Form No.
Revision History Revision Date Description -- 2002 Initial Issue. A 2003 Updated Engine chapter. B 2005 Updated Hydraulic chapter. C 2007 Updated Electrical chapter. D 2007 Updated Hydraulic chapter. E 03/2018 Added revision history. © THE TORO COMPANY 2018 This document and all information contained herein is the sole property of The Toro Company (and/or its affiliated companies).
Reader Comments The Toro Company Technical Assistance Center maintains a continuous effort to improve the quality and usefulness of its publications. To do this effectively, we encourage user feedback. Please comment on the completeness, accuracy, organization, usability, and readability of this manual by an e-mail to servicemanuals@toro.
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PART NO. 02104SL (Rev. E) Service Manual 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 and 4700--D. 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 -2 -2 -2 -- 1 1 2 3 Chapter 3 -- Kubota Diesel Engine General Information . . . . . . . . . . . . . . . . . . . . . . . . 3 -- 2 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 -- 3 Adjustments . . . . . .
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Safety Table of Contents GENERAL SAFETY INSTRUCTIONS . . . . . . . . . . . . Before Operating . . . . . . . . . . . . . . . . . . . . . . . . . . . . While Operating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Maintenance and Service . . . . . . . . . . . . . . . . . . . . Groundsmaster 4500--D/4700--D 2 2 2 3 JACKING INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . 4 SAFETY AND INSTRUCTION DECALS . . . . . . . . . .
General Safety Instructions The GROUNDSMASTER 4500-D/4700--D was tested and certified by TORO for compliance with the B71.4-1999 specifications of the American National Standards Institute. 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. Before servicing or making adjustments, lower decks, stop engine, set parking brake, and remove key from the switch. 10.Do not overspeed the engine by changing governor setting. To assure safety and accuracy, check maximum engine speed. 2. Make sure machine is in safe operating condition by keeping all nuts, bolts and screws tight. 11. Shut engine off before checking or adding oil to the crankcase. 3.
Jacking Instructions CAUTION When changing attachments, tires, or performing other service, use correct blocks, hoists, and jacks. Make sure machine is parked on a solid level surface such as a concrete floor. Prior to raising machine, remove any attachments that may interfere with the safe and proper raising of the machine. Always chock or block wheels. Use jack stands or solid wood blocks to support the raised machine.
Safety Safety and Instruction Decals Numerous safety and instruction decals are affixed to the Groundsmaster 4500--D/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 0.09375 Product Records and Maintenance Page 2 -- 2 Rev.
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 Strong
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 + 5 in--lb 640 + 60 N--cm 78 + 7 in--lb 885 + 80 N--cm M6 X 1.0 96 + 9 in--lb 1018 + 100 N--cm 133 + 13 in--lb 1500 + 150 N--cm M8 X 1.25 19 + 2 ft--lb 26 + 3 N--m 27 + 2 ft--lb 36 + 3 N--m M10 X 1.5 38 + 4 ft--lb 52 + 5 N--m 53 + 5 ft--lb 72 + 7 N--m M12 X 1.
Other Torque Specifications SAE Grade 8 Steel Set Screws Wheel Bolts and Lug Nuts Thread Size Recommended Torque Thread Size Square Head Hex Socket 1/4 -- 20 UNC 140 + 20 in--lb 73 + 12 in--lb 5/16 -- 18 UNC 215 + 35 in--lb 145 + 20 in--lb 3/8 -- 16 UNC 35 + 10 ft--lb 18 + 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 GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine Run Solenoid . . . . . . . . . . . . . . . . . . . . . . . . SERVICE AND REPAIRS . . . . . . . . . . . . . . . . . . . . . . Air Filter System . . . . . . . . . . . . . . . . . . . . . . . . . . . . Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . . .
General Information This Chapter gives information about specifications and repair of the diesel engine used in the Groundsmaster 4500--D/4700--D. General maintenance procedures are described in your Traction Unit Operator’s Manual. Information on engine troubleshooting, testing, disassembly and reassembly is identified in the Kubota Workshop Manual, Diesel Engine, V2003--T that is included at the end of this section.
Specifications Item Description Make / Designation Kubota, 4--Cycle, 4 Cylinder, Water Cooled, Turbocharged, Diesel Engine 58 HP (43.3 kW) @ 2600 RPM Bore mm (in.) 83.0 (3.27) Stroke mm (in.) 92.4 (3.64) Total Displacement cc (cu. in.) 1999 (122.12) Firing Order 1--3--4--2 Combustion Chamber Spherical Type Fuel No. 2 Diesel Fuel (ASTM D975) Fuel Capacity liters (U.S. gallons) 79.5 (21.
Adjustments Engine Run Solenoid 1. When ignition switch is in the RUN position, the engine run solenoid should energize and position the fuel stop lever to within 1/16” (1.6 mm) of stop on the injection pump. 4 2 3 2. If adjustment is needed, loosen lock nut and rotate the threaded end of the swivel until the lever is properly positioned. 3. Tighten lock nut. Recheck adjustment. 1 Figure 1 1. Run solenoid (ON) 2. Lever 3. Swivel 4. Lock nut 2 1 3 Figure 2 1. Run solenoid (OFF) 2.
Service and Repairs Air Filter System 7 8 4 11 Kubota Diesel Engine 10 1 RIGHT 2 9 FRONT 15 12 13 3 5 6 11 14 VACUATOR DIRECTION 16 Figure 3 1. 2. 3. 4. 5. 6. Air cleaner hose Hose clamp Air cleaner assembly Service indicator Air cleaner strap Lock nut 7. 8. 9. 10. 11. Hose clamp Air cleaner hose Hose clamp Cap screw Flat washer 12. 13. 14. 15. 16. Removal Air cleaner body Filter element Filter element Air cleaner cover Vacuator valve 4 1.
Exhaust System 1 14 3 11 2 4 5 16 to 22 ft--lb (21 to 29 N--m) 7 9 7 16 to 22 ft--lb (21 to 29 N--m) 12 11 8 8 RIGHT 10 6 6 FRONT 13 16 to 22 ft--lb (21 to 29 N--m) 1. 2. 3. 4. 5. Muffler Muffler bracket/lift tab Exhaust tailpipe Flange head screw Exhaust gasket Kubota Diesel Engine (Rev. A) 6. 7. 8. 9. 10. Figure 5 Lock nut Cap screw Flat washer Spacer Rubber hanger Page 3 -- 6 11. 12. 13. 14.
Removal 3 CAUTION The muffler and exhaust pipe may be hot. To avoid possible burns, allow the engine and exhaust system to cool before working on the muffler. 2 4 2. Remove muffler and/or muffler bracket from the engine as necessary using Figure 5 as a guide. Installation NOTE: Make sure muffler flange and exhaust manifold sealing surfaces are free of debris or damage that may prevent a tight seal. 1 Figure 6 1. Install new gasket if original gasket is damaged or torn.
Fuel System 1 16 6 3 7 4 RIGHT 2 8 5 FRONT 17 9 10 11 14 12 13 15 Figure 7 1. 2. 3. 4. 5. 6. Suction fitting Fuel line clamp Fuel hose Return fitting Fuel hose Fuel tank cap 7. 8. 9. 10. 11. 12. Bushing Fuel level gauge Grommet Fuel tank Tank mount grommet (4 used) Flat washer (4 used) 13. 14. 15. 16. 17. Cap screw (4 used) Hose clamp Draincock Hose clamp Frame Check Fuel Lines and Connections DANGER Because diesel fuel is highly flammable, use caution when storing or handling it.
