Form No.
Revision History Revision Date Description -- 2009 A 03/2018 Added revision history. B 05/2018 Added VA02 series planetary information. Initial Issue. © THE TORO COMPANY 2018 This document and all information contained herein is the sole property of The Toro Company (and/or its affiliated companies). No intellectual property rights are granted by the delivery of this document or the disclosure of its content.
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Part No. 09172SL Rev. B Service Manual (Models 30857 and 30858) GroundsmasterR 4500−D/4700−D 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 INSTRUCTIONS.
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Product Records . . . . . . . . . . . . . . . . . . . . . . . . . . . Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Equivalents and Conversions . . . . . . . . . . . . . . . . Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . 2−1 2−1 2−2 2−3 Chapter 3 − Kubota Diesel Engine Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 − 2 General Information . . . . . . . . . . . . . . . . . . . . . . . . 3 − 3 Service and Repairs . . . . . . .
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Safety Table of Contents GENERAL SAFETY INSTRUCTIONS . . . . . . . . . . . . Before Operating . . . . . . . . . . . . . . . . . . . . . . . . . . . . While Operating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Maintenance and Service . . . . . . . . . . . . . . . . . . . . JACKING INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . SAFETY AND INSTRUCTION DECALS . . . . . . . . . .
General Safety Instructions The Groundsmaster 4500-D and 4700--D have been tested and certified by TORO for compliance with existing safety standards and specifications. Although hazard control and accident prevention partially are dependent upon the design and configuration of the machine, these factors are also dependent upon the awareness, concern and proper training of the personnel involved in the operation, transport, maintenance and storage of the machine.
1. 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. 11. Do not overspeed the engine by changing governor setting. To assure safety and accuracy, check maximum engine speed. 2.
Jacking Instructions CAUTION When changing attachments, tires or performing other service, use correct jacks and supports. Make sure machine is parked on a solid, level surface such as a concrete floor. Prior to raising machine, remove any attachments that may interfere with the safe and proper raising of the machine. Always chock or block wheels. Use jack stands to support the raised machine.
Safety 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. Decal part numbers are listed in your Parts Catalog.
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Product Records and Maintenance Table of Contents PRODUCT RECORDS . . . . . . . . . . . . . . . . . . . . . . . . . MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EQUIVALENTS AND CONVERSIONS . . . . . . . . . . . Decimal and Millimeter Equivalents . . . . . . . . . . . . U.S. to Metric Conversions . . . . . . . . . . . . . . . . . . . TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . Fastener Identification . . . . . . . . . . . . . . . . . . . . . . .
Equivalents and Conversions 0.
Recommended fastener torque values are listed in the following tables. For critical applications, as determined by Toro, either the recommended torque or a torque that is unique to the application is clearly identified and specified in this Service Manual. These Torque Specifications for the installation and tightening of fasteners shall apply to all fasteners which do not have a specific requirement identified in this Service Manual.
Standard Torque for Dry, Zinc Plated and Steel Fasteners (Inch Series) Thread Size # 6 -- 32 UNC Grade 1, 5 & 8 with Thin Height Nuts SAE Grade 1 Bolts, Screws, Studs & Sems with Regular Height Nuts (SAE J995 Grade 2 or Stronger Nuts) in--lb in--lb N--cm 10 + 2 13 + 2 147 + 23 # 6 -- 40 UNF # 8 -- 32 UNC 13 + 2 25 + 5 282 + 30 # 8 -- 36 UNF # 10 -- 24 UNC 18 + 2 30 + 5 339 + 56 # 10 -- 32 UNF SAE Grade 5 Bolts, Screws, Studs & Sems with Regular Height Nuts (SAE J995 Grade 2 or Stronger N
Thread Size Class 8.8 Bolts, Screws and Studs with Regular Height Nuts (Class 8 or Stronger Nuts) Class 10.9 Bolts, Screws and Studs with Regular Height Nuts (Class 10 or Stronger Nuts) M5 X 0.8 57 + 6 in--lb 644 + 68 N--cm 78 + 8 in--lb 881 + 90 N--cm M6 X 1.0 96 + 10 in--lb 1085 + 113 N--cm 133 + 14 in--lb 1503 + 158 N--cm M8 X 1.25 19 + 2 ft--lb 26 + 3 N--m 28 + 3 ft--lb 38 + 4 N--m M10 X 1.5 38 + 4 ft--lb 52 + 5 N--m 54 + 6 ft--lb 73 + 8 N--m M12 X 1.
Other Torque Specifications SAE Grade 8 Steel Set Screws Wheel Bolts and Lug Nuts Recommended Torque Thread Size Thread Size Square Head Hex Socket 1/4 -- 20 UNC 140 + 20 in--lb 73 + 12 in--lb 5/16 -- 18 UNC 215 + 35 in--lb 145 + 20 in--lb 3/8 -- 16 UNC 35 + 10 ft--lb 18 + 3 ft--lb 1/2 -- 13 UNC 75 + 15 ft--lb 50 + 10 ft--lb Recommended Torque** 7/16 -- 20 UNF Grade 5 65 + 10 ft--lb 88 + 14 N--m 1/2 -- 20 UNF Grade 5 80 + 10 ft--lb 108 + 14 N--m M12 X 1.25 Class 8.
Chapter 3 Kubota Diesel Engine Table of Contents Groundsmaster 4500--D/4700--D Page 3 -- 1 Kubota Diesel Engine SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . 3 Operator’s Manual . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Stopping the Engine . . . . . . . . . . . . . . . . . . . . . . . . . 3 SERVICE AND REPAIRS . . . . . . . . . . . . . . . . . . . . . . 4 Air Filter System . . . . . . . . . . . . . .
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 in3 (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 23.
General Information General maintenance procedures are described in your Traction Unit Operator’s Manual. Information on engine troubleshooting, testing, disassembly and assembly is identified in the Kubota Workshop Manual, Diesel Engine, V2403--M--T--E3B that is included at the end of this section. Most repairs and adjustments require tools which are commonly available in many service shops. Special tools are described in the Kubota Workshop Manual, Diesel Engine, V2403--M--T--E3B.
Service and Repairs Air Filter System RIGHT 27 12 to 15 in--lb (1.4 to 1.6 N--m) FRONT 13 26 14 24 12 28 23 11 VACUATOR DIRECTION 18 10 18 15 25 6 20 16 9 1 19 17 7 21 22 8 4 2 5 6 3 Figure 1 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. Battery support Bracket Flange head screw (8 used) Flange nut (8 used) Support bracket Cap screw (4 used) Flange nut (4 used) Fan drive manifold Air cleaner strap Cap screw (2 used) Kubota Diesel Engine 11. 12. 13. 14. 15. 16. 17. 18. 19.
Removal (Fig. 1) 2 1. Park machine on a level surface, lower cutting decks, stop engine, apply parking brake and remove key from the ignition switch. 4 2. Raise and support hood. 1 3. Remove air cleaner components as needed using Figure 1 as a guide. 3 Installation (Fig. 1) 1. Assemble air filter system using Figure 1 as a guide. 5 Figure 2 1. Air cleaner housing 2. Safety filter element 3. Air filter element A.
Exhaust System 2 RIGHT 1 4 16 to 22 ft--lb (21 to 29 N--m) 5 FRONT 6 15 3 9 10 3 16 7 10 8 7 13 ft--lb (17.6 N--m) 16 to 22 ft--lb (21 to 29 N--m) 13 6 8 12 14 12 11 16 to 22 ft--lb (21 to 29 N--m) 16 to 22 ft--lb (21 to 29 N--m) Figure 5 1. 2. 3. 4. 5. 6. Muffler Flange head screw (2 used) Flange head screw (6 used) Muffler clamp Exhaust pipe Flange nut (4 used) Kubota Diesel Engine 7. 8. 9. 10. 11.
Removal (Fig. 5) F CAUTION B D C 1. Park machine on a level surface, lower cutting decks, stop engine, engage parking brake and remove key from the ignition switch. A Kubota Diesel Engine The muffler and exhaust pipe may be hot. To avoid possible burns, allow the engine and exhaust system to cool before working on the muffler. 2. Raise and support hood. 3. Remove muffler and/or muffler bracket from the engine as necessary using Figure 5 as a guide. E Installation (Fig.
Fuel System 19 16 20 21 16 13 3 18 21 14 15 8 1 8 24 17 25 4 3 8 7 23 2 7 6 5 9 10 22 RIGHT FRONT 11 26 12 27 Figure 7 1. 2. 3. 4. 5. 6. 7. 8. 9. Fuel suction tube Fuel line clamp (2 used) Fuel hose (supply) Return fitting Fuel hose (return) Fuel tank cap Bushing (2 used) Hose clamp (6 used) Fuel tank Kubota Diesel Engine 10. 11. 12. 13. 14. 15. 16. 17. 18.
Fuel Tank Removal (Fig. 7) Because diesel fuel is highly flammable, use caution when storing or handling it. Do not smoke while filling the fuel tank. Do not fill fuel tank while engine is running, hot or when machine is in an enclosed area. Always fill fuel tank outside and wipe up any spilled diesel fuel before starting the engine. Store fuel in a clean, safety--approved container and keep cap in place. Use diesel fuel for the engine only; not for any other purpose. 1.
Radiator 35 46 24 23 RIGHT 10 43 7 42 39 2 11 12 3 37 38 5 15 22 6 18 4 15 40 13 18 3 29 15 FRONT 33 28 25 32 31 30 1 26 44 17 8 19 14 41 28 36 17 20 34 43 27 45 10 9 16 21 9 to 11 ft--lb (12.3 to 14.9 N--m) Figure 8 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16.
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 -- Chassis). CAUTION Do not open radiator cap or drain coolant if the radiator or engine is hot. Pressurized, hot coolant can escape and cause burns. Ethylene--glycol antifreeze is poisonous.
Engine 1 4 6 RIGHT 5 25 3 FRONT 7 9 7 10 3 33 10 8 29 2 32 8 32 14 28 26 23 22 12 11 13 24 31 15 30 22 16 23 20 19 21 27 17 18 17 Figure 10 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. Muffler Flange head screw (2 used) Flange head screw (6 used) Muffler clamp Exhaust pipe Flange nut (4 used) Flat washer (2 used) Cap screw (2 used) Rubber hanger Spacer (2 used) RH engine mount Kubota Diesel Engine 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22.
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. 5 2. Remove hood from the machine (see Hood Removal in the Service and Repairs section of Chapter 7 -- Chassis). 1 3. Remove battery cover. Disconnect negative battery cable first and then positive battery cable. 3 2 CAUTION Do not open radiator cap or drain coolant if the radiator or engine is hot.
11. Remove fan motor and fan assembly (Fig. 13). A. To prevent contamination of hydraulic system, thoroughly clean exterior of fan motor and fittings. 6 B. Disconnect hydraulic hoses from cooling fan motor. Put caps or plugs on fittings and hoses to prevent contamination. Label hydraulic lines for proper assembly. 3 4 1 5 C. Remove six (6) cap screws and flange nuts that secure fan motor bracket to radiator. D. Carefully remove fan motor, fan and motor bracket assembly from machine.
7. Position upper radiator shroud to the radiator. Secure shroud to the radiator and lower radiator bracket with removed fasteners (see Radiator Installation in this section). Make sure that clearance between shroud and fan is at least 0.180” (4.6 mm) at all points. 12.Using notes taken during engine removal, secure wires with cable ties in proper locations. 8. Connect throttle cable to the speed control lever with washer and lock nut. Install cable to mounting bracket. Adjust throttle cable. 14.
Pump Adapter Plate 1 2 RIGHT FRONT 29 to 33 ft--lb (40 to 44 N--m) Loctite #242 5 6 3 4 Boss 4 7 Figure 14 1. Bolt 2. Lock washer 3. Flywheel plate Kubota Diesel Engine 4. Hardened washer (14 used) 5. Spring coupler Page 3 -- 16 6. Bolt (6 used) 7.
Coupler Removal (Fig. 14) NOTE: The hydraulic pump assembly needs to be removed from engine before coupler can be removed. Engine Side Hydraulic Pump Side 1. If engine is in machine, remove hydraulic pump assembly (see Piston (Traction) Pump Removal in the Service and Repairs section of Chapter 4 -- Hydraulic System). 1 2. Remove flywheel plate and spring coupler from engine using Figure 14 as a guide. 1. Position spring coupler to engine flywheel and align mounting holes.
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Chapter 4 Hydraulic System SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . 4 Operator’s Manual . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Towing Traction Unit . . . . . . . . . . . . . . . . . . . . . . . . . 4 Check Hydraulic Fluid . . . . . . . . . . . . . . . . . . . . . . . 4 Relieving Hydraulic System Pressure . . . . . . . . . . 5 Traction Circuit Component Failure . . . . . . . . . . . .
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Specifications Item Description Piston (Traction) Pump Eaton variable displacement piston pump (Model 72400) 5000 PSI (345 bar) 5000 PSI (345 bar) System Relief Pressure: Forward System Relief Pressure: Reverse Charge Pressure 207 PSI (14.3 bar) Front Wheel Motors Eaton fixed displacement piston motors (Model 74315) 2.01 in3 (32.9 cc) Displacement (per revolution) Eaton fixed displacement piston motor (Model 74318) 2.48 in3 (40.
General Information Operator’s Manual The Operator’s Manual provides information regarding the operation, general maintenance and maintenance intervals for your Groundsmaster machine. Refer to that publication for additional information when servicing the machine. Towing Traction Unit IMPORTANT: If towing limits are exceeded, severe damage to the piston pump may occur. 1 If it becomes necessary to tow (or push) the machine, tow (or push) in a forward direction only, at a speed below 3 mph (4.
Relieving Hydraulic System Pressure Before disconnecting or performing any work on the hydraulic system, all pressure in the hydraulic system must be relieved. Park machine on a level surface, lower cutting decks fully, stop engine and apply parking brake. To relieve hydraulic pressure in traction circuit, move traction pedal to both forward and reverse directions. To relieve hydraulic pressure in steering circuit, rotate steering wheel in both directions.
Hydraulic Hoses Hydraulic hoses are subject to extreme conditions such as pressure differentials during operation and exposure to weather, sun, chemicals, very warm storage conditions or mishandling during operation and maintenance. These conditions can cause hose damage and deterioration. Some hoses are more susceptible to these conditions than others.
