (Fig. 30). The sensing plate is located on the cutting deck lift arm. The Groundsmaster 4500--D uses two (2) cutting deck position switches: for decks 4 and 5.

  • Page 197: Hour Meter

    Hour Meter The hour meter is located on the outside of the console arm. Hobbs 1. Connect the positive (+) terminal of a 12 VDC source QUARTZ to the positive (+) terminal of the hour meter. 0 0 0 0 HOURS 2.

  • Page 198: Glow And Main Power Relays

    Glow and Main Power Relays The glow and main power relays are located at the pow- 7. Disconnect voltage and test leads from the relay ter- er center behind the operator seat (Fig. 34). These re- minals. lays are attached to the wire harness with a four (4) wire 8.

  • Page 199: Start Relay

    Start Relay The start relay is located at the power center behind the 10.Secure relay to mounting bracket and connect wire operator seat. This relays is attached to the wire har- harness connector to relay. Install cover to power center. ness with a five (5) wire connector (Fig.

  • Page 200: Hydraulic Solenoid Valve Coils

    Hydraulic Solenoid Valve Coils Numerous hydraulic solenoid valve coils are used on 5. If solenoid coil resistance is incorrect, replace sole- the hydraulic control manifolds of Groundsmaster noid (see Hydraulic Solenoid Valve Coil Removal and 4500--D and 4700--D machines. When energized by the Installation in the Service and Repairs section of this TEC controller, these coils provide hydraulic circuit con- chapter).

  • Page 201: Engine Coolant And Hydraulic Oil Temperature Senders

    Engine Coolant and Hydraulic Oil Temperature Senders Two (2) identical temperature senders are used as in- 7. After allowing the sender to cool, install sender: puts for the TEC--5002 controller to identify if either the A. Install new O--ring on sender and thread sender engine coolant or hydraulic oil temperature has reached into port.

  • Page 202: Fuel Pump

    Fuel Pump The fuel pump is energized by the TEC--5002 controller when the ignition switch is either in the START or ON position. The fuel pump is attached to the left side frame rail. IMPORTANT: When testing fuel pump, make sure that pump is not operated without fuel.

  • Page 203: Temperature Sender

    Open hood to gain access to engine. C. Connect gray wire to sender. Apply skin--over grease (Toro Part No. 505--47) to sender terminal. CAUTION 6. Fill engine cooling system. Make sure engine is cool before removing the temperature sender from engine.

  • Page 204: Traction Neutral Switch

    Traction Neutral Switch The traction neutral switch is closed when the traction See Piston Pump Control Assembly in Chapter 4 -- Hy- pedal is in the neutral position and opens when the pedal draulic Systems for disassembly and assembly proce- is depressed in either direction.

  • Page 205: Service And Repairs

    Service and Repairs NOTE: For more component repair information, see the Kubota Workshop Manual, Diesel Engine, V2403--M--T--E3B at the end of Chapter 3 -- Kubota Die- sel Engines. Battery Storage If the machine will be stored for more than 30 days: 4.

  • Page 206: Battery Service

    Battery Service The battery is the heart of the electrical system. With regular and proper service, battery life can be extended. Additionally, battery and electrical component failure can be prevented. CAUTION When working with batteries, use extreme cau- tion to avoid splashing or spilling electrolyte. Electrolyte can destroy clothing and burn skin or eyes.

  • Page 207: Battery Testing

    Battery Testing C. Make sure battery terminals are free of corrosion. 1. Conduct a hydrometer test of the battery electrolyte. D. Measure the temperature of the center battery cell. IMPORTANT: Make sure the area around the cells is clean before opening the battery caps. E.

  • Page 208: Battery Charging

    Battery Charging CAUTION To minimize possible damage to the battery and allow the battery to be fully charged, the slow charging meth- od is presented here. This charging method can be ac- Do not charge a frozen battery because it can ex- complished with a constant current battery charger plode and cause injury.