Fuel Tank Removal Fuel Tank Installation 1. Park machine on a level surface, lower cutting units, stop engine, engage parking brake, and remove key from the ignition switch. 1. Install fuel tank to frame using Figure 7 as a guide. 2. Disconnect fuel hoses from the suction and return fittings in top of tank. 3. Use draincock to empty fuel tank into a suitable container. 2. Connect fuel hoses to the suction and return fittings in top of tank. 3. Make sure that draincock is closed. 4.
Radiator 4 RIGHT FRONT 8 6 7 1 2 3 29 36 28 15 5 39 3 37 35 34 9 10 12 11 15 13 14 26 18 25 27 33 32 15 30 31 38 40 24 15 23 22 15 21 16 17 9 18 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. Hydraulic fitting Oil cooler Flange nut Radiator bracket Bulb seal Air cleaner hose Hood seal bracket Radiator Reservoir hose Hose clamp Radiator cap Radiator fan shroud Clamp Radiator hose Kubota Diesel Engine (Rev. A) 10 19 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27.
Removal 1. Park machine on a level surface, lower cutting units, stop engine, engage parking brake, and remove key from the ignition switch. 2. Remove hood from the machine (see Traction Unit Operator’s Manual). 4. Attach radiator fan shroud to the radiator with flange screws and flat washers. Make sure that clearance between shroud and fan is at least .180” (4.6 mm) at all points. 5. Connect reservoir hose to the vent tube. 6. Connect hoses (upper and lower) to the radiator. 7. Reinstall air cleaner hose.
Engine 16 to 22 ft--lb (21 to 29 N--m) 16 15 14 12 13 17 16 to 22 ft--lb (21 to 29 N--m) 15 22 18 23 19 20 21 11 1 2 25 RIGHT 6 7 9 8 FRONT 24 10 3 4 5 4 1. 2. 3. 4. 5. 6. 7. 8. 9. Engine Flange head screw Rubber engine support Flange nut Rebound washer LH engine mount Lock washer Cap screw Lock washer Kubota Diesel Engine (Rev. A) 10. 11. 12. 13. 14. 15. 16. 17.
Engine Removal 1. Park machine on a level surface, lower cutting units, stop engine, engage parking brake, and remove key from the ignition switch. Raise hood. 2 3 2. Remove battery strap and cover. Disconnect negative battery cable first and then positive battery cable. Remove battery from machine. 1 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.
7. Disconnect fuel line from injection pump (Fig. 17). Cap fuel line and injector pump fuel inlet to prevent contamination. 8. Disconnect throttle cable from the speed control lever by removing the washer and lock nut. Loosen jam nut and take cable from mounting bracket (Fig. 17). 4 9. Remove coolant reservoir and bracket from fan shroud. 5 10.Remove four flange head screws and flat washers securing the fan shroud to the radiator. 1 2 11.
13.Install air cleaner assembly to the engine (see Air Cleaner Installation). One person should operate lift or hoist while the other person guides the engine into the machine. IMPORTANT: Make sure not to damage the engine, fuel lines, hydraulic lines, electrical harness, or other parts while installing the engine. 4. Slowly lower engine into the machine. 5. Align engine mounts to the rubber engine supports. Secure engine with cap screws, rebound washers, and flange head nuts. 6.
Pump Adapter Plate 1 2 17 to 21 ft--lb (23 to 28 N--m) 3 4 6 7 5 2 9 RIGHT FRONT 10 11 8 17 to 21 ft--lb (23 to 28 N--m) 10 35 to 43 ft--lb (48 to 58 N--m) 12 Figure 18 1. 2. 3. 4. Engine Lock washer Cap screw (4 used) Pump adapter plate Kubota Diesel Engine (Rev. A) 5. 6. 7. 8. Plate pin (2 used) Dowel (2 used) Coupling spacer Shoulder bolt (2 used) Page 3 -- 16 9. 10. 11. 12.
Disassembly 1. Hydraulic pump assembly needs to be removed from engine before coupling can be serviced (see Pump Assembly in Chapter 4 -- Hydraulic Systems). 4 3 2 2. Remove pump adapter plate, spring center coupling, and coupling spacer from engine using Figure 18 as a guide. Assembly 2. Install four cap screws and lockwashers to coupling spacer and flywheel. Torque cap screws from 17 to 21 ft--lb (23 to 28 N--m). 2 3 4 1 Figure 19 1. Coupling spacer 2. Shoulder bolt position 3.
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Chapter 4 Hydraulic System SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . 3 Hydraulic Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Hydraulic Fitting Installation . . . . . . . . . . . . . . . . . . . 3 Towing Traction Unit . . . . . . . . . . . . . . . . . . . . . . . . . 5 Check Hydraulic Fluid . . . . . . . . . . . . . . . . . . . . . . . 5 HYDRAULIC SCHEMATICS . . . . . . . . . . . . . . . . . .
Specifications Item Description Piston (Traction) Pump System Relief Pressure: Forward System Relief Pressure: Reverse Charge Pressure Variable displacement piston pump 5000 PSI (345 bar) 5000 PSI (345 bar) 260 PSI (17.9 bar) Gear Pump Cutting Deck Relief Pressure Steering Relief Pressure Lift/Lower Relief Pressure 3 section, positive displacement gear type pump 3500 PSI (241.5 bar) 1180 PSI (81.4 bar) 2200 PSI (151.
General Information Hydraulic Hoses When replacing a hydraulic hose, be sure that the hose is straight (not twisted) before tightening the fittings. This can be done by observing the imprint on the hose. Use two wrenches; hold the hose straight with one wrench and tighten the hose swivel nut onto the fitting with the other wrench. WARNING Before disconnecting or performing any work on hydraulic system, relieve all pressure in system. Stop engine; lower or support all attachment(s).
SAE Straight Thread O--Ring Port -- Non--adjustable 1. Make sure both threads and sealing surfaces are free of burrs, nicks, scratches, or any foreign material. 2. Always replace the O--ring seal when this type of fitting shows signs of leakage. 3. Lubricate the O--ring with a light coating of oil. O--Ring 4. Install the fitting into the port and tighten it down full length until finger tight. 5. Tighten the fitting to the correct Flats From Finger Tight (F.F.F.T.). Size 4 (1/4 in.
Towing Traction Unit IMPORTANT: If towing limits are exceeded, severe damage to the piston pump may occur. If it becomes necessary to tow (or push) the machine, tow (or push) in a forward direction only, at a speed below 3 mph (4.8 kph), and for a distance less than 1/4 mile (0.4 km). The piston (traction) pump is equipped with a by--pass valve that needs to be turned 90o for towing. 1 See Traction Unit Operator’s Manual for additional towing procedures. Figure 7 1.
Hydraulic System (Rev.
Groundsmaster 4500--D/4700--D Page 4 -- 7 Hydraulic System (Rev.
Hydraulic System (Rev.
Traction Circuit Traction circuit pressure (forward and reverse) can be measured at test ports located on the traction circuit hydraulic tubes of the machine. The traction pump and wheel motors use a small amount of hydraulic fluid for internal lubrication. Fluid is designed to leak across pump and motor parts 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 (Rev.
Lower Cutting Units On the Groundsmaster 4500--D, a single lift lever is used to lift and lower the five cutting decks. The Groundsmaster 4700--D has three lift levers to control the cutting decks: the center lever is for the five center decks, the left lever controls the left, rear deck (#6), and the right lever controls the right, rear deck (#7). Pressure to the lift/lower control valve can be monitored at a port on the end of the gear pump.