Hydraulic Hose and Tube Installation (O--Ring Face Seal Fitting) 1. Make sure threads and sealing surfaces of the hose/ tube and the fitting are free of burrs, nicks, scratches or any foreign material. C. Use a second wrench to tighten the nut to the correct Flats From Wrench Resistance (F.F.W.R.). The markings on the nut and fitting body will verify that the connection has been properly tightened. 2.
Hydraulic Fitting Installation (SAE Straight Thread O--Ring Fitting into Component Port) Non--Adjustable Fitting (Fig. 6) 1. Make sure all threads and sealing surfaces of fitting and component port are free of burrs, nicks, scratches or any foreign material. 5. If a torque wrench is not available, or if space at the port prevents use of a torque wrench, an alternate method of assembly is the Flats From Finger Tight (F.F.F.T.) method. 2.
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 recommended that the O--ring be replaced any time the connection is opened. Lock Nut 3. Lightly lubricate the O--ring with clean hydraulic oil. Fitting threads should be clean with no lubricant applied. Back--up Washer 4. Turn back the lock nut as far as possible.
Hydraulic System Page 4 -- 10 NOTE: A larger hydraulic schematic is included in Chapter 9 -- Foldout Drawings #1 #4 #5 #3 #2 TS BYPASS VALVE S5 R1 S6 TS TS All solenoids are shown as de--energized Groundsmaster 4500--D Hydraulic Schematic PS Hydraulic Schematics Groundsmaster 4500--D/4700--D
Groundsmaster 4500--D/4700--D Page 4 -- 11 Hydraulic System NOTE: A larger hydraulic schematic is included in Chapter 9 -- Foldout Drawings #1 #4 #6 #5 #3 #2 #7 BYPASS VALVE R1 Hydraulic System All solenoids are shown as de--energized Groundsmaster 4700--D Hydraulic Schematic
Hydraulic System TS BYPASS VALVE R1 S5 Page 4 -- 12 TS PS TS Working Pressure Low Pressure (Charge) Return or Suction Flow Groundsmaster 4500--D/4700--D Traction Circuit: Low Speed (GM 4500--D Forward Shown) S6 Hydraulic Flow Diagrams Groundsmaster 4500--D/4700--D
Traction Circuit: Low Speed (4WD) The traction circuit piston pump is a variable displacement pump that is directly coupled to the engine flywheel. Pushing the traction pedal engages a hydraulic servo valve which controls the variable displacement piston pump swash plate to create a flow of oil. This oil is directed to the front wheel and rear axle motors.
Hydraulic System Page 4 -- 14 Groundsmaster 4500--D/4700--D TS BYPASS VALVE R1 S5 TS TS (ENERGIZED) PS Working Pressure Low Pressure (Charge) Return or Suction Flow Groundsmaster 4500--D/4700--D Traction Circuit: High Speed (GM 4500--D Forward Shown) S6
Traction Circuit: High Speed (2WD) Traction circuit pressure (forward and reverse) can be measured at test ports located on the traction circuit hydraulic tubes of the machine. The traction circuit pump and motors use a small amount of hydraulic fluid for internal lubrication. Fluid is designed to leak across traction pump and motor components into the case drain. This leakage results in the loss of hydraulic fluid from the closed loop traction circuit that must be replaced.
Hydraulic System Page 4 -- 16 Groundsmaster 4500--D/4700--D TS BYPASS VALVE R1 S5 S6 TS (ENERGIZED) TS Working Pressure Low Pressure (Charge) Return or Suction Flow Groundsmaster 4500--D Lower Cutting Decks Lift Switch Pressed to Lower Decks PS
Lower Cutting Decks: Groundsmaster 4500--D On the Groundsmaster 4500--D, a single lift switch on the console arm is used to raise and lower the five (5) cutting decks (Fig. 10). When the cutting decks are in a stationary position (not raising or lowering), lift circuit flow from gear pump section P3 bypasses the lift cylinders through the lift control manifold solenoid valve S5 (de--energized) and proportional relief valve TS.
Hydraulic System Page 4 -- 18 Groundsmaster 4500--D/4700--D TS (ENERGIZED) BYPASS VALVE R1 (ENERGIZED) (ENERGIZED) (ENERGIZED) TS (ENERGIZED) (ENERGIZED) TS Working Pressure Low Pressure (Charge) Return or Suction Flow Groundsmaster 4700--D Lower Cutting Decks All Lift Switches Pressed to Lower Decks PS
Lower Cutting Decks: Groundsmaster 4700--D The Groundsmaster 4700--D has three (3) lift switches to control the cutting decks (Fig. 12). The center switch is for the five (5) center decks, the left switch controls the left, rear deck (#6) and the right switch controls the right, rear deck (#7) (Fig. 13).
Hydraulic System Page 4 -- 20 Groundsmaster 4500--D/4700--D TS BYPASS VALVE S5 (ENERGIZED) S6 TS TS Working Pressure Low Pressure (Charge) Return or Suction Flow Groundsmaster 4500--D Raise Cutting Decks Lift Switch Pressed to Raise Decks PS
Raise Cutting Decks: Groundsmaster 4500--D A four section gear pump is coupled to the piston (traction) pump. Gear pump section P3 supplies hydraulic flow to both the lift control manifold and the steering control valve. Hydraulic flow from this pump section is delivered to the circuits through a proportional flow divider located in the fan control manifold. Maximum lift/lower circuit pressure is limited to 1600 PSI (110 bar) by a relief valve (R1) in the lift control manifold.
Hydraulic System Page 4 -- 22 Groundsmaster 4500--D/4700--D TS BYPASS VALVE (ENERGIZED) (ENERGIZED) (ENERGIZED) R1 TS (ENERGIZED) TS Working Pressure Low Pressure (Charge) Return or Suction Flow Groundsmaster 4700--D Raise Cutting Decks All Lift Switches Pressed to Raise Decks PS
Raise Cutting Decks: Groundsmaster 4700--D A four section gear pump is coupled to the piston (traction) pump. Gear pump section P3 supplies hydraulic flow to both the lift control manifold and the steering control valve. Hydraulic flow from this pump section is delivered to the circuits through a proportional flow divider located in the fan control manifold. Maximum lift/lower circuit pressure is limited to 1600 PSI (110 bar) by a relief valve (R1) in the lift control manifold.
Hydraulic System Page 4 -- 24 Groundsmaster 4500--D/4700--D #1 #4 #5 #3 #2 (ENERGIZED) (ENERGIZED) TS BYPASS VALVE S5 R1 S6 TS TS Working Pressure Low Pressure (Charge) Return or Suction Flow Groundsmaster 4500--D/4700--D Mow Circuit (GM 4500--D Shown) PS
Mow Circuit Hydraulic flow for the mow circuit is supplied by two (2) sections of the gear pump (P1 and P2). Gear pump section P1 supplies hydraulic flow to decks 5, 3 and 2 (also 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). #4 Deck A single deck control manifold is used to control flow from the two (2) pump sections. The manifold includes cartridge valves for control of each of the two (2) pump circuits.
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 valves will shift to direct oil away from the deck motors and toward the oil cooler and filter. Hydraulic pressure is reduced to the cutting deck motors which slows the cutting blades and also allows the deck manifold relief valve (RV) to shift.
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Hydraulic System Page 4 -- 28 Groundsmaster 4500--D/4700--D TS BYPASS VALVE R1 S5 S6 PS TS Working Pressure Low Pressure (Charge) Return or Suction Flow Groundsmaster 4500--D/4700--D Steering Circuit (GM 4500--D Right Turn Shown) TS
Steering Circuit A four section gear pump is coupled to the piston (traction) pump. The gear pump section P3 supplies hydraulic flow to the steering control valve and the lift/lower control valve. Pump hydraulic flow is delivered to the two circuits through a proportional flow divider located in the fan control manifold. Steering circuit pressure is limited to 1050 PSI (72 bar) by a relief valve located in the steering control valve.
Hydraulic System Page 4 -- 30 Groundsmaster 4500--D/4700--D TS BYPASS VALVE R1 TS PS TS Working Pressure Low Pressure (Charge) Return or Suction Flow Groundsmaster 4500--D/4700--D Engine Cooling Fan Circuit (GM 4500--D Normal Fan Direction Shown) S5 S6
Engine Cooling Fan Circuit The fan control manifold controls the operation of the hydraulic motor that drives the engine cooling fan in addition to including the flow divider for the steering and lift circuits. The electronically controlled proportional relief valve (TS) in the manifold controls the oil flow to the fan motor. The fan control manifold controls the speed and direction of the fan motor based on electrical output from the TEC--5002 controller.
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. Contains one each: 1000 PSI (70 Bar), 5000 PSI (350 Bar) and 10000 PSI (700 Bar) gauges. Use gauges as recommended in Testing section of this chapter.
Hydraulic Test Fitting Kit 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 Hydraulic System Use this container for doing hydraulic motor efficiency testing (motors with case drain lines only).
O--ring Kit The kit includes O--rings in a variety of sizes for face seal and port seal hydraulic connections. It is recommended that O--rings be replaced whenever a hydraulic connection 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.
Troubleshooting The charts that follow contain information to assist in hydraulic system troubleshooting. There may possibly be more than one cause for a machine malfunction. Refer to the Testing section of this Chapter for precautions and specific testing procedures. General Hydraulic System Problems Problem Possible Cause Hydraulic system operates hot. Engine RPM is too low.
Traction Circuit Problems NOTE: When troubleshooting traction circuit problems, if a problem exists in both low (4WD) and high (2WD) speeds, consider a faulty component that affects the entire traction circuit (e.g. charge circuit, relief valves, pis- ton pump, front wheel motors). If the problem exists in low speed (4WD) but not in high speed (2WD), consider a problem in the 4WD traction system (e.g. rear axle motor, cartridge valves in 4WD/2WD control manifold).
PTO Problems Problem Possible Cause No cutting decks will operate. Decks are not fully lowered to ground. NOTE: Decks have to be fully lowered and traction speed needs to be in low speed (4WD) for decks to operate. Operator seat is unoccupied. Traction system is in high speed (2WD). Electrical problem exists that prevents deck control manifold solenoid valve operation (see Chapter 5 -- Electrical System). Gear pump sections P1 and P2 are damaged.
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. very tall or wet grass) exceed deck capacity. Deck motor relief valve is stuck or damaged. Deck motor has internal leakage (bypassing oil). Cutting deck gear pump section (P1 or P2) is worn or damaged.
Lift/Lower Circuit Problems Problem Possible Cause Cutting decks will not raise. Operator seat is unoccupied. NOTE: Operator must be in seat in order to raise the cutting decks. Hydraulic oil level in reservoir is low. Electrical problem exists that prevents lift control manifold solenoid valve operation (see Chapter 5 -- Electrical System). Lift cylinder(s) is (are) damaged. Lift arm pivots are binding. Lift/lower circuit relief valve in lift control manifold is stuck open.
Engine Cooling Fan Circuit Problems Problem Possible Cause Cooling fan runs only in forward direction (fan does not run in reverse direction). Fan control manifold solenoid cartridge valve (S1) is faulty. Cooling fan does not rotate. Fan motor is worn or damaged. Electrical problem exists that prevents fan control manifold solenoid valve (S1) operation (see Chapter 5 -- Electrical System). Gear pump section (P4) is worn or damaged. Cooling fan always rotates at slow speed.
Testing Before Performing Hydraulic Tests IMPORTANT: All obvious areas such as oil supply, filter, binding linkages, loose fasteners or improper adjustments must be checked before assuming that a hydraulic component is the source of the problem. Precautions for Hydraulic Testing CAUTION Failure to use gauges with recommended pressure (PSI) rating as listed in test procedures could result in damage to the gauge and possible personal injury from leaking hot oil.
Traction Circuit Charge Pressure (Using Pressure Gauge) FROM STEERING AND LIFT CIRCUITS (CHARGE CIRCUIT) PS TS FORWARD DIRECTION SHOWN BYPASS VALVE PRESSURE GAUGE TO DECK CONTROL MANIFOLD TO DECK CONTROL MANIFOLD TO STEERING AND LIFT CIRCUITS (CHARGE CIRCUIT) Working Pressure Low Pressure Return or Suction Flow FROM DECK MOTORS FROM DECK CONTROL MANIFOLD Hydraulic System Page 4 -- 42 FROM STEERING CONTROL VALVE TO FAN CIRCUIT Groundsmaster 4500--D/4700--D
Procedure for Traction Circuit Charge Pressure Test 1. Make sure hydraulic oil is at normal operating temperature 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. Make sure engine is off and the parking brake is engaged. CAUTION Prevent personal injury and/or damage to equipment. Read all WARNINGS, CAUTIONS and Precautions for Hydraulic Testing at the beginning of this section. 7.
Traction Circuit Relief Pressure (Using Pressure Gauge) FROM STEERING AND LIFT CIRCUITS (CHARGE CIRCUIT) PS TS FORWARD DIRECTION TEST SHOWN BYPASS VALVE PRESSURE GAUGE TO DECK CONTROL MANIFOLD TO DECK CONTROL MANIFOLD TO STEERING AND LIFT CIRCUITS (CHARGE CIRCUIT) Working Pressure Low Pressure Return or Suction FROM DECK MOTORS Flow FROM DECK CONTROL MANIFOLD Hydraulic System Page 4 -- 44 FROM STEERING CONTROL VALVE TO FAN CIRCUIT Groundsmaster 4500--D/4700--D
Procedure for Traction Circuit Relief Pressure Test 1. Make sure hydraulic oil is at normal operating temperature by operating the machine for approximately ten (10) minutes. Make sure the hydraulic tank is full. CAUTION Move machine to an open area, away from people and obstructions. NOTE: Seal leakage across pilot directional valves PD1 and PD2 in 4WD/2WD control manifold can also cause low forward traction pressure with reverse pressure meeting specifications.