  • Page 209: Hydraulic Solenoid Valve Coil

    Hydraulic Solenoid Valve Coil A hydraulic solenoid valve coil on a hydraulic control manifold can be replaced without opening the hydraulic system. Removal (Fig. 49) 1. Park machine on a level surface, lower cutting decks, stop engine and engage parking brake. Remove 5 ft- -lb key from ignition switch.
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  • Page 211: General Information 6

    Chapter 6 Axles, Planetaries and Brakes Table of Contents SPECIFICATIONS ......GENERAL INFORMATION .

  • Page 212: Specifications

    Specifications Item Specification Wheel lug nut torque (front and rear) 85 to 100 ft--lb (116 to 135 N--m) Steering cylinder bolt torque 100 to 125 ft--lb (136 to 169 N--m) Planetary, brake housing and wheel motor 75 to 85 ft--lb (102 to 115 N--m) mounting screw torque Rear wheel toe--in 0.125 in (3 mm)

  • Page 213: General Information

    General Information Operator’s Manual The Traction Unit Operator’s Manual provides informa- tion regarding the operation, general maintenance and maintenance intervals for your Groundsmaster ma- chine. Refer to this publication for additional information when servicing the machine. Groundsmaster 4500--D/4700--D Page 6 - - 3 Axles, Planetaries and Brakes...

  • Page 214: Service And Repairs

    Service and Repairs Brake Assembly 75 to 85 ft- -lb (102 to 115 N- -m) RIGHT 75 to 85 ft- -lb (102 to 115 N- -m) 85 to 100 ft- -lb FRONT (116 to 135 N- -m) Figure 1 1. Flange head screw (6 per planetary) 8.
  • Page 215 5. Install brake cable to pull rod on brake assembly. Brake cable end should be completely threaded onto CAUTION pull rod before tightening jam nut. 6. Install new o--ring on hydraulic wheel motor. Install When changing attachments, tires or perform- wheel motor (see Front Wheel Motors in Service and ing other service, use correct blocks, hoists and Repairs section of Chapter 4 -- Hydraulic System).

  • Page 216: Brake Inspection And Repair

    Brake Inspection and Repair Figure 4 1. Brake housing (LH shown) 6. Hitch pin (2 used) 11. Rotating actuator 2. Seal 7. Stationary disc (4 used) 12. Extension spring (3 used) 3. Pull rod 8. Rotating disc (3 used) 13. Ball (3 used) 4.
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  • Page 218: Planetary Wheel Drive Assembly

    Planetary Wheel Drive Assembly 75 to 85 ft- -lb (102 to 115 N- -m) RIGHT 75 to 85 ft- -lb FRONT (102 to 115 N- -m) 85 to 100 ft- -lb (116 to 135 N- -m) Figure 5 1. Flange head screw (6 per planetary) 8.
  • Page 219 3. Chock rear wheels and jack up front of machine (see Jacking Instructions in Chapter 1 -- Safety). Support ma- chine with appropriate jack stands. 4. Remove front wheel assembly. 5. Remove hydraulic wheel motor (see Front Wheel Motor Removal in the Service and Repairs section of Chapter 4 -- Hydraulic System).

  • Page 220: Planetary Wheel Drive Service

    Planetary Wheel Drive Service 118 to 144 in- -lb (13.3 to 16.3 N- -m) Figure 7 1. Spindle 11. Outer bearing cup 20. End cap 2. Boot seal 12. Outer bearing cone 21. Thrust plug 3. Oil seal 13. O- -ring 22.
  • Page 221 NOTE: The planetary wheel drive assembly can be ser- viced with the planetary installed to machine. If the spindle (item 1) needs to be removed from machine, see Planetary Wheel Drive Assembly in this section. Disassembly (Figs. 7 and 8) 1.
  • Page 222 F. Lightly oil bearing journals on spindle shaft. Slide 4. Install secondary carrier (item 28), secondary gear housing assembly onto spindle (item 1) taking care (item 27) and primary carrier (item 26) making sure that to not damage seal or spindle. Make sure that inner carrier gear teeth align with ring gear and spline on bearing in housing fully seats against spindle shaft spindle shaft.
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  • Page 224: Rear Axle Assembly

    Rear Axle Assembly 70 ft- -lb (94 N- -m) maximum 85 to 100 ft- -lb RIGHT (116 to 135 N- -m) FRONT Figure 9 1. Steering cylinder 9. Cap screw (2 used) 16. Hydraulic fitting 2. Needle bearing 10. Flat washer (2 used) 17.
  • Page 225 7. Remove hydraulic hose from hydraulic fitting on side 8. Install wheels to axle. Lower machine to ground. of input gear case. Torque wheel lug nuts from 85 to 100 ft- -lb (116 to 135 N- -m). 8. Remove lock nut and flat washer from axle pivot pin. 9.