Hydraulic System (Rev.
Raise Cutting Units On the Groundsmaster 4500--D, a single lift lever is used to lift and lower the five cutting decks. The Groundsmaster 4700--D has three lift levers to control the cutting decks: the center lever is for the five center decks, the left lever controls the left, rear deck, and the right lever controls the right, rear deck.
Hydraulic System (Rev.
Mow Circuit Return oil from the deck motors is directed to the oil cooler and oil filter. Deck motor case drain leakage returns to the hydraulic reservoir. Maximum mow circuit pressure is limited at each deck manifold by the proportional relief valve (PRV1 and PRV2). The deck relief valve pressure is 3500 PSI. Mow circuit pressure can be measured at port (G1) of the deck control manifold.
Cutting Deck Blade Braking When the operator turns the cutting decks OFF, proportional relief valve (PRV) shift occurs in the deck control manifold (Fig. 15). This shifted valve allows oil return to the oil cooler and gear pump. Hydraulic pressure is reduced to the cutting deck motors which begins to slow the cutting blades and also allows the manifold relief valve (RV) to shift. The inertia of the rotating cutting blades increases pressure of the oil return to the deck control manifold.
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Hydraulic System (Rev.
Steering Circuit a left turn. The rotary meter ensures that the oil flow to the cylinder is proportional to the amount of the turning on the steering wheel. Fluid leaving the cylinder flows back through the spool valve then through the T port and to the hydraulic reservoir. A three 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.
Special Tools Order these special tools from your Toro Distributor. Hydraulic Pressure Test Kit -- TOR47009 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 -- TOR4079 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. Figure 21 Measuring Container -- TOR4077 Hydraulic System Use this container for doing hydraulic motor efficiency testing (motors with case drain lines only).
Troubleshooting The charts that follow contain information to assist in 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 test procedures. Problem Possible Cause Hydraulic system operates hot. Engine RPM is too low. Hydraulic reservoir oil level is low. Hydraulic oil is contaminated or the wrong type. Brakes are engaged or sticking. Piston pump by--pass valve is open or damaged.
Problem Possible Causes Machine travels too far before stopping when the traction pedal is released. Traction linkage is out of adjustment. Piston pump servo control valve is damaged. Traction pedal does not return to neutral. Four wheel drive will not engage. Electrical problem exists (see Chapter 5 -- Electrical System). Solenoid valve in 4WD hydraulic manifold is faulty. Cartridge valve in 4WD manifold is damaged or sticking. Rear axle motor is damaged. Four wheel drive will not disengage.
Problem Possible Causes Cutting units will not raise. Engine RPM is too low. Hydraulic oil level in reservoir is low. Lift cylinder(s) is (are) damaged. Lift arm pivots are binding. Relief valve for lift/lower circuit is stuck. Pilot valve in lift/lower manifold is damaged or sticking. Proportional valve in gear pump is faulty. Gear pump section for lift/lower circuit (P3) is inefficient. Cutting units raise, but will not stay up. Lift circuit lines or fittings are leaking.
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.
TEST NO. 1: Traction Circuit Charge Pressure (Using Pressure Gauge) FROM STEERING CONTROL AND LIFT SYSTEM CHARGE CIRCUIT TO TRACTION CONTROL MANIFOLD TO PTO (MOW) CIRCUIT TO LIFT/LOWER CIRCUIT TO STEERING CIRCUIT FROM PTO (MOW) CIRCUIT FROM STEERING CONTROL Working Pressure Low Pressure FROM PTO (MOW) CIRCUIT Return or Suction Flow Hydraulic System (Rev.
Procedure for Traction Circuit Charge Pressure Test 1. Make sure hydraulic oil is at normal operating temperature by operating the machine for approximately 10 minutes. Make sure the hydraulic tank is full. 1 2. Park machine on a level surface with the cutting units lowered and off. Make sure engine is off and the parking brake is engaged. CAUTION 2 Figure 24 1. Right side frame rail 3.
TEST NO. 2: Traction Circuit Relief Pressure (Using Pressure Gauge) CHARGE CIRCUIT NOTE: FORWARD DIRECTION TEST SHOWN TO TRACTION CONTROL MANIFOLD TO LIFT/LOWER CIRCUIT TO PTO (MOW) CIRCUIT TO STEERING CIRCUIT Working Pressure FROM PTO (MOW) CIRCUIT Low Pressure FROM STEERING CONTROL FROM PTO (MOW) CIRCUIT Hydraulic System (Rev.
Procedure for Traction Circuit Relief Pressure Test 1 1. Make sure hydraulic oil is at normal operating temperature by operating the machine for approximately 10 minutes. Make sure the hydraulic tank is full. CAUTION Move machine to an open area, away from people and obstructions. 2 Figure 26 2. Drive machine to an open area, lower cutting units, turn the engine off and engage the parking brake. 1. Forward traction port (faces forward) 2.
TO STEERING CIRCUIT TO LIFT/LOWER CIRCUIT FROM LIFT/LOWER CIRCUIT TEST NO. 3: Cutting Deck Circuit Pressure (Using Pressure Gauge) GM 4500--D Working Pressure Low Pressure Return or Suction Hydraulic System (Rev.
Procedure for Cutting Deck Circuit Pressure Test 1 1. Make sure hydraulic oil is at normal operating temperature by operating the machine for approximately 10 minutes. Make sure the hydraulic tank is full. 2 2. Park machine on a level surface with the cutting units 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.
TO STEERING CIRCUIT TO LIFT/LOWER CIRCUIT TEST NO. 4: Cutting Deck Gear Pump Flow (Using Tester with Pressure Gauges and Flow Meter) NOTE: PUMP SECTION P1 TEST SHOWN FROM DECK MOTORS FROM DECK CONTROL MANIFOLDS FROM LIFT/LOWER CIRCUIT Working Pressure Low Pressure Return or Suction Flow Hydraulic System (Rev.
Procedure for Cutting Deck Gear Pump Flow Test 8. Flow indication should be approximately 11.5 GPM. NOTE: Over a period of time, the gears and wear plates in the pump can wear. A worn pump will by pass oil and make the pump less efficient. Eventually, enough oil loss will occur to cause the cutting unit motors to stall under heavy cutting conditions. Continued operation with a worn, inefficient pump can generate excessive heat and cause damage to the seals and other components in the hydraulic system. 9.
TO STEERING CIRCUIT TO LIFT/LOWER CIRCUIT TEST NO. 5: Cutting Deck Manifold Relief Pressure (Using Tester with Pressure Gauges and Flow Meter) GM 4500--D FROM LIFT/LOWER CIRCUIT TESTER LOCATION FOR PUMP SECTION P1 TESTER LOCATION FOR PUMP SECTION P2 Working Pressure Low Pressure Return or Suction TO STEERING CIRCUIT TO LIFT/LOWER CIRCUIT Flow GM 4700--D FROM LIFT/LOWER CIRCUIT TESTER LOCATION FOR PUMP SECTION P1 TESTER LOCATION FOR PUMP SECTION P2 Hydraulic System (Rev.
Procedure for Cutting Deck Manifold Relief Pressure Test Rotation Direction 1. Make sure hydraulic oil is at normal operating temperature by operating the machine for approximately 10 minutes. Make sure the hydraulic tank is full. 2. Park machine on a level surface with the cutting units lowered and off. Make sure engine is off and the parking brake is engaged. 1 2 CAUTION 3 Prevent personal injury and/or damage to equipment.