Rear Traction Circuit Relief (RV) Pressure (Using Pressure Gauge) FROM STEERING AND LIFT CIRCUITS (CHARGE CIRCUIT) BYPASS VALVE PS TS PRESSURE GAUGE TO DECK CONTROL MANIFOLD TO DECK CONTROL MANIFOLD TO STEERING AND LIFT CIRCUITS (CHARGE CIRCUIT) Working Pressure Low Pressure Return or Suction FROM DECK MOTORS Flow FROM DECK CONTROL MANIFOLD Hydraulic System Page 4 -- 46 FROM STEERING CONTROL VALVE TO FAN CIRCUIT Groundsmaster 4500--D/4700--D
NOTE: Adjustable relief valve (RV) in the 4WD/2WD control manifold reduces rear axle motor pressure created in down hill, dynamic braking conditions to prevent rear wheel lock up. C. After adjustment is made, recheck relief pressure and make additional adjustment if necessary. Procedure for Rear Traction Circuit Relief (RV) Pressure Test RIGHT FRONT 1. Make sure hydraulic oil is at normal operating temperature by operating the machine for approximately ten (10) minutes.
Traction Circuit Reducing Valve (PR) Pressure (Using Pressure Gauge) FROM STEERING AND LIFT CIRCUITS (CHARGE CIRCUIT) BYPASS VALVE PS TS PRESSURE GAUGE TO DECK CONTROL MANIFOLD TO DECK CONTROL MANIFOLD TO STEERING AND LIFT CIRCUITS (CHARGE CIRCUIT) Working Pressure Low Pressure Return or Suction FROM DECK MOTORS Flow FROM DECK CONTROL MANIFOLD Hydraulic System Page 4 -- 48 FROM STEERING CONTROL VALVE TO FAN CIRCUIT Groundsmaster 4500--D/4700--D
NOTE: When in reverse, pressure reducing valve (PR) limits the pressure to the rear axle motor to 450 PSI (31 bar) so the rear wheels will not scuff the turf. Procedure for Traction Circuit Pressure Reducing Valve (PR) Pressure Test 1. Make sure hydraulic oil is at normal operating temperature by operating the machine for approximately ten (10) minutes. Make sure the hydraulic tank is full. B.
Cutting Deck Circuit Pressure (Using Pressure Gauge) BYPASS VALVE TEST FOR GM4500--D DECKS 2, 3 AND 5 SHOWN TO STEERING AND LIFT CIRCUITS FROM FAN CONTROL TO FAN CIRCUIT FROM STEERING CONTROL (ENERGIZED) (ENERGIZED) PRESSURE GAUGE Working Pressure Low Pressure Return or Suction #1 #4 #5 #3 #2 Flow FROM FAN MOTOR Hydraulic System Page 4 -- 50 Groundsmaster 4500--D/4700--D
Procedure for Cutting Deck Circuit Pressure Test 1. Make sure hydraulic oil is at normal operating temperature by operating the machine for approximately ten (10) minutes. Make sure the hydraulic tank is full. GM 4500--D 1 2. Park machine on a level surface with the cutting decks lowered and off. Make sure engine is off and the parking brake is engaged. 2 3. Raise hood to allow access to deck control manifold. FRONT Figure 41 Prevent personal injury and/or damage to equipment.
Cutting Deck Circuit Relief Pressure (Using Tester with Pressure Gauges and Flow Meter) BYPASS VALVE TEST FOR GM4500--D PUMP SECTION P2 SHOWN TO STEERING AND LIFT CIRCUITS FROM FAN CONTROL TO FAN CIRCUIT Working Pressure (ENERGIZED) (ENERGIZED) FROM STEERING CONTROL Low Pressure Return or Suction Flow #1 #4 #5 #3 #2 TESTER FROM FAN MOTOR Hydraulic System Page 4 -- 52 Groundsmaster 4500--D/4700--D
Procedure for Cutting Deck Circuit Relief Pressure Test 10.Open the tester flow control valve, disengage cutting decks and stop the engine. Record test results. 1. Make sure hydraulic oil is at normal operating temperature by operating the machine for approximately ten (10) minutes. Make sure the hydraulic tank is full. 11.
TEST FOR GM4500--D DECK MOTOR #1 SHOWN TO RESERVOIR FROM PUMP SECTION P2 FROM FAN CONTROL MANIFOLD FROM PUMP SECTION P1 Cutting Deck Motor Case Drain Leakage (Using Tester with Pressure Gauges and Flow Meter) (ENERGIZED) (ENERGIZED) TO OIL COOLER Working Pressure Low Pressure Return or Suction Flow #1 #4 #5 #3 #2 TESTER FROM FAN MOTOR STEEL CAP MEASURING CONTAINER Hydraulic System Page 4 -- 54 Groundsmaster 4500--D/4700--D
Procedure for Cutting Deck Motor Case Drain Leakage Test 5. Sit on seat and start the engine. Move throttle to full speed (2870 RPM). Move PTO switch to ON. NOTE: Over a period of time, a deck motor can wear internally. A worn motor may bypass oil to its case drain causing the motor to be less efficient. Eventually, enough oil loss will cause the deck motor to stall under heavy cutting conditions.
Gear Pump P1 and P2 Flow (Cutting Deck Circuits) (Using Tester with Pressure Gauges and Flow Meter) BYPASS VALVE TEST FOR GEAR PUMP SECTION P1 SHOWN TO STEERING AND LIFT CIRCUITS TO FAN CIRCUIT FROM DECK MOTORS FROM STEERING CONTROL TO DECK CONTROL MANIFOLD TO DECK CONTROL MANIFOLD TESTER FROM DECK CONTROL MANIFOLD Working Pressure Low Pressure Return or Suction Flow Hydraulic System Page 4 -- 56 Groundsmaster 4500--D/4700--D
NOTE: Gear pump P1 supplies hydraulic flow to cutting decks 5, 3 and 2 (also deck 7 on the GM 4700--D). Gear pump P2 supplies flow to cutting decks 1 and 4 (also deck 6 on the GM 4700--D). IMPORTANT: Do not fully restrict oil flow through tester. In this test, the flow tester is positioned before the circuit relief valve. Pump damage can occur if the oil flow is fully restricted. Procedure for Gear Pump P1 and P2 Flow Test 8.
Steering Circuit Relief Pressure (Using Pressure Gauge) STEEL CAP #1 #4 #5 #3 PRESSURE GAUGE #2 TS BYPASS VALVE TO LIFT MANIFOLD TO OIL FILTER TEST FOR GM4500--D SHOWN (STEERING WHEEL TURNED FOR RIGHT TURN) Working Pressure Low Pressure Return or Suction Flow Hydraulic System Page 4 -- 58 Groundsmaster 4500--D/4700--D
Procedure for Steering Circuit Relief Pressure Test 1. Make sure hydraulic oil is at normal operating temperature 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. Make sure engine is off and the parking brake is engaged. CAUTION Prevent personal injury and/or damage to equipment. Read all WARNINGS, CAUTIONS and Precautions for Hydraulic Testing at the beginning of this section. 9.
Lift/Lower Circuit Relief Pressure (Using Pressure Gauge) R1 BYPASS VALVE S5 (ENERGIZED) S6 TS PS TS GM 4500--D SHOWN PRESSURE GAUGE TO OIL FILTER (CHARGE CIRCUIT) 3 GPM PRIORITY FLOW TS TO STEERING CONTROL VALVE Hydraulic System Page 4 -- 60 FROM DECK CONTROL MANIFOLD TO DECK CONTROL MANIFOLD TO DECK CONTROL MANIFOLD TO DECK CONTROL MANIFOLD TO RESERVOIR FROM DECK MOTORS Working Pressure Low Pressure Return or Suction Flow Groundsmaster 4500--D/4700--D
Procedure for Lift/Lower Circuit Relief Pressure Test 1. Make sure hydraulic oil is at normal operating temperature by operating the machine for approximately ten (10) minutes. Make sure the hydraulic tank is full. B. If pressure is too low, check for restriction in gear pump intake line. Check the lift cylinders for internal leakage. If pump intake line is not restricted and lift cylinders are not leaking, remove cap on relief valve (Fig. 52).
BYPASS VALVE 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 DECK MOTORS TO DECK CONTROL MANIFOLD TO DECK CONTROL MANIFOLD 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
NOTE: Gear Pump P3 supplies oil flow for the steering and lift circuits. Procedure for Gear Pump P3 Flow Test 1. Make sure hydraulic oil is at normal operating temperature 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. Make sure engine is off and the parking brake is engaged. 3. Raise hood to allow access to pump assembly. IMPORTANT: The pump is a positive displacement type.
Cooling Fan Circuit (Using Pressure Gauge and Phototac) #1 #4 #5 #3 #2 PRESSURE GAUGE TS TO LIFT CONTROL MANIFOLD TO CHARGE CIRCUIT BYPASS VALVE GM 4500--D SHOWN Working Pressure Low Pressure Return or Suction Flow Hydraulic System Page 4 -- 64 Groundsmaster 4500--D/4700--D
Procedure for Cooling Fan Circuit Test 3 1 1. Make sure hydraulic oil is at normal operating temperature 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. Make sure engine is off and the parking brake is applied. 2 CAUTION Prevent personal injury and/or damage to equipment. Read all WARNINGS, CAUTIONS and Precautions for Hydraulic Testing at the beginning of this section.
BYPASS VALVE Gear Pump P4 Flow (Cooling Fan Circuit) (Using Tester with Pressure Gauges and Flow Meter) TO STEERING AND LIFT CIRCUITS TESTER FROM DECK MOTORS TO DECK CONTROL MANIFOLD FROM STEERING CONTROL TO DECK CONTROL MANIFOLD TO FAN CIRCUIT FROM DECK CONTROL MANIFOLD Working Pressure Low Pressure Return or Suction Flow Hydraulic System Page 4 -- 66 Groundsmaster 4500--D/4700--D
NOTE: Gear Pump P4 supplies oil flow for the engine cooling fan circuit. Procedure for Gear Pump P4 Flow Test 1. Make sure hydraulic oil is at normal operating temperature 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. Make sure engine is off and the parking brake is engaged. 3. Raise hood to allow access to pump assembly. IMPORTANT: The gear pump is a positive displacement type.
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 system, park machine on a level surface, engage parking brake, lower cutting decks or attachments and stop engine. Remove key from the ignition switch. 1. Check oil level in the hydraulic reservoir and add correct oil if necessary.
Flush Hydraulic System IMPORTANT: Flush the hydraulic system any time there is a severe component failure or the system is contaminated (oil appears milky, black or contains metal particles). IMPORTANT: Flush hydraulic system when changIng from petroleum base hydraulic fluid to a biodegradable fluid. Operate machine under normal operating conditions for at least four (4) hours before draining. 1. Park machine on a level surface. Lower cutting decks, stop engine and engage parking brake.
Charge Hydraulic System NOTE: When initially starting the hydraulic system with new or rebuilt components such as pumps, motors or lift cylinders, it is important that the hydraulic system be charged properly. Air must be purged from the system and its components to reduce the chance of damage. IMPORTANT: Change hydraulic oil filter whenever hydraulic components are repaired or replaced. 11.
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Gear Pump 15 14 77 to 93 ft--lb (105 to 126 N--m) 18 13 7 3 18 11 11 8 2 1 16 9 16 17 12 5 8 4 5 12 22 23 6 19 RIGHT FRONT 20 11 21 103 to 118 ft--lb (140 to 160 N--m) 10 Figure 56 1. 2. 3. 4. 5. 6. 7. 8. Flat washer (2 used) Cap screw (2 used) 90o hydraulic fitting Hydraulic tee fitting O--ring Gear pump assembly Piston pump assembly 90o hydraulic fitting 9. 10. 11. 12. 13. 14. 15. 16.
7. Support gear pump assembly to prevent it from falling. 8. Remove two (2) cap screws and washers securing gear pump to piston pump. Remove gear pump, coupler (item 9), spacer (item 17) and O--rings (item 16) from machine. 9. If hydraulic fittings are to be removed from gear pump, mark fitting orientation to allow correct assembly. Remove fittings from pump and discard O--rings. RIGHT FRONT 3 4 5 Installation (Fig. 56) 1 2. Lubricate new O--rings (item 16) with clean hydraulic oil.
Gear Pump Service 18 6 9 12 10 13 14 15 17 16 5 3 19 4 11 24 21 9 11 1 2 7 8 21 26 25 23 22 33 ft--lb (45 N--m) 22 20 Figure 58 1. 2. 3. 4. 5. 6. 7. 8. 9. Dust seal Retaining ring Flange washer Shaft seal Front cover Dowel pin (16 used) Pressure seal Back--up gasket Thrust plate (8 used) 10. 11. 12. 13. 14. 15. 16. 17. 18.
3. Secure the front cover of the pump in a vise with the drive shaft pointing down. 4. Loosen the four (4) cap screws that secure pump assembly. 5. Remove pump from vise and remove fasteners. 6. Support the pump assembly and gently tap the pump case with a soft face hammer to loosen the pump sections. Be careful to not drop parts or disengage gear mesh. IMPORTANT: Mark the relative positions of the gear teeth and the thrust plates so they can be reassembled in the same position.
Piston (Traction) Pump 15 14 77 to 93 ft--lb (105 to 126 N--m) 13 18 7 3 18 11 11 8 2 1 16 16 17 9 12 5 8 4 5 12 22 6 23 19 FRONT 20 11 21 103 to 118 ft--lb (140 to 160 N--m) RIGHT 10 Figure 60 1. 2. 3. 4. 5. 6. 7. 8. Flat washer (2 used) Cap screw (2 used) 90o hydraulic fitting Hydraulic tee fitting O--ring Gear pump assembly Piston pump assembly 90o hydraulic fitting 9. 10. 11. 12. 13. 14. 15. 16.
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 retaining pump assembly to engine adapter plate. Carefully pull pump assembly from adapter plate and raise it out of the machine. 9. If hydraulic fittings are to be removed from piston pump, mark fitting orientation to allow correct assembly. Remove fittings from pump and discard O--rings. 1 2 3 5 Installation (Fig. 60) 2.
Piston (Traction) Pump Service 40 to 48 in--lb (4.5 to 5.4 N--m) 4 to 6 ft--lb (5 to 8 N--m) 40 to 48 in--lb (4.5 to 5.
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4WD/2WD and Filtration/Charge Control Manifolds 1 2 3 4 11 5 6 RIGHT 7 FRONT 8 9 12 10 Figure 64 1. 2. 3. 4. Flange head screw (2 used) Filtration manifold bracket Filtration/charge control manifold Hydraulic oil filter Hydraulic System 5. 6. 7. 8. 4WD/2WD control manifold Manifold bracket Flange head screw (3 used) Flange nut (2 used) Page 4 -- 80 9. 10. 11. 12.