  • Page 226: Rear Axle Service

    Rear Axle Service Figure 12 Axles, Planetaries and Brakes Page 6 - - 16 Groundsmaster 4500--D/4700--D...
  • Page 227 Figure 12 (Continued) 1. LH axle support 23. RH axle support 44. Bevel gear (17 tooth) 2. Flange bushing (2 used) 24. Input shaft assembly 45. Bevel gear shaft 3. Axle vent 25. Bolt (8 used) 46. Axle case (LH shown) 4.

  • Page 228: Bevel Gear Case And Axle Case

    Bevel Gear Case and Axle Case The following procedures assume the rear axle assem- 35 to 41 ft- -lb bly has been removed from the machine. (47 to 56 N- -m) Removal 1. Remove the mounting screws, nuts and lock wash- ers.
  • Page 229 5. Remove the knuckle pin mounting screws and the knuckle pin. Remove the gasket and any remaining gas- ket material from either mating surface (Fig. 16). 6. While holding the bevel gear case, tap the upper end 17 to 20 ft- -lb (23 to 27 N- -m) of the bevel gear shaft out of the upper bearing and up- per bevel gear.
  • Page 230 Installation 1. Coat new shaft seal with grease and install in axle case as shown (Fig. 18). Figure 18 1. Axle case 3. Shaft seal 2. Bevel gear case 2. Install the lower bevel gear and bevel gear shaft in the axle case cover.
  • Page 231 5. Determine necessary quantity of support shims. 57 to 67 ft- -lb A. Lubricate the axle case support bushing with a (77 to 91 N- -m) thin coat of grease and slide axle case support onto knuckle pin. B. Position support shims that were removed during VERTICAL disassembly between axle case support and axle ENDPLAY...

  • Page 232: Differential Shafts

    9. Remove the bevel gear case/axle case assembly NOTE: Axle bearing shims are available in 0.008 in. from the axle support. Coat a new O-ring with grease (0.2 mm), 0.012 in. (0.3 mm) and 0.020 in. (0.5 mm) and temporarily install the axle cover assembly. Position thickness.

  • Page 233: Axle Shafts

    Axle Shafts The following procedures assume the rear axle assem- 17 to 20 ft- -lb bly has been removed from the machine. (23 to 27 N- -m) Removal 1. Remove the axle cover mounting screws. Remove the axle cover from the axle case as an assembly (Fig.

  • Page 234: Input Shaft/Pinion Gear

    Input Shaft/Pinion Gear 35 to 41 ft- -lb (47 to 56 N- -m) 35 to 41 ft- -lb (47 to 56 N- -m) Figure 28 1. Nut (2 used) 8. Seal collar 15. Gear case 2. Lock washer (2 used) 9.
  • Page 235 5. Install a new stake washer. Install the lock nut finger tight. 6. Set the bearing preload by securing the bearing case in a vise. Thread a M12 x 1.5 hex head cap screw into the splined end of the input shaft/pinion gear and slowly tighten the lock nut until 4 to 6 in-lb (0.4 to 0.7 N--m) of 0.040 in.

  • Page 236: Differential Gear

    Differential Gear The following procedures assume the rear axle assem- 35 to 41 ft- -lb bly has been removed from the machine. (47 to 56 N- -m) Removal 1. Remove bevel gear case/axle case assemblies (see Bevel Gear Case/Axle Case Assembly in this section of this manual).
  • Page 237 Inspection 1. Measure the differential side gear O.D. and the dif- ferential case I.D. to determine the side gear to case clearance (Fig. 35). Replace components as necessary. SIDE GEAR TO CASE CLEARANCE: 0.002 to 0.012 in. (0.05 to 0.30 mm) SIDE GEAR O.D.
  • Page 238 Installation 1. If the ring gear was removed from the differential case, use medium strength Loctite thread locker and tighten the mounting screws from 22 to 25 ft-lb (30 to 34 N- -m). 2. Apply molybdenum disulfide lubricant (Three Bond 1901 or equivalent) to the splines and bearing surfaces of the differential pinion gears, pinion washers and side gears.