TEST NO. 6: Cutting Deck Motor Case Drain Leakage (Using Tester with Pressure Gauges and Flow Meter) TO LIFT/LOWER CIRCUIT FROM STEERING CONTROL VALVE TO STEERING CIRCUIT GM 4500--D DECK #2 TEST SHOWN TESTER LOCATION FOR DECK 2 MEASURING CONTAINER Working Pressure Low Pressure Return or Suction Flow Hydraulic System (Rev.
Procedure for Cutting Deck Motor Case Drain Leakage Test 5. Sit on seat and start the engine. Move throttle to full speed (2800 + 50 RPM). Move PTO switch to ON. NOTE: Over a period of time, a deck motor can wear internally. A worn motor may by--pass 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.
TEST NO. 7: Steering Circuit Relief Pressure (Using Pressure Gauge) STEERING CYLINDER NOTE: LEFT TURN SHOWN R L 1180 PSI STEERING CONTROL T VALVE PB P TO LIFT/LOWER CIRCUIT CHARGE CIRCUIT TO RESERVOIR TO PTO (MOW) CIRCUIT G 50 / 50 PROPORTIONAL FLOW DIVIDER P3 P2 P1 P4 TRACTION CIRCUIT FROM RESERVOIR FROM OIL FILTER Working Pressure Low Pressure Return or Suction Flow Hydraulic System (Rev.
Procedure for Steering Circuit Relief Pressure Test 1. Make sure hydraulic oil is at normal operating temperature by operating the machine for approximately 10 minutes. Make sure the hydraulic tank is full. 2 2. Park machine on a level surface with the cutting units lowered and off. Make sure engine is off and the parking brake is engaged. 1 CAUTION Prevent personal injury and/or damage to equipment. Read all WARNINGS, CAUTIONS, and Precautions for Hydraulic Testing at the beginning of this section.
TEST NO. 8: Lift/Lower Circuit Relief Pressure (Using Pressure Gauge) FROM STEERING CIRCUIT 2200 PSI GM 4500--D SHOWN FROM STEERING CIRCUIT TO PTO (MOW) CIRCUIT FROM PTO (MOW) CIRCUIT TO STEERING CIRCUIT FROM PTO (MOW) CIRCUIT Working Pressure Low Pressure Return or Suction Flow Hydraulic System (Rev.
Procedure for Lift/Lower Circuit Relief Pressure Test 1. Make sure hydraulic oil is at normal operating temperature by operating the machine for approximately 10 minutes. Make sure the hydraulic tank is full. 2. Park machine on a level surface with the cutting units lowered and off. Make sure engine is off and the parking brake is engaged. 2 1 CAUTION Prevent personal injury and/or damage to equipment. Read all WARNINGS, CAUTIONS, and Precautions for Hydraulic Testing at the beginning of this section.
TEST NO. 9: Steering and Lift/Lower Gear Pump Flow (Using Tester with Pressure Gauges and Flow Meter) NOTE: LIFT/LOWER GEAR PUMP FLOW TEST SHOWN TO STEERING CIRCUIT TO PTO (MOW) CIRCUIT TO PTO (MOW) CIRCUIT TO LIFT/LOWER CIRCUIT FORWARD 50 / 50 PROPORTIONAL FLOW DIVIDER P3 P2 P1 TRACTION CIRCUIT P4 TOW VALVE FROM RESERVOIR FROM OIL FILTER CHARGE CIRCUIT Working Pressure Low Pressure Return or Suction Flow Hydraulic System (Rev.
Procedure for Steering and Lift/Lower Gear Pump Flow Test Output from the steering and lift/lower gear pump section is equally divided by a proportional valve to provide flow to the steering circuit and the lift circuit. To test gear pump flow, testing of both circuits is required. Total gear pump flow is the combined flow from the two circuits. 1. Make sure hydraulic oil is at normal operating temperature by operating the machine for approximately 10 minutes. Make sure the hydraulic tank is full. 7.
TEST NO. 10: Counterbalance (RV1) Pressure (Using Pressure Gauge) TO STEERING CIRCUIT FROM PTO (MOW) CIRCUIT FROM PTO (MOW) CIRCUIT FROM STEERING CIRCUIT FROM STEERING CIRCUIT 2200 PSI GM 4500--D SHOWN Working Pressure Low Pressure Return or Suction Flow Hydraulic System (Rev.
Procedure for Counterbalance (RV1) Pressure Test 1. Make sure hydraulic oil is at normal operating temperature by operating the machine for approximately 10 minutes. Make sure the hydraulic tank is full. 1 2. Park machine on a level surface with the cutting units lowered and off. Make sure engine is off and the parking brake is engaged. 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.
TEST NO. 11: Rear Traction Circuit (RV5) Relief Pressure (Using Pressure Gauge) CHARGE CIRCUIT TO TRACTION CONTROL MANIFOLD TO LIFT/LOWER CIRCUIT TO PTO (MOW) CIRCUIT TO STEERING CIRCUIT Working Pressure FROM PTO (MOW) CIRCUIT Low Pressure FROM STEERING CONTROL FROM PTO (MOW) CIRCUIT Hydraulic System (Rev.
Procedure for Rear Traction Circuit (RV5) Relief Pressure Test 1. Make sure hydraulic oil is at normal operating temperature by operating the machine for approximately 10 minutes. Make sure the hydraulic tank is full. 1 2. Park machine on a level surface with the cutting units lowered and off. Make sure engine is off and the parking brake is engaged. 2 CAUTION Figure 46 Prevent personal injury and/or damage to equipment.
TEST NO. 12: Traction Circuit Reducing Valve (PR1) Pressure (Using Pressure Gauge) CHARGE CIRCUIT TO TRACTION CONTROL MANIFOLD TO LIFT/LOWER CIRCUIT TO PTO (MOW) CIRCUIT TO STEERING CIRCUIT Working Pressure FROM PTO (MOW) CIRCUIT Low Pressure FROM STEERING CONTROL FROM PTO (MOW) CIRCUIT Hydraulic System (Rev.
Procedure for Traction Circuit Reducing Valve (PR1) Pressure Test 1. Make sure hydraulic oil is at normal operating temperature by operating the machine for approximately 10 minutes. Make sure the hydraulic tank is full. 1 2. Park machine on a level surface with the cutting units lowered and off. Make sure engine is off and the parking brake is engaged. 2 CAUTION Figure 49 Prevent personal injury and/or damage to equipment.
TEST NO. 13: Traction Assist (RV2) Pressure (Using Pressure Gauges) TO STEERING CIRCUIT FROM PTO (MOW) CIRCUIT FROM PTO (MOW) CIRCUIT FROM STEERING CIRCUIT FROM STEERING CIRCUIT 2200 PSI GM 4500--D SHOWN Working Pressure Low Pressure Return or Suction Flow Hydraulic System (Rev.
Procedure for Traction Assist (RV2) Pressure Test 1. Make sure hydraulic oil is at normal operating temperature by operating the machine for approximately 10 minutes. Make sure the hydraulic tank is full. 1 2. Park machine on a level surface with the cutting units lowered and off. Make sure engine is off and the parking brake is engaged. 2 CAUTION Figure 51 Prevent personal injury and/or damage to equipment.
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 units 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 such as Mobil EAL 224H. Operate machine under normal operating conditions for at least four (4) hours before draining. 1. Park machine on a level surface.