Removal (Fig. 64) 2. To prevent contamination of hydraulic system during manifold removal, thoroughly clean exterior of manifold. 12 5. Remove hydraulic manifold from the frame using Figure 64 as guide. 6. If hydraulic fittings are to be removed from control manifold, mark fitting orientation to allow correct assembly (Figure 65 or 66). Remove fittings from manifold and discard O--rings. Installation (Fig. 64) 1.
4WD/2WD Control Manifold Service 50 ft--lb (68 N--m) 6 7 15 ft--lb (20.3 N--m) 25 ft--lb (33.9 N--m) 25 ft--lb (33.9 N--m) 14 UP 1 9 to 11 ft--lb (12.3 to 14.9 N--m) 10 15 5 8 5 3 20 ft--lb (27.1 N--m) 35 ft--lb (47 N--m) 20 ft--lb (27.1 N--m) 25 ft--lb (33.9 N--m) 50 ft--lb (68 N--m) 50 ft--lb (68 N--m) 7 6 UP 11 9 1 4 12 13 5 ft--lb (6.8 N--m) 2 20 ft--lb (27.1 N--m) Figure 67 1. 2. 3. 4. 5. Manifold body Nut Orifice (0.050) Orifice disc (0.
NOTE: The ports on the manifold are marked for easy identification of components (e.g. P1 is a piston pump connection port and SV is the location for the solenoid valve). See Hydraulic Schematics in Chapter 9 -- Foldout Drawings to identify the function of the hydraulic lines and cartridge valves at each port. 5. Visually inspect cartridge valve for damaged sealing surfaces and contamination. NOTE: The 4WD/2WD control manifold uses several zero leak plugs.
Filtration/Charge Control Manifold Service 25 ft--lb (33.9 N--m) 25 ft--lb (33.9 N--m) 3 4 3 30 ft--lb (40.6 N--m) 30 ft--lb (40.6 N--m) 5 1 UP 50 ft--lb (68 N--m) 25 ft--lb (33.9 N--m) 2 6 Figure 68 1. Manifold body 2. Zero leak plug (#8) 3. Zero leak plug (#6) 4. Check valve (reservoir return) NOTE: The ports on the manifold are marked for easy identification of components (e.g. P2 is the gear pump connection port and P1 is the connection from the oil cooler).
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Rear Axle Motor Arrows on side of motor case point up 5 6 7 7 8 4 5 2 1 10 9 3 RIGHT FRONT Figure 69 1. 2. 3. 4. Axle motor O--ring Pinion gear External snap ring Hydraulic System 5. O--ring 6. Hydraulic fitting 7. O--ring Page 4 -- 86 8. 90o hydraulic fitting 9. Cap screw (2 used) 10.
Removal (Fig. 69) Installation (Fig. 69) 1. Park machine on a level surface, lower cutting decks, stop engine, engage parking brake and remove key from the ignition switch. 1. If fittings were removed from axle motor, lubricate and place new O--rings onto fittings. Install fittings into motor ports using marks made during the removal process to properly orientate fittings. Tighten fittings (see Hydraulic Fitting Installation in the General Information section of this chapter). 3.
Front Wheel Motors 1 2 20 3 15 14 10 18 22 16 14 15 23 24 25 19 18 6 10 19 17 16 10 15 14 13 10 12 11 9 75 to 85 ft--lb (102 to 115 N--m) RIGHT 8 5 7 21 4 Arrows on side of motor case point up FRONT Figure 70 1. 2. 3. 4. 5. 6. 7. 8. 9. Flange head screw (6 per planetary) Splined brake shaft Planetary assembly Wheel assembly Lug nut (8 per wheel) Retaining ring LH brake assembly Flange head screw (4 per brake) Plug Hydraulic System 10. 11. 12. 13. 14. 15. 16. 17.
Removal (Fig. 70) Installation (Fig. 70) 1. Park machine on a level surface, lower cutting decks, stop engine, engage parking brake and remove key from the ignition switch. 1. If fittings were removed from wheel motor, lubricate and place new O--rings onto fittings. Install fittings into motor ports using marks made during the removal process to properly orientate fittings. Tighten fittings (see Hydraulic Fitting Installation in the General Information section of this chapter). 3.
Rear Axle and Front Wheel Motor Service 15 to 18 ft--lb (20 to 24 N--m) FRONT WHEEL MOTOR SHOWN 1 7 9 10 13 10 2 9 11 18 8 6 19 20 14 15 16 12 4 5 3 17 Figure 71 1. 2. 3. 4. 5. 6. 7. Drive shaft Backplate Housing assembly Rotating assembly Cam plate insert Retaining ring Cap screw 8. 9. 10. 11. 12. 13. 14. Shaft seal (front motor only) Retaining ring Thrust race O--ring Valve plate Thrust bearing Roll pin NOTE: The front wheel motors (shown in Figure 71) are identical.
Cutting Deck Motor The hydraulic motors used on all cutting decks are the same. Removal 2 1. Park machine on a level surface, lower cutting decks, stop engine, engage parking brake and remove key from the ignition switch. 1 2. Read the General Precautions for Removing and Installing Hydraulic System Components at the beginning of the Service and Repairs section of this chapter. 1 3. To prevent contamination of hydraulic system during deck motor removal, thoroughly clean exterior of motor. 5.
Cutting Deck Motor Service 33 ft--lb (45 N--m) 19 26 ft--lb (35 N--m) 18 16 10 13 9 5 6 8 3 1 6 15 17 7 14 12 12 10 2 4 26 ft--lb (35 N--m) 11 7 Figure 74 1. 2. 3. 4. 5. 6. 7. Dust seal Retaining ring Flange washer Shaft seal Front flange Pressure seal Backup gasket 8. 9. 10. 11. 12. 13. Front wear plate Drive gear Dowel pin Idler gear O--ring Body 14. 15. 16. 17. 18. 19. Rear wear plate Rear cover Anti--cavitation valve Relief valve Cap screw (4 used) Washer (4 used) Disassembly (Fig.
5. Remove motor from the vise. Turn motor so that the shaft end is facing down. Remove cap screws. 6. Separate rear cover from body. Lift rear cover from motor. 7. Carefully remove body. Lift body straight up to remove. Make sure the rear wear plate remains on the drive and idler gear shafts. Remove and discard O-rings from the body. Locate and retrieve dowel pins. IMPORTANT: Note position of the open and closed side of the wear plates before removing.
Assembly (Fig. 74) NOTE: When assembling the motor, check the marker line on each part to make sure the parts are properly aligned during assembly. 1. Lubricate O--rings, pressure seals, back--up gaskets and wear plate grooves with a thin coat of petroleum jelly. Lubricate all other internal parts freely with clean hydraulic oil. 2. Install new seals into front flange (Fig. 76): A. Press shaft seal into front flange until it reaches the bottom of the bore. B.
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Deck Control Manifold RIGHT 8 FRONT 2 7 1 3 4 5 6 GROUNDSMASTER 4500--D SHOWN Figure 78 1. Deck control manifold 2. Filter mount bracket 3. Filter head 4. Hydraulic oil filter 5. Valve mount bracket 6. Flange head screw (2 used) 7. Lift control manifold 8. Flange head screw NOTE: The deck control manifolds used on Groundsmaster 4500--D and 4700--D are different but they mount to the machine in the same location. The control manifolds used on the Groundsmaster 4500--D are shown in Figure 78.
Removal (Fig. 78) 7 6 1 5 4 2 3 1. Park machine on a level surface, lower cutting decks, stop engine, apply parking brake and remove key from the ignition switch. 11 14 2. Read the General Precautions for Removing and Installing Hydraulic System Components at the beginning of the Service and Repairs section of this chapter. 11 3. Unlatch and raise hood. 6. Disconnect hydraulic lines from manifold and put caps or plugs on open hydraulic lines and fittings.
Deck Control Manifold Service (GM 4500--D) 5 ft--lb (6.8 N--m) 7 3 20 ft--lb (27.1 N--m) 3 4 25 ft--lb (33.9 N--m) 25 ft--lb (33.9 N--m) 2 2 5 20 ft--lb (27.1 N--m) 4 6 25 ft--lb (33.9 N--m) 25 ft--lb (33.9 N--m) 5 8 6 UP 1 50 ft--lb (68 N--m) 8 25 ft--lb (33.9 N--m) 9 Figure 81 1. Manifold body 2. Proportional relief (PRV1 & PRV2) 3. Solenoid coil 4. Relief valve (RV8 & RV9) 5. Logic valve (LC1 & LC2) 6.
For solenoid and control valve service procedures, see 4WD/2WD Control Manifold Service in this section. Refer to Figures 81 and 82 for cartridge valve and plug installation torque. IMPORTANT: A pilot piston (item 6) is placed beneath each of the relief valves in deck control manifold ports RV8 and RV9. If a relief valve is removed from the manifold, make sure to remove pilot piston and label its position for assembly purposes.
Deck Control Manifold Service (GM 4700--D) 5 ft--lb (6.8 N--m) 25 ft--lb (33.9 N--m) 25 ft--lb (33.9 N--m) 2 20 ft--lb (27.1 N--m) 25 ft--lb (33.9 N--m) 10 6 8 7 5 ft--lb (6.8 N--m) 10 6 2 7 7 9 10 20 ft--lb (27.1 N--m) 20 ft--lb (27.1 N--m) 9 11 25 ft--lb (33.9 N--m) 25 ft--lb (33.9 N--m) 8 7 20 ft--lb (27.1 N--m) 3 25 ft--lb (33.9 N--m) 3 11 3 50 ft--lb (68 N--m) 25 ft--lb (33.9 N--m) 25 ft--lb (33.9 N--m) 3 4 1 3 UP 5 20 ft--lb (27.1 N--m) Figure 83 1. 2. 3. 4.
For solenoid and control valve service procedures, see 4WD/2WD Control Manifold Service in this section. Refer to Figures 83 and 84 for cartridge valve and plug installation torque. IMPORTANT: A pilot piston (item 6) is placed beneath each of the relief valves in deck control manifold ports RV8, RV9, RV10 and RV11. If a relief valve is removed from the manifold, make sure to remove pilot piston and label its position for assembly purposes.
Steering Control Valve 1 4 RIGHT FRONT 2 3 20 to 26 ft--lb (28 to 35 N--m) 5 7 Antiseize Lubricant 10 9 11 14 15 16 7 to 10 ft--lb (9.5 to 13.5 N--m) 13 Antiseize Lubricant 6 8 6 6 12 Figure 85 1. 2. 3. 4. 5. 6. Steering wheel cover Lock nut Steering wheel Flat washer Foam collar Flange head screw (4 used) 7. 8. 9. 10. 11. Steering column Steering control valve Socket head screw (4 used) Flange nut (4 used) Tinnerman nut (4 used) Removal (Fig. 85) 1.
7. Position steering column brace (item 12) to machine and secure with four (4) flange head screws. CAUTION 8. Slide rubber bellows to bottom of steering column. 8. Disconnect hydraulic lines from steering control valve. Allow lines to drain into a suitable container. 9. Position shroud in place and secure with removed fasteners (Fig. 86). 10.Check oil level in hydraulic reservoir and add correct oil if necessary. 11.
Steering Control Valve Service 2 3 1 8 4 5 6 5 9 7 10 22 11 12 13 14 13 15 13 16 17 18 19 20 to 24 ft--lb (27 to 33 N--m) 20 21 Figure 88 1. 2. 3. 4. 5. 6. 7. 8. Relief valve assembly Dust seal ring Steering valve housing Shaft seal Thrust washer Bearing race Ring Spring set 9. 10. 11. 12. 13. 14. 15. Cross pin Sleeve Spool Cardan shaft O--ring Distributor plate Outer gearwheel 16. 17. 18. 19. 20. 21. 22.
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Steering Cylinder 7 6 9 15 7 4 9 8 2 16 5 4 1 3 10 12 14 11 13 14 RIGHT FRONT 100 to 125 ft--lb (136 to 169 N--m) Figure 89 1. 2. 3. 4. 5. 6. Steering cylinder Ball joint Ball joint Retaining ring Grease fitting Grease fitting Hydraulic System 7. 8. 9. 10. 11. 90o hydraulic fitting O--ring O--ring Drive axle assembly Ball joint spacer Page 4 -- 106 12. 13. 14. 15. 16.
Removal (Fig. 89) Installation (Fig. 89) 1. Park machine on a level surface, lower cutting decks, stop engine, engage parking brake and remove key from the ignition switch. 1. If fittings were removed from steering cylinder, lubricate and place new O--rings onto fittings. Install fittings into cylinder ports using marks made during the removal process to properly orientate fittings. Tighten fittings (see Hydraulic Fitting Installation in the General Information section of this chapter). 3.
Steering Cylinder Service 11 10 9 30 to 36 ft--lb (41 to 48 N--m) 5 13 4 3 2 12 8 1 7 6 2 9 1 5 11 6 3 4 13 7 10 8 12 Figure 90 1. 2. 3. 4. 5. Tube assembly Lock nut Seal O--ring O--ring Hydraulic System 6. 7. 8. 9. Piston O--ring Back--up seal Seal Page 4 -- 108 10. 11. 12. 13.
Disassembly (Fig. 90) Assembly (Fig. 90) 1. Remove oil from steering cylinder into a drain pan by slowly pumping the cylinder shaft. Plug both ports and clean the outside of the cylinder. 1. Make sure all cylinder components are clean before assembly. 2. Mount steering cylinder securely in a vise by clamping on the clevis end of the barrel. Use of a vise with soft jaws is recommended. 3. Loosen head from barrel: A.
Engine Cooling Fan Motor RIGHT FRONT 4 3 2 1 5 27 to 33 ft--lb (37 to 44 N--m) 21 6 20 7 8 2 9 4 5 19 10 18 13 14 15 16 17 12 11 12 to 14 ft--lb (17 to 18 N--m) Figure 91 1. 2. 3. 4. 5. 6. 7. Hydraulic fan motor O--ring Bracket 45o hydraulic fitting O--ring Hydraulic hose Fan hub 8. 9. 10. 11. 12. 13. 14. Washer Hex nut Engine Cap screw (4 used) Washer (4 used) Fan Lock nut (2 used) 15. 16. 17. 18. 19. 20. 21. Removal (Fig. 91) 1.