  • Page 239: Pinion Gear To Ring Gear Engagement

    Pinion Gear to Ring Gear Engagement The final position of the pinion gear is verified by using PROFILE the gear contact pattern method as described in the fol- TOP LAND lowing procedure. GEAR TOOTH DEFINITIONS (Fig. 39): Toe -- the portion of the tooth surface at the end to- LENGTHWISE wards the center.
  • Page 240 Gear Pattern Movement Summary Heel Contact Base Contact Every gear has a characteristic pattern. The illustrations show typical patterns only and explain how patterns shift as gear location is changed. 1. If contact is toward the heel or base of the gear (Fig. 42): A.
  • Page 241 Chapter 7 Chassis Table of Contents GENERAL INFORMATION ..... Operator’s Manual ......Cutting Deck Identification .

  • Page 242: General Information

    General Information Operator’s Manual The Traction Unit and Cutting Deck Operator’s Manuals provide information regarding the operation, general maintenance and maintenance intervals for your Groundsmaster machine. Refer to these publications for additional information when servicing the machine. Cutting Deck Identification Cutting decks on the Groundsmaster 4500--D and 4700--D are identified as shown in Figure 1.
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  • Page 244: Service And Repairs

    Service and Repairs Steering Column RIGHT FRONT 20 to 26 ft- -lb (28 to 35 N- -m) ANTISEIZE LUBRICANT 7 to 10 ft- -lb (9.5 to 13.5 N- -m) ANTISEIZE LUBRICANT Figure 2 1. Steering wheel cover 6. Flange head screw (4 used) 10.
  • Page 245 7. Slide rubber bellows up steering column to allow ac- cess to fasteners that secure steering control valve and steering column to machine. 8. Support steering control valve to prevent it from shif- ting during steering column removal. 9. Loosen and remove four (4) socket head screws (item 13) that secure steering control valve to steering column.

  • Page 246: Console Arm

    Console Arm RIGHT FRONT Figure 5 1. Console arm frame 17. Flange nut (2 used) 32. Foam seal 2. LH cover 18. Ignition switch 33. Power point 3. RH cover 19. Indicator light (charge/oil pressure) 34. Cap 4. Washer head screw (10 used) 20.
  • Page 247 Disassembly (Fig. 5) 1. Park machine on a level surface, lower cutting units, stop engine and engage parking brake. Remove key from ignition switch. 2. Remove two (2) flange head screws (item 8) and then cover plate (item 7) from outside of console arm. Locate and retrieve two (2) flange spacers (item 37).

  • Page 248: Lift Arms For Cutting Decks #1, #4 And #5

    Lift Arms for Cutting Decks #1, #4 and #5 RIGHT FRONT Figure 7 1. Flat washer 13. Slotted roll pin 25. Deck position switch 2. Flange nut 14. Lift cylinder pin 26. Switch plate 3. Lift arm (#1 deck) 15. Flange nut 27.
  • Page 249 5. Loosen and remove lock nut (item 11) from lift arm pivot pin. #4 Deck #1 Deck #5 Deck 6. Support lift arm and pull lift arm pivot pin from lift arm and frame. Locate and remove thrust washer from rear of lift arm during pivot pin removal.

  • Page 250: Lift Arms For Cutting Decks #2 And #3

    Lift Arms for Cutting Decks #2 and #3 RIGHT FRONT Loctite #242 Figure 10 1. Grease fitting 7. Pivot pin 13. Flange nut 2. Set screw (2 used per stop) 8. Bumper 14. Thrust washer 3. Rotation stop 9. Thrust washer 15.
  • Page 251 Removal (Fig. 10) 7. After assembly, raise and lower the cutting deck to verify that hydraulic hoses and fittings do not contact 1. Park machine on a level surface, lower cutting anything. decks, stop engine, engage parking brake and remove key from the ignition switch.