Charge Hydraulic System NOTE: When initially starting the hydraulic system with new or rebuilt components such as motors, pumps, 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 85 to 95 ft--lb (115 to 128 N--m) 27 32 30 25 28 17 18 1 2 3 29 24 23 4 19 13 31 21 23 22 26 5 20 24 16 6 11 14 RIGHT 7 15 8 12 FRONT 9 10 Figure 54 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. Flat washer Cap screw 90o hydraulic fitting Hydraulic tee fitting O--ring Quick fitting Dust cap 90o hydraulic fitting Clamp 90o hydraulic fitting O--ring Hydraulic System (Rev. A) 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22.
Removal Installation 1. Park machine on a level surface, lower cutting units, stop engine, engage parking brake, and remove key from the ignition switch. 1. Lubricate new o--rings with clean hydraulic oil and position on gear pump. 2. Slide coupler onto the piston pump output shaft. 3. Drain the hydraulic reservoir (see Traction Unit Operator’s Manual). 3. Position o--rings and spacer to gear pump. Align gear teeth and slide gear pump input shaft into coupler.
Gear Pump Service 5 15 14 8 3 12 1 25 to 28 ft--lb (34 to 38 N--m) 2 10 11 4 4 23 13 19 16 18 17 24 21 to 24 ft--lb (29 to 33 N--m) 14 20 28 29 9 12 21 7 4 4 13 22 27 25 21 to 24 ft--lb (29 to 33 N--m) 26 12 6 Figure 55 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. Shaft seal Washer Cap screw O--ring Washer Proportional valve Plug Plug O--ring Front body 11. 12. 13. 14. 15. 16. 17. 18. 19. 20.
3. Remove pump from vise, hold pump in hands and bump shaft against wooden block to separate front pump sections. Front body (10) will remain with either front plate (15) or front adapter plate (23). Inspection 4. Place front idler gear (16) into gear pocket and tap with soft face hammer until the front body separates. Remove idler gear from front plate or adapter plate. 2. Check spline drive shaft for twisted or broken teeth.
Reassembly It is important that the relationship of the backplate, adapter plates, bodies, wear plates and front plate is correct. The two half moon cavities in the bodies must face away from the front plate or adapter plate. The smaller half moon port cavity must be on the pressure side of the pump. The side of the wear plate with mid section cut out must be on suction side of pump. Suction side of backplate or adapter plate is always the side with larger port boss. 1.
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Piston (Traction) Pump 85 to 95 ft--lb (115 to 128 N--m) 27 32 30 25 28 17 18 1 2 3 29 24 23 4 19 13 31 21 23 22 26 5 20 16 24 33 35 6 36 5 14 RIGHT 7 15 8 12 34 21 FRONT 11 9 37 11 10 Figure 56 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. Flat washer Cap screw 90o hydraulic fitting Hydraulic tee fitting O--ring Quick fitting Dust cap 90o hydraulic fitting Clamp 90o hydraulic fitting Hydraulic fitting Hydraulic tee fitting 90o hydraulic fitting Hydraulic System (Rev. A) 14.
Removal Installation 1. Park machine on a level surface, lower cutting units, stop engine, engage parking brake, and remove key from the ignition switch. 2. To prevent contamination of hydraulic system during removal, thoroughly clean exterior of pump assembly. 1. Carefully lower piston pump into the machine and position it to the engine adapter plate. Support pump to prevent it from falling while installing two (2) cap screws and washers securing piston pump to engine adapter plate.
Piston (Traction) Pump Service 100 to 110 ft--lb (136 to 149 N--m) 27 to 31 ft--lb (37 to 42 N--m) 16 20 150 to 160 in--lb (17 to 18 N--m) 38 18 100 to 110 ft--lb (136 to 149 N--m) 15 4 to 6 ft--lb (5 to 8 N--m) 14 1 29 26 4 22 45 10 33 28 23 17 8 30 7 5 27 40 to 48 in--lb (4.5 to 5.4 N--m) 34 43 35 31 32 44 36 11 40 to 48 in--lb (4.5 to 5.4 N--m) 37 19 25 to 28 ft--lb (34 to 38 N--m) 42 41 40 6 31 5 39 37 21 12 40 to 48 in--lb (4.5 to 5.
Work in a clean area as cleanliness is extremely important when repairing hydraulic pumps. Thoroughly clean the outside of pump. After cleaning, remove port plugs and drain oil from pump. 1. Position the pump into a protected jaw vise, clamping onto the outer portion of the flange, with the cap screws up. Mark the relationship of the working ports (for reassembly identification) to the servo control assembly with a scribe. Remove the four cap screws (15) retaining backplate (20). 2.
3. Inspect camplate assembly: A. The finish on the piston shoe surfaces of the camplate (11) should show no signs of scoring. 3 2 1 B. Inspect camplate (11) bushing surface for wear. Also inspect surface for coating transfer from bushing. 5 4. Inspect bushing (44) for contamination embedment within coating of bushing surface coming in contact with camplate (11). 4 Figure 60 5. Inspect rotating kit (Fig. 60): A. The pistons should move freely in the rotating kit piston block bore.
9. Install shaft assembly into front of housing. Seat seal (25) into position with seal driver and retain with interior retaining ring (2). 10.Install servo piston follower (8) onto camplate dowel pin. Install camplate (11) carefully onto bushing (44) (coat bushing surface with hydraulic oil), aligning servo piston follower (8) with slot in servo piston assembly (7). 11. Position housing in a horizontal position.
Piston Pump Manual Servo Control Assembly 44 to 52 ft--lb (60 to 70 N--m) 15 10 1 2 14 3 4 5 7 4 9 13 12 8 6 16 24 17 to 26 in--lb (2 to 3 N--m) 17 23 11 22 28 to 34 in--lb (3.2 to 3.8 N--m) 21 18 20 19 Figure 62 1. 2. 3. 4. 5. 6. 7. 8. Plug O--ring Retaining ring Spring retainer Spring Spool valve Control housing Input shaft 9. 10. 11. 12. 13. 14. 15. 16. O--ring Wiper seal O--ring Adaptor Ball Pin Neutral switch O--ring 17. 18. 19. 20. 21. 22. 23. 24.
5. Apply Loctite #242 or equivalent to set screw (18) and install into control housing. Adjust set screw until it bottoms out on input shaft and back out one--quarter turn. 6. Install wiper seal on input shaft. 7. Install new o--ring (2) onto plug and install plug. Adjust plug until there is no end play in the valve spool with input shaft held stationary. Secure plug in place with set screw (24). Torque set screw from 17 to 26 in--lb (2 to 3 N--m). 5.
Hydraulic Control Manifolds: 2 Wheel/4 Wheel Drive, Filtration and Charge, Power Down and Traction Assist 1 4 2 RIGHT 3 6 FRONT 5 7 Figure 64 1. Power down/traction assist manifold 2. Flange head screw (3 used) 3. Filtration/charge manifold Hydraulic System (Rev. A) 4. Flange head screw (4 used) 5. 2WD/4WD manifold Page 4 -- 70 6. Cap screw (2 used) 7.
Removal Installation NOTE: The ports on the manifolds are marked for easy identification of components. Refer to the Hydraulic Schematics to identify the function of the hydraulic lines and cartridge valves at each port. 1. Install hydraulic manifold to the frame using Figure 64 as guide. 1. Read the General Precautions for Removing and Installing Hydraulic System Components at the beginning of the Service and Repairs section of this chapter. 2.