IMPORTANT: Make sure to not damage the radiator or other machine components while loosening and removing the fan motor and bracket assembly. 6. Remove cooling fan motor and bracket assembly. A. To prevent contamination of hydraulic system, thoroughly clean exterior of fan motor and fittings. B. Disconnect hydraulic hoses from fan motor. Put caps or plugs on fittings and hoses to prevent contamination. Label hydraulic lines for proper assembly. C.
Engine Cooling Fan Motor Service 11 10 15 6 3 1 14 7 16 9 8 12 8 5 4 14 33 ft--lb (45 N--m) 9 2 13 Figure 93 1. 2. 3. 4. 5. 6. Flange washer O--ring Front flange Dust seal Retaining ring Front wear plate 7. 8. 9. 10. 11. Shaft seal Backup gasket Pressure seal Rear wear plate Body 12. 13. 14. 15. 16.
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Fan Control Manifold 4 2 3 5 1 6 RIGHT FRONT Figure 94 1. Fan control manifold 2. Support bracket Hydraulic System 3. Flange head screw (2 used) 4. Battery support Page 4 -- 114 5. Bracket 6.
Removal (Fig. 94) NOTE: The ports on the manifold are marked for easy 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). 2 2 1 50 ft--lb (68 N--m) 2 3 1. Park machine on a level surface, lower cutting decks, stop engine, apply parking brake and remove key from the ignition switch. 2 2.
Fan Control Manifold Service 5 ft--lb (6.8 N--m) 50 ft--lb (68 N--m) 10 5 2 25 ft--lb (33.9 N--m) 5 ft--lb (6.8 N--m) 7 1 6 6 25 ft--lb (33.9 N--m) 2 9 2 25 ft--lb (33.9 N--m) 8 25 ft--lb (33.9 N--m) 3 UP 4 1 20 ft--lb (27.1 N--m) UP 20 ft--lb (27.1 N--m) Figure 96 1. 2. 3. 4. Manifold body Zero leak plug (#6) (3 used) Zero leak plug (#4) (2 used) Check valve (port CV) 5. Flow divider cartridge (port FD) 6. Solenoid coil (2 used) 7.
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Lift Control Manifold RIGHT FRONT 2 1 7 3 4 5 6 GROUNDSMASTER 4500--D SHOWN Figure 97 1. Lift control manifold 2. Filter mount bracket 3. Filter head 4. Hydraulic oil filter 5. Valve mount bracket NOTE: The lift control manifolds used on Groundsmaster 4500--D and 4700--D machines are different but they mount to the machine in the same location. The Groundsmaster 4500--D control manifolds are shown in Figure 97. Removal (Fig.
WARNING GROUNDSMASTER 4500--D Make sure that cutting decks are fully lowered before loosening hydraulic lines from lift manifold. If decks are raised as hydraulic lines are loosened, decks may drop unexpectedly. 7. Remove hydraulic manifold from the frame using Figure 97 as guide. 50 ft--lb (68 N--m) 5 4 6 3 7 8. If hydraulic fittings are to be removed from lift control manifold, mark fitting orientation to allow correct assembly (Fig. 98 or 99). Remove fittings from manifold and discard O--rings.
Lift Control Manifold Service (GM 4500--D) 5 ft--lb (6.8 N--m) 15 8 25 ft--lb (33.9 N--m) 14 4 20 ft--lb (27.1 N--m) 25 ft--lb (33.9 N--m) 5 ft--lb (6.8 N--m) 2 3 7 13 20 ft--lb (27.1 N--m) 20 ft--lb (27.1 N--m) 1 UP 7 5 ft--lb (6.8 N--m) 16 4 5 11 6 20 ft--lb (27.1 N--m) 10 9 12 25 ft--lb (33.9 N--m) Figure 100 1. 2. 3. 4. 5. 6. Manifold body Proportional relief valve (port TS) Solenoid valve (port S6) Solenoid coil (2 used) Check valve (port CV) Orifice (0.080) 7. 8. 9. 10. 11.
WARNING If lift manifold is attached to machine, make sure that cutting decks are fully lowered before loosening hydraulic lines, cartridge valves or plugs from lift manifold. If decks are raised as components are loosened, decks may drop unexpectedly. IMPORTANT: A flow control orifice (item 6) is placed beneath the hydraulic fitting in lift control manifold port C2. If this fitting is removed from the manifold, make sure to remove orifice and label its position for assembly purposes.
Lift Control Manifold Service (GM 4700--D) 20 ft--lb (27.1 N--m) 25 ft--lb (33.9 N--m) 5 ft--lb (6.8 N--m) 4 7 11 10 20 ft--lb (27.1 N--m) 5 2 1 20 ft--lb (27.1 N--m) 3 5 ft--lb (6.8 N--m) 25 ft--lb (33.9 N--m) 6 10 12 8 UP 11 8 6 20 ft--lb (27.1 N--m) 10 12 9 11 5 ft--lb (6.8 N--m) 11 12 25 ft--lb (33.9 N--m) 10 12 20 ft--lb (27.1 N--m) 5 ft--lb (6.8 N--m) Figure 101 1. 2. 3. 4. Manifold body Nut Zero leak plug (#4) Relief valve (port R1) 5. 6. 7. 8.
25 ft--lb (33.9 N--m) WARNING If lift manifold is attached to machine, make sure that cutting decks are fully lowered before loosening hydraulic lines, cartridge valves or plugs from lift manifold. If decks are raised as components are loosened, decks may drop unexpectedly. 7 20 ft--lb (27.1 N--m) 25 ft--lb (33.9 N--m) 7 2 3 2 6 6 4 5 1 3 IMPORTANT: A flow control orifice is placed beneath several of the hydraulic fittings on the lift control manifold (Fig. 102).
Lift Circuit Junction Manifold 1 2 3 4 11 5 6 7 8 9 RIGHT FRONT 12 10 Figure 103 1. 2. 3. 4. Flange head screw (2 used) Filter manifold bracket Filtration and charge control manifold Hydraulic oil filter Hydraulic System 5. 6. 7. 8. 4WD/2WD control manifold Manifold bracket Flange head screw (3 used) Flange nut (2 used) Page 4 -- 124 9. 10. 11. 12.
NOTE: The ports on the lift circuit junction manifold are marked for easy identification of components (e.g. P1 is the gear pump connection port). See Hydraulic Schematics in Chapter 9 -- Foldout Drawings to identify the function of the hydraulic lines at each port. 1. Park machine on a level surface, lower cutting decks, stop engine, engage parking brake and remove key from the ignition switch. 2.
Lift Cylinders: Decks #1, #4 and #5 9 8 7 6 5 3 4 2 10 11 12 2 13 4 13 1 5 RIGHT FRONT Figure 105 1. 2. 3. 4. 5. Lift arm (deck #4) Flange nut Lift arm (deck #1) Cylinder pin (3 used) Flange head screw Hydraulic System 6. 7. 8. 9. O--ring 90o hydraulic fitting O--ring Lift arm (deck #5) Page 4 -- 126 10. 11. 12. 13.
Removal (Fig. 105) Installation (Fig. 105) 1. Park machine on a level surface, lower cutting decks, stop engine, engage parking brake and remove key from the ignition switch. 1. If fittings were removed from lift cylinder, lubricate and place new O--rings onto fittings. Install fittings into cylinder openings using marks made during the removal process to properly orientate fittings. Tighten fittings (see Hydraulic Fitting Installation in the General Information section of this chapter). 3.
Lift Cylinders: Decks #2 and #3 8 9 4 7 11 10 7 6 12 6 5 4 2 3 14 RIGHT 13 1 FRONT Figure 107 1. 2. 3. 4. 5. Lift arm (deck #2 shown) Cylinder pin Flange head screw O--ring 90o hydraulic fitting Hydraulic System 6. 7. 8. 9. 10. O--ring Retaining ring Cylinder pin Hydraulic fitting Grease fitting Page 4 -- 128 11. 12. 13. 14.
Removal (Fig. 107) 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 beginning of the Service and Repairs section of this chapter. 3. To prevent contamination of hydraulic system during lift cylinder removal, thoroughly clean exterior of lift cylinder. 2.
Lift Cylinders: Decks #6 and #7 (GM 4700--D) 1 14 10 13 12 11 10 7 9 8 4 2 1 15 7 6 1 3 5 16 RIGHT 2 FRONT 4 1 3 Figure 109 1. 2. 3. 4. 5. 6. Retaining ring Cylinder pin Thrust washer Lift link Link assembly Bushing Hydraulic System 7. 8. 9. 10. 11. Plastic roller Rear link Lock nut 90o hydraulic fitting Lift cylinder Page 4 -- 130 12. 13. 14. 15. 16.
Removal (Fig. 109) 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 beginning of the Service and Repairs section of this chapter. 3. To prevent contamination of hydraulic system during lift cylinder removal, thoroughly clean exterior of lift cylinder. WARNING 2.
Lift Cylinder Service See text for torque specification 2 5 6 1 10 11 3 13 4 14 7 8 9 12 2 3 1 6 7 13 4 9 11 5 8 10 14 12 Figure 111 1. 2. 3. 4. 5. Tube assembly Lock nut Wear ring Seal Piston 6. 7. 8. 9. 10. O--ring O--ring Back--up ring Seal Retaining ring 11. 12. 13. 14. Head Wiper Rod assembly Grease fitting NOTE: The lift cylinders used on the Groundsmaster are all very similar regardless of the location on the machine.
Disassembly (Fig. 111) Assembly (Fig. 111) 1. Remove oil from lift cylinder into a drain pan by slowly pumping the cylinder shaft. Plug both ports and clean the outside of the cylinder. 1. Make sure all cylinder components are clean before assembly. 2. Mount lift cylinder securely in a vise by clamping on the clevis end of the barrel. Use of a vise with soft jaws is recommended. 3. Loosen head from barrel: 2. Coat new seal kit components with clean hydraulic oil. A.
Hydraulic Reservoir RIGHT 27 FRONT 28 30 1 31 2 3 4 14 5 18 29 21 16 21 11 36 32 12 15 68 to 75 ft--lb (93 to 101 N--m) 22 17 13 6 26 20 7 37 35 33 154 to 170 ft--lb (209 to 230 N--m) 13 38 34 23 25 9 13 8 39 24 10 36 to 40 ft--lb (49 to 54 N--m) 13 19 19 Figure 112 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13.
Removal (Fig. 112) Inspection 1. Park machine on a level surface, lower cutting decks, stop engine, engage parking brake and remove key from the ignition switch. 1. Clean hydraulic reservoir and suction strainer with solvent. 3. To prevent contamination of hydraulic system during hydraulic reservoir removal, thoroughly clean exterior of reservoir. 4. Disconnect one of the hydraulic tubes from the tee fitting on bottom of reservoir to allow draining of reservoir.
Hydraulic Oil Cooler 12 11 10 13 RIGHT 8 9 FRONT 14 7 15 3 16 8 1 6 4 3 2 5 Figure 113 1. 2. 3. 4. 5. 6. Oil cooler Mount plate (2 used) Flange head screw (8 used) Radiator mount Radiator Air intake hose Hydraulic System 7. 8. 9. 10. 11. Plenum Flange nut (4 used) O--ring 90o hydraulic fitting (2 used) O--ring Page 4 -- 136 12. 13. 14. 15. 16.
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. 1 1 1.
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Chapter 5 Electrical System Table of Contents Groundsmaster 4500--D/4700--D Hi--Lo Speed and Headlight Switches . . . . . . . . . Engine Cooling Fan Switch . . . . . . . . . . . . . . . . . . Seat Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Parking Brake Switch . . . . . . . . . . . . . . . . . . . . . . . Cutting Deck Position Switch . . . . . . . . . . . . . . . . Hour Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Temperature Gauge . . . . . . . . . . .
General Information Operator’s Manual The Operator’s Manual provides information regarding the operation, general maintenance and maintenance intervals for your Groundsmaster machine. Refer to the Operator’s Manual for additional information when servicing the machine. Toro Electronic Controllers (TEC) Groundsmaster 4500--D machines use a single Toro Electronic Controller (TEC--5002) to manage machine electrical functions.
Electrical Drawings Electrical System The electrical schematics and other electrical drawings for the Groundsmaster 4500--D and Groundsmaster 4700--D are located in Chapter 9 -- Foldout Drawings.
Special Tools Order special tools from your Toro distributor. Some tools may also be available from a local supplier. Multimeter The multimeter can test electrical components and circuits 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.
Diagnostic Display The Diagnostic Display (Fig. 5) can be connected to the wiring harness connector located inside the console arm to verify correct electrical functions of the machine. Toro Electronic Controllers (TEC) inputs and outputs can be checked using the Diagnostic Display.
Troubleshooting For effective troubleshooting and repairs, there must be a good understanding of the electrical circuits and components used on this machine (see Chapter 9 -- Electrical Diagrams). CAUTION Remove all jewelry, especially rings and watches, before doing any electrical troubleshooting or testing. Disconnect the battery cables unless the test requires battery voltage. If the machine has any interlock switches by--passed, reconnect the switches for proper safety and troubleshooting.
6. The Diagnostic Display will illuminate the LED associated with each of the inputs when that input switch is closed. Individually, change each of the switches from open to closed (i.e., sit on seat, press traction pedal, etc.), and note that the appropriate LED on the Diagnostic Display will illuminate when the corresponding switch is closed. Repeat on each switch that is possible to be changed by hand (see Inputs and LED Operation chart on following page).
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 Operator seat empty: LED OFF HI RANGE Hi -- Lo speed switch in HI range: LED ON Hi -- Lo speed switch in LO range: LED OFF DECK RAISE
Verify Diagnostic Display Output Functions A. If the correct output LED’s do not illuminate, verify that the required input switches are in the necessary positions to allow that function to occur. The Diagnostic Display also has the ability to detect which output solenoids or relays are energized by the TEC controller(s). This is a quick way to determine if a machine malfunction is electrical or hydraulic. B.
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. NOTE: If the solenoid clicks, the problem is not in the in- Battery cables are loose or corroded. terlock circuit. Ground connection on machine is loose or corroded.
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. Fuel pump is faulty. Engine or fuel system is malfunctioning (see Chapter 3 -- Kubota Diesel Engine). Starter cranks, but should not when the traction pedal is depressed.