  • Page 252: Lift Arms For Cutting Decks #6 And #7 (Groundsmaster 4700--D)

    Lift Arms for Cutting Decks #6 and #7 (Groundsmaster 4700- -D) 135 to 165 ft- -lb (184 to 223 N- -m) 135 to 165 ft- -lb (184 to 223 N- -m) RIGHT FRONT Figure 12 1. Retaining ring 15. Thrust washer 29.
  • Page 253 Removal (Fig. 12) 1. Park machine on a level surface, lower cutting #4 Deck #1 Deck #5 Deck decks, stop engine, engage parking brake and remove key from the ignition switch. 2. Remove cutting deck from lift arm (see Cutting Deck Operator’s Manual).

  • Page 254: Operator Seat

    Operator Seat RIGHT FRONT Figure 14 1. Seat frame 12. Hair pin 23. Arm support 2. Seat plate 13. Seat pivot shaft 24. Support bracket 3. Torsion spring 14. Seat belt buckle 25. Flange head screw (4 used) 4. Seat plate latch 15.
  • Page 255 Removal (Fig. 14) C. Place flat washer (item 11), seat belt buckle (item 14) and spacer (item 26) between seat and console 1. Park machine on a level surface, lower cutting arm support (item 23). Secure with cap screw (item decks, stop engine, apply parking brake and remove 27).

  • Page 256: Operator Seat Service

    Operator Seat Service Figure 16 1. Backrest cushion 12. Cap screw (2 used) 22. RH adjustment rail 2. Seat cushion 13. Seat 23. Rail stop 3. LH armrest cover 14. Nut 24. Torx screw 4. LH armrest 15. Spring (2 used) 25.
  • Page 257 Disassembly (Fig. 16) Assembly (Fig. 16) 1. Remove seat from machine for service (see Opera- 1. Assemble operator seat using Figure 16 as a guide. tor Seat Removal in this section). 2. Install seat to machine (see Operator Seat Installa- 2.
  • Page 258 Operator Seat Suspension RIGHT FRONT Figure 17 1. Cover 14. Washer (2 used) 27. Clamp (2 used) 2. Cover 15. Tether 28. Hose nipple 3. Level control 16. Rivet (2 used) 29. Screw 4. Air control valve 17. Washer (4 used) 30.
  • Page 259 NOTE: Most of the seat suspension components can be serviced with the seat suspension base mounted to the seat plate. If the air spring assembly (item 6) requires removal, the seat suspension base will have to be re- moved from the seat plate. Disassembly (Fig.

  • Page 260: Hood

    Hood RIGHT FRONT Figure 19 1. Screen 12. Rubber bumper (2 used) 23. LH hood frame tube 2. Latch keeper 13. Flange nut (2 used) 24. Hood frame tube 3. Pop rivet (2 used) 14. Bulb seal (2 used) 25. Flange head screw (26 used) 4.
  • Page 261 Removal (Fig. 19) Installation (Fig. 19) 1. Park machine on a level surface, lower cutting 1. If components were removed from hood, assemble decks, stop engine, engage parking brake and remove hood using Figure 19 as a guide. key from the ignition switch. 2.
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  • Page 263: Troubleshooting 8

    Chapter 8 Cutting Decks Table of Contents SPECIFICATIONS ......GENERAL INFORMATION ..... Operator’s Manual .

  • Page 264: Specifications

    Specifications Groundsmaster 4500- -D Groundsmaster 4700- -D MOUNTING: All cutting decks are supported by inde- DISCHARGE: Clippings are discharged from the rear of pendent lift arms and are interchangeable to any cutting the mowing decks. Pre--drilled mounting holes allow at- deck positions.

  • Page 265: General Information

    General Information CAUTION Never install or work on the cutting decks or lift arms with the engine running. Always stop en- gine and remove key from ignition switch first. Operator’s Manual The Cutting Deck Operator’s Manual provides informa- tion regarding the operation, general maintenance and maintenance intervals for the cutting deck on your Groundsmaster machine.