Hydraulic Control Manifold Service: 2 Wheel/4 Wheel Drive Control 80 to 90 ft--lb (108 to 122 N--m) 18 19 12 13 18 7 16 17 19 18 1 80 to 90 ft--lb (108 to 122 N--m) 19 17 21 18 17 19 16 16 16 17 5 17 16 25 20 7 4 12 24 11 60 to 70 ft--lb (81 to 95 N--m) 9 10 8 20 2 25 to 30 ft--lb (34 to 41 N--m) 23 13 17 15 16 14 13 12 21 3 35 to 40 ft--lb (47 to 54 N--m) 4 to 6 ft--lb (5 to 8 N--m) 6 22 PLUG TORQUE SAE #2: 41 TO 49 in--lb (4.6 to 5.
5. Visually inspect cartridge valve for damaged sealing surfaces and contamination. A. Contamination may cause valves to stick or hang up. Contamination can become lodged in small valve orifices or seal areas causing malfunction. B. If valve sealing surfaces appear pitted or damaged, the hydraulic system may be overheating or there may be water in the system. CAUTION A. Lubricate new seal kit components with clean hydraulic oil and install on valve.
Hydraulic Control Manifold Service: Filtration and Charge Control 35 to 40 ft--lb (47 to 54 N--m) 4 60 to 70 ft--lb (81 to 95 N--m) 7 6 2 10 5 11 12 10 13 9 8 3 11 12 1 15 8 14 16 PLUG TORQUE SAE #4: 6 to 10 ft--lb (8 to 13 N--m) SAE #5: 10 to 15 ft--lb (13 to 20 N--m) SAE #6: 15 to 20 ft--lb (20 to 27 N--m) SAE #10: 35 to 40 ft--lb (48 to 54 N--m) Figure 66 1. 2. 3. 4. 5. 6.
Hydraulic Control Manifold Service: Power Down and Traction Assist (GM 4500--D) 3 25 ft--lb (33.9 N--m) 20 ft--lb (27.1 N--m) 25 ft--lb (33.9 N--m) 2 6 20 ft--lb (27.1 N--m) 5 Hydraulic System 4 1 6 Figure 67 1. Manifold body 2. Traction assist valve (RV2: port 2) 3. Counterbalance valve (RV1: port 4) 4. Expanding plug (not serviced) 5. Lift relief valve (RV7: port 7) 6.
Hydraulic Control Manifold Service: Power Down and Traction Assist (GM 4700--D) 25 ft--lb (33.9 N--m) 3 2 20 ft--lb (27.1 N--m) 25 ft--lb (33.9 N--m) 3 4 20 ft--lb (27.1 N--m) 20 ft--lb (27.1 N--m) 6 7 5 20 ft--lb (27.1 N--m) 7 1 7 Figure 68 1. Manifold body 2. Traction assist valve (RV2: port 2) 3. Power down valve (deck 6) 4. Counterbalance valve (RV1: port 4) 5. Traction pressure sensing valve (PD3: port 5) 6. Lift relief valve (RV7: port 7) 7. Expanding plug (not serviced) 8.
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Hydraulic Control Manifold: Deck Drive (GM 4500--D) 9 8 16 15 1 2 17 10 11 11 3 2 13 18 11 4 RIGHT FRONT 2 5 11 12 4 10 6 12 13 14 7 Figure 69 1. 2. 3. 4. 5. 6. Hydraulic manifold: decks 2, 3, & 5 Hydraulic adapter 90o hydraulic fitting 90o hydraulic fitting Hydraulic manifold: decks 1 & 4 Straight hydraulic fitting 7. 8. 9. 10. 11. 12.
Hydraulic Control Manifold Service: Deck Drive (GM 4500--D) 7 4 to 5 ft--lb (5.4 to 6.8 N--m) 3 165 in--lb (18.6 N--m) 20 ft--lb (27.1 N--m) 5 9 25 ft--lb (33.9 N--m) 25 ft--lb (33.9 N--m) 4 6 8 198 in--lb (22.4 N--m) 1 120 in--lb (13.6 N--m) 10 11 11 Figure 70 1. 2. 3. 4. Manifold body Solenoid valve (PRV2) Solenoid coil Logic cartridge (LC1) 5. 6. 7. 8. Relief valve (RV8) Pilot piston Nut Zero leak plug (#6) NOTE: The ports on the manifold are marked for easy identification of components.
Hydraulic Control Manifold: Deck Drive (GM 4700--D) 9 8 15 17 1 11 2 10 2 16 2 11 3 13 4 11 12 4 2 18 RIGHT 10 5 13 FRONT 11 12 14 6 7 Figure 71 1. 2. 3. 4. 5. 6. Hydraulic manifold: decks 2, 3, 5, & 7 Hydraulic adapter 90o hydraulic fitting 90o hydraulic fitting Hydraulic manifold: decks 1, 4, & 6 Straight hydraulic fitting 7. 8. 9. 10. 11. 12.
Hydraulic Control Manifold Service: Deck Drive (GM 4700--D) 8 4 to 5 ft--lb (5.4 to 6.8 N--m) 20 ft--lb (27.1 N--m) 8 20 ft--lb (27.1 N--m) 7 5 5 25 ft--lb (33.9 N--m) 3 7 25 ft--lb (33.9 N--m) 4 198 in--lb (22.4 N--m) 9 2 198 in--lb (22.4 N--m) 9 6 1 120 in--lb (13.6 N--m) 10 75 ft--lb (101.7 N--m) 9 198 in--lb (22.4 N--m) 12 11 165 in--lb (18.6 N--m) Figure 72 1. 2. 3. 4. Manifold body Proportional relief solenoid (PRV2) Solenoid valve (SV2) Logic valve (LC1 and LC2) 5. 6. 7. 8.
Rear Axle Motor Arrows on side of motor case point up 5 6 7 7 8 4 5 3 2 1 10 9 59 to 73 ft--lb (80 to 99 N--m) RIGHT FRONT Figure 73 1. 2. 3. 4. Axle motor O--ring Pinion gear External snap ring Hydraulic System (Rev. A) 5. O--ring 6. Hydraulic fitting 7. O--ring Page 4 -- 82 8. 90o hydraulic fitting 9. Cap screw 10.
Removal Installation 1. Park machine on a level surface, lower cutting units, stop engine, engage parking brake, and remove key from the ignition switch. 1. If removed, install pinion gear to axle motor. 2. Read the General Precautions for Removing and Installing Hydraulic System Components at the beginning of the Service and Repairs section of this chapter. NOTE: To ease reassembly, tag the hydraulic hoses to show their correct position on the axle motor.
Front Wheel Motors 1 2 20 3 21 10 14 18 22 16 14 15 23 24 25 19 18 6 10 19 17 16 10 15 14 75 to 85 ft--lb (101 to 115 N--m) RIGHT 13 12 10 11 9 8 5 7 4 Arrows on side of motor case point up FRONT Figure 74 1. 2. 3. 4. 5. 6. 7. 8. 9. Flange head screw Splined brake shaft Planetary assembly Wheel assembly Lug nut Retaining ring LH brake assembly Flange head screw Plug Hydraulic System (Rev. A) 10. 11. 12. 13. 14. 15. 16. 17.
Removal Installation 1. Park machine on a level surface, lower cutting units, stop engine, engage parking brake, and remove key from the ignition switch. 1. Position wheel motor to brake assembly making sure that arrows on the side of motor case point upward. 2. Read the General Precautions for Removing and Installing Hydraulic System Components at the beginning of the Service and Repairs section of this chapter.
Rear Axle/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 75 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 75) are identical.