Cutting Deck Operating Problems Cutting decks run, but should not, when raised. Decks shut off with PTO switch. The cutting deck position switch or circuit wiring is faulty. Wire harness connections are incorrectly connected to hydraulic solenoid valve coils on hydraulic deck control manifold. Cutting decks run, but should not, when raised. Decks do not shut off with the PTO switch. The deck position switch or circuit wiring AND PTO switch or circuit wiring are faulty.
Electrical System Quick Checks Battery Test (Open Circuit Test) Use a multimeter to measure the voltage between the battery terminals. Voltage Measured Battery Charge Level 12.68 V (or higher) Fully charged (100%) Set multimeter to the DC volts setting. The battery should be at a temperature of 60o to 100oF (16o to 38oC). The ignition key should be off and all accessories turned off.
Check Operation of Interlock Switches CAUTION Do not disconnect safety switches. They are for the operator’s protection. Check the operation of the interlock switches daily for proper operation. Replace any malfunctioning switches before operating the machine. Electrical System Interlock switch operation is described in the Traction Unit Operator’s Manual. Your Groundsmaster is equipped with an Toro Electronic Controller (TEC) which monitors interlock switch operation.
Component Testing For accurate resistance and/or continuity checks, electrically disconnect the component being tested from the circuit (e.g. unplug the ignition switch connector before checking continuity on the switch terminals). NOTE: For engine component testing information, see the Kubota Workshop Manual, Diesel Engine, V2403--M--T--E3B at the end of Chapter 3 -- Kubota Diesel Engine.
Fuses Groundsmaster 4500--D and 4700--D use numerous fuses for circuit protection. The fuses are located in two (2) areas of the machine. Most of the fuses reside in the power center behind the operator’s seat. An in--line fuse holder located in the wire harness near the engine starter motor holds an additional fuse (F5--1) that protects the engine run solenoid circuit. Fuse Testing Fuse Identification and Function (Figs. 14 and 15) 3. Remove fuse from fuse block for testing.
Indicator Lights Charge Indicator Light The charge indicator light should come on when the ignition switch is in ON with the engine not running or with an improperly operating charging circuit while the engine is running. 2 To test the charge indicator light and circuit wiring, ground the white wire attached to alternator. Turn ignition switch to ON; the charge indicator light should illuminate indicating correct operation of the electrical wiring to the alternator.
PTO Switch The PTO switch is located on the console arm (Fig. 18). The PTO switch is pulled up to engage the PTO and pushed in to disengage the PTO. NOTE: To engage the PTO, the seat has to be occupied, traction speed has to be in low range (4WD) and the cutting decks have to be fully lowered. 7. After testing is completed, connect the wire harness connector to the PTO switch. 8. Assemble console arm (see Console Arm Assembly in the Service and Repairs section of Chapter 7 -- Chassis). Testing 1.
Cutting Deck Lift Switches The cutting deck lift switches are used as inputs for the TEC controller to raise or lower the cutting decks. When the front of a lift switch is depressed and held, the controlled decks will lower. When the rear of a lift switch is depressed and held, the controlled decks will raise. The decks will remain in position when the switch is released. The lift switches are located on the console arm (Fig. 20). 7.
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 traction 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. 23). This two position rocker switch allows the headlights to be turned on and off.
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. 2 Testing 1. Before disconnecting the engine cooling fan switch for testing, the switch and its circuit wiring should be tested as a TEC input with the Diagnostic Display (see Diagnostic Display in the Troubleshooting section of this chapter).
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 traction system or PTO switch is engaged when the operator raises out of the seat, the engine will stop. Testing of the switch can be done without seat removal by disconnecting the switch wire from the machine wire harness (Fig. 27). 1 2 Testing 1.
Parking Brake Switch The parking brake switch is a normally open proximity switch. The parking brake switch is attached to the bottom 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. The parking brake detent is moved away from the switch when the parking brake is applied causing the switch to open. Switch Testing 1 1.
Cutting Deck Position Switch The cutting deck position switch is a normally open proximity 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. There are four (4) deck position switches on the Groundsmaster 4700--D: for decks 4, 5, 6 and 7.
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 to the positive (+) terminal of the hour meter. QUARTZ 00001 HOURS 2. Connect the negative (--) terminal of the voltage source to the other terminal of the hour meter. 1 10 + 3. The hour meter should move a 1/10 of an hour in six minutes. 4. Disconnect voltage source from the hour meter.
Glow and Main Power Relays The glow and main power relays are located at the power center behind the operator seat (Fig. 34). These relays are attached to the wire harness with a four (4) wire connector (Fig. 35). The glow relay is used to provide current to the engine glow plugs when energized by the TEC--5002 controller. The TEC--5002 controls and monitors the operation of the glow relay. 7. Disconnect voltage and test leads from the relay terminals. 8.
Start Relay The start relay is located at the power center behind the operator seat. This relays is attached to the wire harness with a five (5) wire connector (Fig. 37). The start relay is used to provide current to the engine starter motor when energized by the TEC--5002 controller. The TEC--5002 controls and monitors the operation of the start relay. 10.Secure relay to mounting bracket and connect wire harness connector to relay. Install cover to power center. 11.
Hydraulic Solenoid Valve Coils Numerous hydraulic solenoid valve coils are used on the hydraulic control manifolds of Groundsmaster 4500--D and 4700--D machines. When energized by the TEC controller, these coils provide hydraulic circuit control. Two (2) different solenoid valve coils are used on the 4500--D and 4700--D. A coil can be identified by measuring it’s height and diameter (Fig. 38). Testing of the coils can be done with the coil remaining on the hydraulic valve. 5.
Engine Coolant and Hydraulic Oil Temperature Senders Two (2) identical temperature senders are used as inputs for the TEC--5002 controller to identify if either the engine coolant or hydraulic oil temperature has reached an excessive level. The coolant temperature sender threads into the radiator (Fig. 39). The hydraulic oil temperature sender is attached to the 4WD/2WD control manifold at the front of the machine (Fig. 40). 7. After allowing the sender to cool, install sender: Testing 8.
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. 1 3 IMPORTANT: When testing fuel pump, make sure that pump is not operated without fuel. Fuel Pump Capacity Test 1. Park machine on a level surface, lower cutting decks, stop engine and engage parking brake. Remove key from ignition switch. 2 2. Raise and support hood. 3. Remove 20A fuse (F1--1) (Fig.
Temperature Sender The temperature sender is located near the alternator on the water flange attached to the engine cylinder head (Fig. 44). There is a gray wire attached to the terminal of the sender. The resistance of the temperature sender reduces as the engine coolant temperature increases. The changing resistance of the temperature sender signals the console temperature gauge to indicate engine coolant temperature during machine operation.
Traction Neutral Switch The traction neutral switch is closed when the traction pedal is in the neutral position and opens when the pedal is depressed in either direction. The switch is located on the right side of the piston (traction) pump (Fig. 46). See Piston Pump Control Assembly in Chapter 4 -- Hydraulic Systems for disassembly and assembly procedures for the neutral switch.
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 Diesel Engines. Battery Storage If the machine will be stored for more than 30 days: 1. Remove the battery and charge it fully (see Battery Service in this section). 2. Either store battery on a shelf or on the machine. 4. Store battery in a cool atmosphere to avoid quick deterioration of the battery charge. 5.
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. 1 3 CAUTION When working with batteries, use extreme caution to avoid splashing or spilling electrolyte. Electrolyte can destroy clothing and burn skin or eyes. Always wear safety goggles and a face shield when working with batteries. Electrolyte Specific Gravity Fully charged: 1.
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. A. Measure the specific gravity of each cell with a hydrometer. Draw electrolyte in and out of the hydrometer barrel prior to taking a reading to warm-up the hydrometer. At the same time take the temperature of the cell. B. Temperature correct each cell reading. For each 10oF (5.5oC) above 80oF (26.7oC) add 0.
Battery Charging To minimize possible damage to the battery and allow the battery to be fully charged, the slow charging method is presented here. This charging method can be accomplished with a constant current battery charger which is available in most locations. CAUTION Follow the battery charger manufacturer’s instructions when using a battery charger. NOTE: Using specific gravity of the battery cells is the most accurate method of determining battery condition. 1.
Hydraulic Solenoid Valve Coil A hydraulic solenoid valve coil on a hydraulic control manifold can be replaced without opening the hydraulic system. 4 3 Removal (Fig. 49) 1. Park machine on a level surface, lower cutting decks, stop engine and engage parking brake. Remove key from ignition switch. 5 ft--lb (6.7 N--m) 2. Locate the solenoid valve coil that is to be removed. 2 3. Disconnect the wire harness electrical connector from the coil that is to be removed.
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Chapter 6 Axles, Planetaries and Brakes Table of Contents Axles, Planetaries and Brakes SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . 3 Operator’s Manual . . . . . . . . . . . . . . . . . . . . . . . . . . 3 ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Planetary Drive End Play (OPH−2 series planetary drives)l . . . . . . . . . . . . . . 4 SERVICE AND REPAIRS . . . . . . . . . . . . . . .
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 Assembly and Wheel Motor Mounting Screw Torque OPH−2 series planetary VA02 series planetary 60 ft−lb (81 N−m) 75 to 85 ft−lb (101 to 115 N−m) Rear wheel toe−in 0.125 in (3 mm) Tire pressure (front and rear) 20 psi (138 kPa) Planetary Drive Lubricant Capacity (each wheel) SAE 85W−140 wt.
General Information Operator’s Manual Axles, Planetaries and Brakes The Traction Unit Operator’s Manual provides information regarding the operation, general maintenance and maintenance intervals for your Groundsmaster machine. Refer to this publication for additional information when servicing the machine.
Adjustments Planetary Drive Endplay (OPH−2 series planetary drives) A front planetary drive assembly that is properly operating should have no endplay. Any endplay in a planetary assembly indicates that there are potential problems with the planetary. Check planetary endplay at intervals specified in your Operator’s Manual. Endplay Checking Procedure OPH−2 series planetary 1. Park machine on a level surface, lower cutting decks, stop engine and remove key from the ignition switch. Figure 1 2.
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Service and Repairs Brake Assembly OPH−2 series planetary VA02 series planetary OPH−2 series planetary = 60 ft−lbs (81 N−m) VA02 series planetary = 75 to 85 ft−lbs (101 to 115 N−m) 19 1 18 3 6 RIGHT FRONT 2 17 17 8 9 15 14 20 7 16 13 12 11 10 5 19 OPH−2 series planetary = 60 ft−lbs (81 N−m) VA02 series planetary = 75 to 85 ft−lbs (101 to 115 N−m) 4 85 to 100 ft−lb (116 to 135 N−m) Figure 2 1. 2. 3. 4. 5. 6. 7. 8.
Brake Assembly Installation (Fig. 2) Brake Assembly Removal (Fig. 2) 1. Park machine on a level surface and raise cutting decks to allow easier access to front brake assembly. Stop engine, engage parking brake and remove key from the ignition switch. 3 2. Drain oil from planetary drive and brake assembly; refer to traction unit Operator’s Manual. 2 CAUTION 1 When changing attachments, tires or performing other service, use correct blocks, hoists and jacks to raise and support machine.
3. Install brake cable to pull rod on brake assembly. Brake cable end should be completely threaded onto pull rod before tightening jam nut. 7. Check and adjust brake cables for proper brake operation (see machine Operator’s Manual). WARNING 4. Make sure wheel motor O−ring (item 4) is in position and secure wheel motor to planetary with two (2) cap screws and flat washers. For OPH−2 series planetary drives: tighten screws from 60 ft−lb (81 N−m).
Brake Inspection and Repair 3 2 1 4 5 6 7 8 9 15 14 10 13 12 11 Brake housing (LH shown) Seal Pull rod Clevis pin (2 used) Link (2 used) 6. 7. 8. 9. 10. Hitch pin (2 used) Stationary disc (4 used) Rotating disc (3 used) Retaining ring Gasket 11. 12. 13. 14. 15. Rotating actuator Extension spring (3 used) Ball (3 used) Plug O−ring Brake Inspection and Repair (Fig. 5) 6. Remove seal (item 2) from brake housing. 1.
Planetary Drive Assembly OPH−2 series planetary VA02 series planetary OPH−2 series planetary = 60 ft−lbs (81 N−m) VA02 series planetary = 75 to 85 ft−lbs (101 to 115 N−m) 19 1 18 3 6 RIGHT FRONT 2 17 17 8 9 15 14 20 7 16 13 12 11 10 5 19 OPH−2 series planetary = 60 ft−lbs (81 N−m) VA02 series planetary = 75 to 85 ft−lbs (101 to 115 N−m) 4 85 to 100 ft−lb (116 to 135 N−m) Figure 6 1. 2. 3. 4. 5. 6. 7. 8.
Planetary Drive Removal (Fig. 6) Planetary Drive Installation (Fig. 6) 1. Park machine on a level surface, lower cutting decks, stop engine, engage parking brake and remove key from the ignition switch. 1. Position planetary assembly to machine making sure to engage splined brake shaft with planetary drive shaft. Secure planetary assembly to frame with six (6) flange head screws. 2. Drain the oil from the brake assembly and the Planetary drive; refer to the traction unit Operator’s Manual.
OPH−2 Series Planetary Drive Service 2 118 to 144 in−lb (13.3 to 16.3 N−m) 3 4 7 8 9 11 1 12 13 14 5 15 16 6 10 28 21 13 27 26 17 25 24 23 22 20 OPH−2 series planetary 19 18 Figure 7 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. Spindle Boot seal Oil seal Inner bearing cone Inner bearing cup Wheel stud (8 used) Socket head screw (16 used) Lock washer (16 used) Housing Dowel pin (2 used) Axles, Planetaries and Brakes 11. 12. 13. 14. 15. 16. 17. 18. 19.
NOTE: The planetary drive assembly can be serviced 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. Park machine on a level surface, stop engine and remove key from the ignition switch. 2. Drain oil from planetary drive/brake assembly; refer to traction unit Operator’s Manual. 3. Chock rear wheels and jack up front of machine (see Jacking Instructions in Chapter 1 − Safety).