  • Page 266: Troubleshooting

    Troubleshooting There are a number of factors that can contribute to un- Remember that the “effective” or actual height--of--cut satisfactory quality of cut, some of which may be turf depends on cutting deck weight, counterbalance setting conditions. Turf conditions such as excessive thatch, and turf conditions.

  • Page 267: Special Tools

    Special Tools Order special tools from your Toro Distributor. Rear Roller Bearing and Seal Installation Tools These tools are used to assemble the cutting deck rear roller. Inner Seal Toro Part Numbers: Tool Inner Seal Tool 115- -0852 Bearing/Outer Seal Tool...

  • Page 268: Adjustments

    Adjustments CAUTION Never install or work on the cutting decks or lift arms with the engine running. Always stop en- gine and remove key from ignition switch first. See the Cutting Deck Operator’s Manual for adjustment procedures for cutting decks on the Groundsmaster 4500--D and Groundsmaster 4700--D.
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  • Page 270: Service And Repairs

    Service and Repairs CAUTION Never install or work on the cutting decks or lift arms with the engine running. Always stop en- gine and remove key from ignition switch first. Blade Spindle Assembly RIGHT 88 to 108 ft- -lb (120 to 146 N- -m) FRONT Figure 3 1.
  • Page 271 Removal (Fig. 3) 1. Park machine on a level surface, lower cutting decks, stop engine, engage parking brake and remove key from the ignition switch. 2. Remove two (2) socket head screws and flat wash- ers that secure hydraulic motor to the cutting deck (Fig. 4).

  • Page 272: Blade Spindle Service

    Blade Spindle Service Disassembly (Fig. 5) 1. Remove blade spindle from cutting deck (see Blade Spindle Removal in this section). 2. Loosen and remove spindle nut from top of spindle 130 to 160 ft- -lb (177 to 216 N- -m) shaft.
  • Page 273 3. Using an arbor press, push the bearing cups into the top and bottom of the spindle housing. The top bearing PRESS cup must contact the outer bearing spacer previously installed, and the bottom bearing cup must contact the large snap ring. Make sure that the assembly is correct by supporting the first bearing cup and pressing the sec- ond cup against it (Fig 7).

  • Page 274: Rear Roller

    Rear Roller 29 to 35 ft- -lb (40 to 47 N- -m) RIGHT FRONT 29 to 35 ft- -lb (40 to 47 N- -m) Figure 9 1. Deck frame 4. Roller shaft screw 7. Skid bracket 2. Rear roller assembly 5.
  • Page 275 Removal (Fig. 9) 30 ft- -lb 1. Park machine on a level surface, lower cutting (41 N- -m) decks, stop engine, engage parking brake and remove key from the ignition switch. 2. If cutting deck is equipped with a roller scraper (Fig. 29 to 35 ft- -lb 10), remove fasteners securing left and right scraper rod (40 to 47 N- -m)

  • Page 276: Rear Roller Service

    Rear Roller Service Disassembly (Fig. 11) 50 to 60 ft- -lb 1. Remove bearing lock nut from each end of roller (68 to 81 N- -m) shaft. 2. Loosely secure roller assembly in bench vise and lightly tap one end of roller shaft until outer seals and bearing are removed from opposite end of roller tube.
  • Page 277 3. From the roller tube end with only the inner seal NOTE: After roller is installed to cutting deck, lubricate installed, carefully install the roller shaft into the roller roller grease fittings, rotate roller to properly distribute tube. Make sure that seals are not damaged as shaft is grease in bearings and clean excess grease from roller installed.

  • Page 278: Front Roller Service

    Front Roller Service Disassembly (Fig. 17) 1. Remove roller mounting bolt. 2. Remove roller assembly from carrier frame. 3. To remove bearings and bearing spacer: A. Insert punch through end of roller and drive oppo- site bearing out by alternating taps to opposite side of inner bearing race.
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  • Page 280: Cutting Deck Carrier Frame

    Cutting Deck Carrier Frame Decks #2 and #3 Decks #1, #4 and #5 Decks #6 and #7 RIGHT FRONT Figure 18 1. Carrier frame 7. Hardened washer (2 used per deck) 13. Lock nut 2. Lynch pin 8. Cap screw (2 used per deck) 14.
  • Page 281 Removal and Installation (Fig. 18) Each cutting deck is suspended from a carrier frame. #4 Deck #1 Deck #5 Deck The cutting deck carrier frame is attached to the lift arm and allows the cutting deck to pivot on the lift arm pivot shaft.
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  • Page 283: Hydraulic Schematics