2. If necessary, install new needle bearing (17) in housing (3) with numbered end of the bearing outward. 5. Remove the camplate insert (5) from housing. Use caution not to mar the finish that makes contact with pistons. 3. Install retaining ring (9) on shaft. Install thrust race (10), thrust bearing (13), and second thrust race (10). Secure with second retaining ring (9). 6. Remove retaining ring (6) from housing. Press shaft from housing and remove shaft seal (8) and washer (18). 4.
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Cutting Deck Motor The hydraulic motors used on all cutting decks are the same. 2 Removal 1. Park machine on a level surface, lower cutting units, 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. NOTE: Before disconnecting the hydraulic lines, clean the port area of the deck motor. 1 Figure 77 1. Socket head screw 2.
Cutting Deck Motor Service 1 2 3 8 4 5 6 7 7 8 12 9 5 10 38 to 43 ft--lb (51 to 58 N--m) 11 30 to 35 ft--lb (41 to 47 N--m) 13 15 14 Figure 78 1. 2. 3. 4. 5. Outer shaft seal Inner shaft seal Retaining ring Front flange Pressure seal 6. 7. 8. 9. 10. Front bearing block O--ring Dowel pin Housing Drive gear Disassembly (Fig. 78) 1. Plug motor ports and clean the outside of the motor thoroughly. After cleaning, remove plugs and drain any oil out of the motor. 11. 12. 13. 14. 15.
8. Carefully remove rear bearing block, idler gear, drive gear, and front bearing block from the front flange. 5. Inspect front flange and rear cover for damage or wear. C. Thickness of bearing blocks should be equal. 3 10.Turn front flange over, with seal side up. 2 IMPORTANT: Make sure not to damage the counter bore when removing the shaft seals and retaining ring from the front flange. 11. Remove outer shaft seal, retaining ring and inner shaft seal from the front flange. Discard seals.
8. Lubricate the drive gear shaft with clean hydraulic oil. Noting the open and closed sides of the front bearing block, insert the drive end of the drive shaft through the bearing block with the pressure seal side down. Carefully install shaft into front flange. 2 9. Lubricate the idler gear shaft with clean hydraulic oil. Install idler gear shaft into the remaining position in the bearing block. Apply a light coating of clean hydraulic oil to gear faces. 10.
Relief Valve Service IMPORTANT: Do not remove the relief valve assembly unless testing shows it to be faulty. 1. When removing or installing the relief valve, motor should be removed from deck and positioned horizontally with the relief valve pointed down (Fig. 83). This process will prevent the relief valve from falling into motor passages. 5 4 NOTE: The relief valve seat is difficult to remove because it has a thin, hex head and has sealant applied to the threads.
Lift/Lower Control Valve (GM 4500--D) 10 11 9 25 9 12 5 6 13 8 7 4 3 24 14 2 15 1 16 17 23 22 21 18 20 RIGHT 19 FRONT Figure 84 1. 2. 3. 4. 5. 6. 7. 8. 9. Control valve assembly (1 spool) O--ring Hydraulic adapter O--ring Hydraulic fitting Orifice (port B) Cap screw Spacer Spacer tube Hydraulic System (Rev. A) 10. 11. 12. 13. 14. 15. 16. 17. Lift lever Control knob Curved washer Cotter pin Thread forming screw Proximity switch Flange head screw Switch plate Page 4 -- 94 18. 19.
Removal Installation 1. Park machine on a level surface, lower cutting units, stop engine, engage parking brake, and remove key from the ignition switch. 1. Install control valve using Figure 86 as a guide. 2. Read the General Precautions for Removing and Installing Hydraulic System Components at the beginning of the Service and Repairs section of this chapter. 2. Make sure hydraulic tank is full. Add correct oil if necessary before returning machine to service.
Lift/Lower Control Valve Service (GM 4500--D) 4 to 5 ft--lb (5 to 7 N--m) 19 13 24 25 30 to 35 ft--lb (41 to 48 N--m) 10 to 12 ft--lb (13 to 16 N--m) 23 18 9 17 26 22 11 27 6 7 15 30 to 35 ft--lb (41 to 48 N--m) 12 4 28 1 2 5 21 20 to 25 ft--lb (27 to 33 N--m) 15 8 10 16 3 14 20 Figure 85 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. Poppet Plunger Spacer Spool Seat Plug Seat retaining plug Bushing Lockout spring Spool cap Hydraulic System (Rev. A) 11. 12. 13. 14. 15. 16. 17. 18. 19.
Disassembly 1. Plug all ports and clean outside of valve thoroughly. 2. Remove spool cap (10). Do not remove retaining ring (16) from spool (4) unless spool spring (14) is broken. 3. Remove spool (4) from control valve body (12). 4. Remove bushing (8) and O--rings (15) from spool and O--ring from spool bore. Assembly 1. Thoroughly clean and dry all parts. Apply a light coating of clean hydraulic oil to parts prior to assembly.
Lift/Lower Control Valve (GM 4700--D) 14 13 12 16 8 4 11 10 15 7 6 5 4 9 17 6 4 18 20 3 19 2 1 27 21 26 25 22 RIGHT 24 23 FRONT Figure 86 1. 2. 3. 4. 5. 6. 7. 8. 9. Control valve assembly (3 spool) O--ring Hydraulic adapter O--ring Hydraulic fitting O--ring Orifice (port D) Cap screw 90o hydraulic fitting Hydraulic System (Rev. A) 10. 11. 12. 13. 14. 15. 16. 17. 18.
Removal Installation 1. Park machine on a level surface, lower cutting units, stop engine, engage parking brake, and remove key from the ignition switch. 1. Install control valve using Figure 86 as a guide. 2. Read the General Precautions for Removing and Installing Hydraulic System Components at the beginning of the Service and Repairs section of this chapter. 2. Make sure hydraulic tank is full. Add correct oil if necessary before returning machine to service.
Lift/Lower Control Valve Service (G 4700--D) 6 30 to 35 ft--lb (41 to 48 N--m) 4 29 28 10 to 12 ft--lb (13 to 16 N--m) 4 to 5 ft--lb (5 to 7 N--m) 18 19 20 17 26 22 12 21 27 11 2 16 25 5 24 1 13 23 20 to 25 ft--lb (27 to 33 N--m) 10 9 30 to 35 ft--lb (41 to 48 N--m) 12 8 14 15 3 7 Figure 87 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. Poppet Plunger Spacer Spool Seat Plug Seat retaining plug Bushing Lockout spring Spool cap Hydraulic System (Rev. A) 11. 12. 13. 14. 15. 16. 17. 18. 19. 20.
Disassembly 1. Plug all ports and clean outside of valve thoroughly. 2. Remove spool caps (10). Do not remove retaining rings (13) from spools unless spool spring (15) is broken. NOTE: Spools and spool bores are matched sets. Be sure each spool is identified with the correct control valve body spool bore. 3. Remove spools (4) from control valve body (11). 4. Remove bushings (8) and O--rings (12) from spools and O--rings from spool bores. 5. Remove plugs (6).
Steering Valve 7 20 to 26 ft--lb (28 to 35 N--m) 6 5 8 4 9 10 3 11 12 21 13 20 9 19 RIGHT 2 17 18 FRONT 14 15 1 16 Figure 88 1. 2. 3. 4. 5. 6. 7. Steering valve Steering column Flange head screw (3 used) Dust cover Steering wheel Hex nut Steering wheel cover Hydraulic System (Rev. A) 8. 9. 10. 11. 12. 13. 14. Steering column bracket Flange head screw Flange head screw (1 used) Lock washer Flat washer Steering tower cover O--ring Page 4 -- 102 Rev. D 15. 16. 17. 18. 19. 20. 21.