C. Make sure that seal bore in housing is thoroughly cleaned. If OD of seal (item 3) is not rubber or does not have a sealant coating, apply light coating of silicone sealant to seal bore in housing. Install seal into housing so it is flush with housing face. Lightly grease seal lips. D. Pack boot seal (item 2) with grease and install on housing. E. If ring gear was removed from housing, place dowel pins (item 10) in housing.
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VA02 Series Planetary Drive Service 1 2 3 5 37 N−m (27 ft−lb) VA02 series planetary 7 4 8 9 4 5 11 12 13 14 6 15 10 28 27 20 19 26 24 25 24 23 22 21 18 17 16 G248465 Figure 9 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. Spindle Boot seal Lip seal Inner bearing cup (2) Inner bearing cone (2) Wheel stud (8) Socket head screw (8) Lock washer (8) Housing Dowel pin (4) Axles, Planetaries and Brakes 11. 12. 13. 14. 15. 16. 17. 18. 19.
NOTE: The planetary drive assembly is best serviced with the planetary installed to machine or the spindle firmly secured to a fixture or workbench. If the spindle (item 1) needs to be removed from machine, see Planetary Drive Assembly in this chapter. 2 7 8 13 11 10 14 28 27 15 24 3 16 Disassembly 1. Park machine on a level surface, stop engine and remove key from the ignition switch. 2. Drain oil from planetary drive and brake assembly; refer to traction unit Operator’s Manual.
4. If previously removed, press bearing cups into housing. Cups should be pressed fully to shoulder of the housing bore. 5. Fit inner bearing cone onto spindle. Make sure inner bearing cone seats fully against spindle shoulder. If inner bearing is not seated fully, lightly tap bearing cone on inner hub until it seats properly. 6. Make sure that seal bore in housing is thoroughly cleaned.
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Rear Axle Assembly 7 6 70 ft−lb (94 N−m) maximum 8 1 3 4 5 2 14 13 10 12 11 9 16 22 15 17 5 21 RIGHT 20 85 to 100 ft−lb (116 to 135 N−m) 19 FRONT 18 Figure 11 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. Steering cylinder Needle bearing External snap ring External snap ring Thrust washer Flat washer Lock nut Grease fitting Cap screw (2 used) Flat washer (2 used) Piston motor O−ring Pinion gear Gear Stop pin 16. 17. 18. 19. 20. 21. 22.
7. Remove hydraulic hose from hydraulic fitting on side of input gear case. 8. Remove lock nut and flat washer from axle pivot pin. 9. Support rear axle to prevent it from falling. Remove pivot pin. Lower rear axle from machine. Note location of thrust washer on both ends of axle mounting boss. 10.If needed for further axle disassembly, remove steering cylinder from axle (see Steering Cylinder in Service and Repairs section of Chapter 4 − Hydraulic System). 11.
Rear Axle Service 10 11 21 20 19 17 18 24 22 2 23 16 1 25 4 13 15 12 5 26 43 6 7 8 44 45 27 61 33 28 29 46 62 14 3 9 47 8 32 30 31 10 11 48 37 50 63 64 42 22 60 51 38 41 52 8 9 35 36 49 13 34 40 53 59 54 58 39 57 56 55 Figure 14 Axles, Planetaries and Brakes Page 6 − 22 Groundsmaster 4500−D/4700−D
Figure 12 (Continued) 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. LH axle support Flange bushing (2 used) Axle vent Filter Vent extension Cap screw (4 used per gear case) Shim set Seal washer Plug Lock nut Lock washer Grease fitting Ball bearing Screw (2 used per steering arm) Axle case support (LH shown) Bolt (2 used) Stud (2 used) Shim set Differential assembly O−ring Plug O−ring 23. 24. 25. 26. 27. 28. 29. 30. 31. 32. 33. 34. 35. 36. 37. 38. 39. 40. 41. 42. 43.
Bevel Gear Case and Axle Case The following procedures assume the rear axle assembly has been removed from the machine. 35 to 41 ft−lb (47 to 56 N−m) Removal 1 6 1. Remove the mounting screws, nuts and lock washers. Remove the bevel gear case/axle case assembly and O-ring from the axle support (Fig. 15). 4 5 2 2. Mark both right and left bevel gear case/axle case assemblies. 3 35 to 41 ft−lb (47 to 56 N−m) IMPORTANT: Do not interchange right and left bevel gear case/axle case assemblies.
5. Remove the knuckle pin mounting screws and the knuckle pin. Remove the gasket and any remaining gasket material from either mating surface (Fig. 18). 6. While holding the bevel gear case, tap the upper end of the bevel gear shaft out of the upper bearing and upper bevel gear. 2 1 17 to 20 ft−lb (23 to 27 N−m) 3 4 Thread−locking Compound 7. Pull the bevel gear case from the axle case and remove the upper bevel gear and collar from the gear case. 5 8.
Installation 1. Coat new shaft seal with grease and install in axle case as shown (Fig. 20). 3 2 1 Figure 20 1. Axle case 2. Bevel gear case 2. Install the lower bevel gear and bevel gear shaft in the axle case cover. Coat a new O-ring with grease and install the axle case cover (Fig. 21). Tighten cover screws from 17 to 20 ft-lb (23 to 27 N−m). 3. Shaft seal 7 8 3. Slide the bevel gear case over the bevel gear shaft and install the bevel gear and collar.
5. Determine necessary quantity of support shims. 4 A. Lubricate the axle case support bushing with a thin coat of grease and slide axle case support onto knuckle pin. B. Position support shims that were removed during disassembly between axle case support and axle case. Install mounting screws into axle case. Slowly tighten screws while frequently checking for clearance (vertical endplay) between axle case support and knuckle pin.
9. Remove the bevel gear case/axle case assembly from the axle support. Coat a new O-ring with grease and temporarily install the axle cover assembly. Position a dial indicator at the tooths center. Prevent the axle from turning and measure the lower bevel gear to axle gear backlash (Fig. 24). LOWER BEVEL GEAR BACKLASH: 0.004 to 0.016 in. (0.10 to 0.40 mm) 10.Adjust backlash by increasing or reducing axle bearing shim thickness (see Axle Shafts in this section of this manual).
Axle Shafts The following procedures assume the rear axle assembly has been removed from the machine. 17 to 20 ft−lb (23 to 27 N−m) 1 Removal 1. Remove the axle cover mounting screws. Remove the axle cover from the axle case as an assembly (Fig. 27). 4 3 2. Use a bearing puller to remove the bearing and bevel gear as shown (Fig. 28). 3. Remove the shims, spacer and retaining ring. Drive the axle out of the bearing and cover. Remove and discard the axle shaft seal. 4.
Input Shaft/Pinion Gear 35 to 41 ft−lb (47 to 56 N−m) 1 3 2 18 20 19 9 8 7 6 5 17 4 18 16 15 10 14 10 9 13 11 35 to 41 ft−lb (47 to 56 N−m) 12 Figure 30 1. 2. 3. 4. 5. 6. 7. Nut (2 used) Lock washer (2 used) Stud (2 used) Lock nut Stake washer Oil seal O-ring 8. 9. 10. 11. 12. 13. 14. Seal collar Bearing O-ring Input shaft/pinion gear Bearing case Shim Screw (2 used) The following procedures assume the rear axle assembly has been removed from the machine. Removal (Fig. 30) 1.
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 force is required to rotate the input shaft/pinion gear in the bearing case. 0.040 in. (1.0 mm) 2 1 7. Secure the lock nut with the stake washer. 8.
Differential Gear The following procedures assume the rear axle assembly has been removed from the machine. 35 to 41 ft−lb (47 to 56 N−m) 1 Removal 1. Remove bevel gear case/axle case assemblies (see Bevel Gear Case/Axle Case Assembly in this section of this manual). IMPORTANT: Do not interchange right and left differential shafts assemblies. 2. Mark and pull the differential shaft assemblies from the axle support. 3. Remove input shaft/pinion gear assembly, shims and O-ring from the axle support (Fig.
Inspection 1. Measure the differential side gear O.D. and the differential case I.D. to determine the side gear to case clearance (Fig. 37). Replace components as necessary. SIDE GEAR TO CASE CLEARANCE: 0.002 to 0.012 in. (0.05 to 0.30 mm) 1 SIDE GEAR O.D. (Factory Spec.): 1.335 to 1.337 in. (33.91 to 33.95 mm) DIFFERENTIAL CASE I.D. (Factory Spec.): 1.339 to 1.341 in. (34.00 to 34.06 mm) 2 2. Measure the differential pinion shaft O.D. and the pinion gear I.D.
Installation 3 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 1 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. 3. Install the side gear shims and side gears in their original location in the differential case. 4.
Pinion Gear to Ring Gear Engagement The final position of the pinion gear is verified by using the gear contact pattern method as described in the following procedure. PROFILE TOP LAND GEAR TOOTH DEFINITIONS (Fig. 41): Toe − the portion of the tooth surface at the end towards the center. TOE HEEL Heel − the portion of the gear tooth at the outer end. LENGTHWISE BEARING ARC Top Land − top surface of tooth. 1.
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. 44): A. Install thicker or additional bearing case shim(s) to move pinion shaft toward ring gear. Figure 44 B. Install thinner or remove differential bearing shim(s) to move ring gear backward. C.
Chapter 7 Chassis Table of Contents Chassis GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . 2 Operator’s Manual . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Cutting Deck Identification . . . . . . . . . . . . . . . . . . . . 2 SERVICE AND REPAIRS . . . . . . . . . . . . . . . . . . . . . . 4 Steering Column . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Console Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Lift Arms For Cutting Decks #1, #4 and #5 .
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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Service and Repairs Steering Column 1 4 RIGHT FRONT 2 3 20 to 26 ft--lb (28 to 35 N--m) 5 7 ANTISEIZE LUBRICANT 10 9 11 7 to 10 ft--lb (9.5 to 13.5 N--m) 13 ANTISEIZE LUBRICANT 6 8 6 6 12 Figure 2 1. 2. 3. 4. 5. Steering wheel cover Lock nut Steering wheel Flat washer Foam collar 6. 7. 8. 9. Flange head screw (4 used) Steering column Steering control valve Socket head screw (4 used) Removal (Fig. 2) 1.
7. Slide rubber bellows up steering column to allow access to fasteners that secure steering control valve and steering column to machine. 1 2 4 8. Support steering control valve to prevent it from shifting during steering column removal. 3 9. Loosen and remove four (4) socket head screws (item 13) that secure steering control valve to steering column. 4 10.Loosen and remove four (4) socket head screws (item 9) and flange nuts (item 10) that secure steering column to machine. 5 6 11.
Console Arm 28 39 40 7 34 33 14 12 26 37 13 41 8 15 24 27 10 36 45 21 19 20 35 25 27 46 9 5 15 44 31 23 43 3 11 38 1 42 18 16 36 17 32 22 30 RIGHT 6 6 FRONT 2 4 29 Figure 5 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16.
Disassembly (Fig. 5) 1. Park machine on a level surface, lower cutting units, stop engine and engage parking brake. Remove key from ignition switch. 9 10 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). 3. At front of console arm, remove screw (item 5) and lock nut (item 6) that secure console arm covers to each other. 6 5 4 3 2 1 5 12 11 13 14 5. Remove console arm covers from machine.
Lift Arms for Cutting Decks #1, #4 and #5 7 1 17 19 30 22 2 3 35 4 4 8 35 5 32 6 20 9 14 2 34 10 34 13 11 12 15 33 10 14 20 4 22 33 7 5 1 21 31 34 19 29 RIGHT 17 27 28 26 25 24 23 16 FRONT 33 20 35 18 6 19 Figure 7 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. Flat washer Flange nut Lift arm (#1 deck) Lift cylinder pin Flange head screw Flange nut Cap screw Lift cylinder (#4 and #5 decks) Lift cylinder (#1 deck) Thrust washer Lock nut Pivot pin 13. 14. 15. 16. 17. 18.
5. Loosen and remove lock nut (item 11) from lift arm pivot pin. #4 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. #1 Deck #5 Deck 7. Remove lift arm from machine (see Cutting Deck Operator’s Manual). 8. Disassemble lift arm as needed using Figure 7 as a guide. #2 Deck #6 Deck (GM4700) #3 Deck #7 Deck (GM4700) 9. Clean lift arm and pivot pin.
Lift Arms for Cutting Decks #2 and #3 5 RIGHT FRONT 17 13 16 14 7 18 4 8 6 10 1 15 2 3 Loctite #242 12 9 11 Figure 10 1. 2. 3. 4. 5. 6. Grease fitting Set screw (2 used per stop) Rotation stop Flange head screw Lock nut Slotted roll pin Chassis 7. 8. 9. 10. 11. 12. Pivot pin Bumper Thrust washer Lift cylinder pin Deck pivot shaft Lift arm (#2 deck shown) Page 7 -- 10 13. 14. 15. 16. 17. 18.
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. 7. After assembly, raise and lower the cutting deck to verify that hydraulic hoses and fittings do not contact anything. 2. Remove cutting deck from lift arm (see Cutting Deck Operator’s Manual). #4 Deck #1 Deck #5 Deck 3. Remove lift cylinder pin (item 10) that secures lift cylinder to lift arm. 4. Loosen and remove lock nut (item 17) from pivot pin. 5.
Lift Arms for Cutting Decks #6 and #7 (Groundsmaster 4700--D) 1 2 3 135 to 165 ft--lb (184 to 223 N--m) 5 7 1 40 9 6 37 27 25 10 30 39 36 26 135 to 165 ft--lb (184 to 223 N--m) 8 34 41 31 6 32 1 33 14 12 13 11 18 4 1 15 17 15 19 20 27 10 28 29 4 38 42 35 16 RIGHT FRONT 23 21 24 42 22 Figure 12 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14.
Removal (Fig. 12) 1. Park machine on a level surface, lower cutting decks, stop engine, engage parking brake and remove key from the ignition switch. #4 Deck #1 Deck #5 Deck 2. Remove cutting deck from lift arm (see Cutting Deck Operator’s Manual). 3. Remove pin (item 27) that secures lift links (item 10) to lift arm. 4. Loosen and remove lock nut (item 19) from pivot pin (item 28). 5. Support lift arm and pull lift arm pivot pin from lift arm and support arm.