    Chapter 9 Foldout Drawings Table of Contents HYDRAULIC SCHEMATICS Groundsmaster 4500--D ..... . Groundsmaster 4700--D ..... . ELECTRICAL SCHEMATIC Groundsmaster 4500--D/4700--D (3 Sheets) .
  • Page 284 This page is intentionally blank. Foldout Drawings Page 9 - 2 Groundsmaster 4500--D/4700--D...
  • Page 285 STEERING CYLINDER FRONT PORTS BYPASS VALVE Groundsmaster 4500--D Hydraulic Schematic Page 9 - 3...
  • Page 286 STEERING CYLINDER FRONT PORTS BYPASS VALVE Groundsmaster 4700--D Hydraulic Schematic Page 9 - 4...
  • Page 287 Groundsmaster 4500--D/4700--D Electrical Schematic Sheet 1 of 3 All relays and solenoids are shown as de- - energized. All ground wires are black. Page 9 - 5...
  • Page 288 Groundsmaster 4500--D/4700--D Electrical Schematic Sheet 2 of 3 All relays and solenoids are shown as de- - energized. All ground wires are black. Page 9 - 6...
  • Page 289 Groundsmaster 4500--D/4700--D Electrical Schematic Sheet 3 of 3 (Groundsmaster 4700--D) All relays and solenoids are shown as de- - energized. All ground wires are black. Page 9 - 7...
  • Page 290 Groundsmaster 4500--D/4700--D Main Wire Harness Page 9 - 8...
  • Page 291 WHITE/BLACK BROWN/BLACK TAN/BLACK GRAY/BLACK BLUE PINK/BLACK ORANGE/WHITE PINK/WHITE ORANGE BLACK BLACK BROWN PINK WHITE/BLACK BLACK BLACK RED/WHITE RED/BLACK BLACK/WHITE BLACK BLACK BLACK BLACK BLACK BLACK BLUE BLACK BLACK BLACK BLACK BLACK Groundsmaster 4500--D/4700--D Main Wire Harness Page 9 - 9...
  • Page 292 Groundsmaster 4500--D/4700--D Seat and Console Wire Harness Page 9 - 10...
  • Page 293 GRAY BLUE/BLACK RED/YELLOW PINK/BLACK BLACK RED/GREEN BLACK PINK PINK BLACK BLACK BLACK BLACK BLACK BLACK BLACK BLACK Groundsmaster 4500--D/4700--D Seat and Console Wire Harness Page 9 - 11...
  • Page 294 Groundsmaster 4500--D/4700--D Power Center Wire Harness Page 9 - 12...
  • Page 295 VIOLET BLACK WHITE/BLACK BROWN/BLACK TAN/BLACK GRAY/BLACK BLUE PINK/BLACK BLACK ORANGE ORANGE BLACK BLACK WHITE/YELLOW BLUE BROWN PINK RED/BLUE RED/GREEN WHITE/BLACK BROWN/BLACK TAN/BLACK GRAY/BLACK Groundsmaster 4500--D/4700--D Power Center Wire Harness Page 9 - 13...
  • Page 296 Groundsmaster 4700--D Deck 6 and 7 Wire Harness Page 9 - 14...
  • Page 297 GRAY/BLACK VIOLET BLACK BLUE PINK/BLACK BROWN/BLACK BLACK PINK PINK/WHITE ORANGE/WHITE BLACK GREEN/BLACK ORANGE/BLACK BLACK BLACK BLACK BLACK WHITE/BLUE PINK/BLACK BLACK BLACK BLACK BLACK BLACK BLACK TAN/BLACK TAN/WHITE BLUE/BLACK YELLOW/BLUE BLACK WHITE/BLACK YELLOW/BLACK BLACK BLACK VIOLET/BLACK ORANGE GREEN/PINK BLACK BLACK/WHITE RED/WHITE PINK BLACK BLACK...

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