Operator Seat RIGHT FRONT 18 32 23 30 31 27 20 33 28 14 22 11 28 4 26 3 29 16 7 19 29 10 21 6 25 24 11 2 5 12 13 9 17 9 29 1 15 8 Figure 14 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. Seat frame Seat plate Torsion spring Seat plate latch Clevis pin Flat washer Cotter pin Hair pin (2 used) Seat frame rod (2 used) Cotter pin (2 used) Flat washer (3 used) Chassis 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22.
Removal (Fig. 14) 1. Park machine on a level surface, lower cutting decks, stop engine, apply parking brake and remove key from the ignition switch. 2. Disconnect seat electrical connector from machine wire harness. 3. Support console arm assembly to prevent it from shifting. C. Place flat washer (item 11), seat belt buckle (item 14) and spacer (item 26) between seat and console arm support (item 23). Secure with cap screw (item 27). D. Fully tighten all fasteners to secure console arm assembly to seat. 4.
Operator Seat Service 28 7 6 21 1 2 5 13 12 21 29 22 26 25 31 30 18 19 20 11 4 16 14 17 24 3 23 9 8 27 10 15 Figure 16 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. Backrest cushion Seat cushion LH armrest cover LH armrest Bushing (2 used) Backrest Plug (2 used) Cable tie (3 used) LH adjustment rail Bumper (2 used) Washer Chassis 12. 13. 14. 15. 16. 17. 18. 19. 20. 21.
Disassembly (Fig. 16) Assembly (Fig. 16) 1. Remove seat from machine for service (see Operator Seat Removal in this section). 1. Assemble operator seat using Figure 16 as a guide. 2. Install seat to machine (see Operator Seat Installation in this section). Chassis 2. Disassemble operator seat as necessary using Figure 16 as a guide.
Operator Seat Suspension RIGHT 16 17 FRONT 24 22 25 23 5 18 2 19 21 33 1 20 3 39 14 12 7 35 28 30 6 15 38 27 13 31 4 36 8 29 9 10 26 33 11 34 32 37 Figure 17 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. Cover Cover Level control Air control valve Shock absorber Air spring Air tube assembly Wire harness Compressor Bellows Stop Bumper set (2 used) Roller (4 used) Chassis 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26.
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 removed from the seat plate. Disassembly (Fig. 17) 5 4 1. Park machine on a level surface, lower cutting decks, stop engine, apply parking brake and remove key from the ignition switch. 3 2. Remove operator seat from seat suspension (see Operator Seat Removal in this section). 3.
Hood 5 6 RIGHT 4 26 FRONT 1 7 25 22 8 30 33 24 11 31 20 21 26 25 32 29 23 3 14 10 12 13 2 9 17 16 28 15 18 27 19 Figure 19 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. Screen Latch keeper Pop rivet (2 used) Hood Plastic plug (20 used) Hood screen Bulb seal (2 used) Adjustable latch Hair pin (2 used) Rear bumper Pop rivet (2 used) Chassis 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22.
Removal (Fig. 19) Installation (Fig. 19) 1. Park machine on a level surface, lower cutting decks, stop engine, engage parking brake and remove key from the ignition switch. 1. If components were removed from hood, assemble hood using Figure 19 as a guide. 2. Release hood latches and raise hood. 3. Remove hair pins and washers from pivot pins on radiator frame. 4. Remove hood from pivot pins and machine. 2. Slide hood frame onto radiator frame pivot pins. 3.
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Chapter 8 Cutting Decks Table of Contents Cutting Decks SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . 3 Operator’s Manual . . . . . . . . . . . . . . . . . . . . . . . . . . 3 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . 4 Factors That Can Affect Quality of Cut . . . . . . . . . 4 SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 ADJUSTMENTS . . . . . . . . . . . . . . .
Specifications Groundsmaster 4500--D Groundsmaster 4700--D MOUNTING: All cutting decks are supported by independent lift arms and are interchangeable to any cutting deck positions. The Groundsmaster 4500--D uses five (5) cutting decks. The Groundsmaster 4700--D uses seven (7) cutting decks. CONSTRUCTION: Deck chamber and frame are welded steel construction reinforced with channels and plates. HEIGHT--OF--CUT RANGE: 3/4 to 4 inch (19 to 101 mm) in 1/4 inch (6.4 mm) increments.
General Information CAUTION Never install or work on the cutting decks or lift arms with the engine running. Always stop engine and remove key from ignition switch first. Operator’s Manual Cutting Decks The Cutting Deck Operator’s Manual provides information regarding the operation, general maintenance and maintenance intervals for the cutting deck on your Groundsmaster machine. Refer to that publication for additional information when servicing the cutting deck.
Troubleshooting There are a number of factors that can contribute to unsatisfactory quality of cut, some of which may be turf conditions. Turf conditions such as excessive thatch, “sponginess”, uneven ground conditions or attempting to cut off too much grass height may not always be overcome by adjusting the machine. It is important to remember that the lower the height--of--cut, the more critical these factors are.
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.
Adjustments CAUTION Never install or work on the cutting decks or lift arms with the engine running. Always stop engine 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. Blade Stopping Time The blades of the cutting decks are to come to a complete stop in approximately five (5) seconds after the PTO is disengaged.
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Service and Repairs CAUTION Never install or work on the cutting decks or lift arms with the engine running. Always stop engine and remove key from ignition switch first. Blade Spindle Assembly 11 2 12 1 3 4 6 5 8 7 RIGHT 88 to 108 ft--lb (120 to 146 N--m) FRONT 9 10 Figure 3 1. 2. 3. 4. Flange nut (6 used) Hydraulic deck motor Spindle plate Cutting deck Cutting Decks 5. 6. 7. 8. O--ring Spindle assembly Cap screw (6 used) Cutting blade Page 8 -- 8 9. 10. 11. 12.
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 washers that secure hydraulic motor to the cutting deck (Fig. 4). Remove hydraulic motor and O--ring from deck. 1 3. Cover top of spindle to prevent debris from entering spindle. A spindle plug (see Special Tools in this chapter) can be used to cover spindle. 4. Start the engine and raise the cutting deck.
Blade Spindle Service Disassembly (Fig. 5) 2 6 1. Remove blade spindle from cutting deck (see Blade Spindle Removal in this section). 2. Loosen and remove spindle nut from top of spindle shaft. 4 11 130 to 160 ft--lb (177 to 216 N--m) 10 3. Remove the spindle shaft from the spindle housing which may require the use of an arbor press. The spindle shaft spacer should remain on the spindle shaft as the shaft is being removed. 9 12 8 7 1 4.
3. Using an arbor press, push the bearing cups into the top and bottom of the spindle housing. The top bearing cup must contact the outer bearing spacer previously installed, and the bottom bearing cup must contact the large snap ring. Make sure that the assembly is correct by supporting the first bearing cup and pressing the second cup against it (Fig 7). PRESS 4 4. Pack the bearing cones with grease. Apply a film of grease on lips of oil seals. 5.
Rear Roller 2 29 to 35 ft--lb (40 to 47 N--m) 3 4 5 RIGHT 6 1 7 FRONT 8 29 to 35 ft--lb (40 to 47 N--m) Figure 9 1. Deck frame 2. Rear roller assembly 3. Grease fitting Cutting Decks 4. Roller shaft screw 5. Roller mount 6. Flange head screw Page 8 -- 12 7. Skid bracket 8.
Removal (Fig. 9) 30 ft--lb (41 N--m) 1. Park machine on a level surface, lower cutting decks, stop engine, engage parking brake and remove key from the ignition switch. 4 2. If cutting deck is equipped with a roller scraper (Fig. 10), remove fasteners securing left and right scraper rod brackets to roller mounts. Remove scraper rod assembly. 1 3 29 to 35 ft--lb (40 to 47 N--m) 2 3. Remove four (4) flange head screws securing roller mounts to rear of deck frame.
Rear Roller Service Disassembly (Fig. 11) 2 1. Remove bearing lock nut from each end of roller shaft. 50 to 60 ft--lb (68 to 81 N--m) 3 4 2. Loosely secure roller assembly in bench vise and lightly tap one end of roller shaft until outer seals and bearing are removed from opposite end of roller tube. Remove second set of outer seals and bearing from roller tube by tapping on opposite end of shaft. Remove shaft from roller tube. 5 6 7 1 2 4 3 5 3.
3. From the roller tube end with only the inner seal installed, carefully install the roller shaft into the roller tube. Make sure that seals are not damaged as shaft is installed. 4. Install new bearing and outer seals into second end of roller tube: NOTE: After roller is installed to cutting deck, lubricate roller grease fittings, rotate roller to properly distribute grease in bearings and clean excess grease from roller ends. A properly assembled roller should rotate with less than 5 in--lbs (0.
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: 1 A. Insert punch through end of roller and drive opposite bearing out by alternating taps to opposite side of inner bearing race. There should be a lip of inner race exposed for this process. 2 80 ft--lb (108 N--m) 3 B. Remove bearing spacer. Remove second bearing from roller using a press. 4 2 4.
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Cutting Deck Carrier Frame Decks #2 and #3 Decks #1, #4 and #5 12 3 11 5 1 1 10 9 4 3 2 Decks #6 and #7 17 15 6 RIGHT 16 7 8 3 FRONT 14 1 13 Figure 18 1. 2. 3. 4. 5. 6. Carrier frame Lynch pin Thrust washer Pivot shaft Lift arm (#4 shown) Flange nut (2 used per deck) Cutting Decks 7. 8. 9. 10. 11. 12. Hardened washer (2 used per deck) Cap screw (2 used per deck) Cap screw Rebound washer Pivot shaft Lift arm (#2 shown) Page 8 -- 18 13. 14. 15. 16. 17.
Removal and Installation (Fig. 18) Each cutting deck is suspended from a carrier frame. The cutting deck carrier frame is attached to the lift arm and allows the cutting deck to pivot on the lift arm pivot shaft. Cutting deck positions are identified in Figure 19. #4 Deck #1 Deck #5 Deck Cutting deck carrier frames are secured to lift arms as follows: 1. Carrier frames for the front three cutting decks (#1, #4 and #5) have a thrust washer between the carrier frame and the lift arm.
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Chapter 9 Foldout Drawings Table of Contents Groundsmaster 4500--D/4700--D Page 9 - 1 Foldout Drawings Foldout Drawings HYDRAULIC SCHEMATICS Groundsmaster 4500--D . . . . . . . . . . . . . . . . . . . . . . 3 Groundsmaster 4700--D . . . . . . . . . . . . . . . . . . . . . . 4 ELECTRICAL SCHEMATIC Groundsmaster 4500--D/4700--D (3 Sheets) . . . . 5 WIRE HARNESS DRAWINGS Main Wire Harness . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Seat and Console Wire Harness . . . . . . . . . . . . .
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S6 STEERING CYLINDER S5 R1 TS S1 CV TS #2 PS #3 CM1 #5 FRONT PORTS BYPASS VALVE TS #4 #1 Groundsmaster 4500--D Hydraulic Schematic Page 9 - 3
S4 S9 S6 STEERING CYLINDER S2 S3 S8 S7 S5 S1 R1 TS #7 S1 CV #2 TS PS #3 CM1 #5 FRONT PORTS BYPASS VALVE #6 TS #4 #1 Groundsmaster 4700--D Hydraulic Schematic Page 9 - 4
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.
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.
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.
Groundsmaster 4500--D/4700--D Main Wire Harness Page 9 - 8
BLACK PINK PINK/ BLACK PINK/WHITE BLACK BLUE BLACK PINK WHITE BLACK WHITE RED BLACK VIOLET BLACK VIOLET BLACK BLACK VIOLET WHITE GREEN WHITE/ORANGE PINK BLACK/WHITE RED/WHITE ORANGE BLUE/BLACK TAN/BLACK WHITE/BLACK PINK/BLACK BROWN/WHITE BLACK WHITE/YELLOW RED/GREEN BROWN GREEN GRAY BLACK BLACK RED/BLACK BLUE ORANGE/WHITE BLACK BLACK/WHITE RED/WHITE WHITE/BLACK WHITE/GREEN TAN/WHITE BLACK/YELLOW WHITE/VIOLET WHITE/YELLOW GRAY/BLUE BROWN/WHITE BLACK TAN/BLACK PINK/BLUE GRAY VIOLE
Groundsmaster 4500--D/4700--D Seat and Console Wire Harness Page 9 - 10
BLACK BLACK RED/GREEN RED/YELLOW TAN/BLACK TAN/WHITE PINK/GREEN WHITE/BLACK GRAY/BLUE BROWN BLACK PINK BLACK PINK BLACK PINK PINK WHITE BLUE RED/WHITE PINK YELLOW BLUE/BLACK WHITE GREEN VIOLET ORANGE BLACK/WHITE WHITE/ORANGE ORANGE/WHITE VIOLET/WHITE PINK/WHITE BROWN/YELLOW GRAY VIOLET/BLACK BLUE/WHITE PINK/BLACK WHITE/YELLOW BROWN/WHITE BLUE/BLACK BLACK BLACK BLACK BLACK BLACK GRAY PINK BLACK BLACK BLACK BLACK BLACK BLACK BLACK Groundsmaster 4500--D/4700-
Groundsmaster 4500--D/4700--D Power Center Wire Harness Page 9 - 12
RED RED RED RED ORANGE/WHITE RED VIOLET BLACK WHITE/BLACK BROWN/BLACK TAN/BLACK GRAY/BLACK BLUE RED PINK/BLACK BLACK ORANGE RED RED ORANGE BLACK BLACK WHITE/YELLOW BROWN BLUE PINK RED/BLUE WHITE/BLACK RED/GREEN BROWN/BLACK TAN/BLACK RED RED RED RED RED BLACK PINK BLACK RED RED GRAY/BLACK Groundsmaster 4500--D/4700--D Power Center Wire Harness Page 9 - 13
Groundsmaster 4700--D Deck 6 and 7 Wire Harness Page 9 - 14
BLACK GRAY/BLACK VIOLET BLACK BLUE PINK/BLACK TAN 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/WHITE TAN/BLACK BLUE/BLACK YELLOW/BLUE BLACK WHITE/BLACK YELLOW/BLACK BLACK BLACK VIOLET/BLACK GREEN/PINK ORANGE BLACK BLACK/WHITE RED/WHITE PINK BLACK BLACK GRAY RED/WHITE BLACK/WHITE BLACK/WHITE RED/WHITE Groundsmaster 4700--D Deck 6 and 7 Wire Harness Page 9 - 15