Removal Installation 1. Park machine on a level surface, lower cutting units, stop engine, engage parking brake, and remove key from the ignition switch. 1. Install steering valve using Figure 88 as a guide. 2. Read the General Precautions for Removing and Installing Hydraulic System Components at the beginning of the Service and Repairs section of this chapter. 2. Make sure hydraulic tank is full. Add correct oil if necessary before returning machine to service.
Steering Valve Service 8 1 3 24 2 4 5 20 19 23 6 7 19 22 21 150 in--lb (17 N--m) 9 10 13 11 12 14 18 17 16 140 to 160 in--lb (16 to 18 N--m) 15 Figure 89 1. 2. 3. 4. 5. 6. 7. 8. Steering valve housing Dust seal O--ring Spool Spring retaining ring Pin Sleeve Centering springs/spacers 9. 10. 11. 12. 13. 14. 15. 16. Cap screw End cap O--ring Seal ring O--ring Geroter O--ring Spacer Disassembly NOTE: Cleanliness is extremely important when repairing hydraulic components.
8. Put the thrust bearing and races into the housing. The thrust bearing goes between the two races (Fig. 90). The centering springs are under tension. Remove the retaining ring carefully. IMPORTANT: Do not damage the dust or quad seals when installing the spool and sleeve assembly. 10.Remove the spring retaining ring and centering springs from the spool. 9. Apply a light coating of clean hydraulic fluid to the spool and sleeve assembly and slide carefully the assembly into the housing.
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 91 1. 2. 3. 4. 5. Lift arm (deck #4) Flange nut Lift arm (deck #1) Cylinder pin (3 used) Flange head screw Hydraulic System (Rev. A) 6. 7. 8. 9. O--ring 90o hydraulic fitting O--ring Lift arm (deck #5) Page 4 -- 106 10. 11. 12. 13.
Removal (Fig. 91) 1. Park machine on a level surface, lower cutting units, stop engine, engage parking brake, and remove key from the ignition switch. #4 Deck #1 Deck #5 Deck 2. Read the General Precautions for Removing and Installing Hydraulic System Components at the beginning of the Service and Repairs section of this chapter. NOTE: To ease reassembly, tag the hydraulic hoses to show their correct position on the lift cylinder.
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 93 1. 2. 3. 4. 5. Lift arm (deck #2 shown) Cylinder pin Flange head screw O--ring 90o hydraulic fitting Hydraulic System (Rev. A) 6. 7. 8. 9. 10. O--ring Retaining ring Cylinder pin Hydraulic fitting Grease fitting Page 4 -- 108 11. 12. 13. 14.
Removal (Fig. 93) 1. Park machine on a level surface, lower cutting units, stop engine, engage parking brake, and remove key from the ignition switch. #4 Deck #1 Deck #5 Deck 2. Read the General Precautions for Removing and Installing Hydraulic System Components at the beginning of the Service and Repairs section of this chapter. NOTE: Before disconnecting the hydraulic lines, clean the port area of the steering valve assembly.
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 95 1. 2. 3. 4. 5. 6. Retaining ring Cylinder pin Thrust washer Lift link Link assembly Bushing Hydraulic System (Rev. A) 7. 8. 9. 10. 11. Plastic roller Rear link Lock nut 90o hydraulic fitting Lift cylinder Page 4 -- 110 12. 13. 14. 15. 16.
Removal (Fig. 95) 1. Park machine on a level surface, lower cutting units, stop engine, engage parking brake, and remove key from the ignition switch. #4 Deck #1 Deck #5 Deck 2. Read the General Precautions for Removing and Installing Hydraulic System Components at the beginning of the Service and Repairs section of this chapter. NOTE: To ease reassembly, tag the hydraulic hoses to show their correct position on the lift cylinder.
Lift Cylinder Service 12 10 9 5 7 4 1 2 3 11 6 8 Figure 97 1. 2. 3. 4. Barrel with clevis Collar Shaft with clevis Dust seal Hydraulic System (Rev. A) 5. 6. 7. 8. Rod seal O--ring Back--up ring Head Page 4 -- 112 9. 10. 11. 12.
Disassembly Assembly 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 parts are clean before reassembly. 2. Mount lift cylinder into a vice. Remove collar with a spanner wrench. 3. Extract shaft with head and piston by carefully twisting and pulling on the shaft. IMPORTANT: Do not clamp vise jaws against the shaft surface. Protect shaft surface before mounting in a vice. 4.
Steering Cylinder 9 6 7 4 9 1 8 5 2 4 10 3 15 12 100 to 125 ft--lb (135 to 169 N--m) 13 14 11 RIGHT 100 to 125 ft--lb (135 to 169 N--m) FRONT Figure 98 1. 2. 3. 4. 5. Steering cylinder Ball joint Ball joint Retaining ring Grease fitting Hydraulic System (Rev. A) 6. 7. 8. 9. 10. Grease fitting 90o hydraulic fitting O--ring O--ring Ball joint spacer Page 4 -- 114 11. 12. 13. 14. 15.
Removal Installation 1. Park machine on a level surface, lower cutting units, stop engine, engage parking brake, and remove key from the ignition switch. 1. Place a washer onto each ball joint. Slide ram end ball joint through hole on steering arm. Secure with axle washer and hex slotted nut. Slide fixed end of cylinder through hole on axle. Install spacer onto ball joint and secure with hex slotted nut. Torque slotted nuts from 100 to 125 ft--lbs (135 to 169 N--m) prior to inserting cotter pins. 2.
Steering Cylinder Service 11 4 10 8 7 2 5 9 3 6 1 Figure 99 1. 2. 3. 4. Butt and tube assembly Shaft Piston rod assembly Gland Hydraulic System (Rev. A) 5. 6. 7. 8. Lock nut O--ring PTFE seal O--ring Page 4 -- 116 Rev. C 9. O--ring 10. U--cup 11.
Disassembly Assembly IMPORTANT: To prevent damage when clamping cylinder barrel or rod in a vise, clamp only on pivotal ends. 1. Use a complete repair kit when rebuilding the cylinder. Put a coating of clean hydraulic oil on all new seals, and O--rings. 1. Pump oil out of cylinder into a drain pan by SLOWLY moving rod and piston in and out of cylinder bore. Plug ports and clean outside of cylinder. 2. Install new O--rings and PTFE seal to the piston rod and new O--ring, U--cup, and wiper to gland. 2.
Hydraulic Reservoir 5 6 4 3 2 1 19 80 to 87 ft--lb (108 to 118 N--m) 9 16 8 12 7 RIGHT 18 10 11 FRONT 11 13 17 14 15 30 to 60 in--lb (3.4 to 6.8 N--m) 1. 2. 3. 4. 5. 6. 7. Hydraulic reservoir cap O--ring Dipstick Air breather Breather adapter Hydraulic tank Hydraulic fitting 8. 9. 10. 11. 12. 13. Figure 100 O--ring O--ring Hydraulic tee fitting O--ring O--ring Tank mount grommet (3 used) 14. 15. 16. 17. 18. 19.
Hydraulic Oil Cooler Removal 1 CAUTION 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. 3 2 1. Park machine on a level surface, lower cutting units, stop engine, engage parking brake, and remove key from the ignition switch. 1. Oil cooler latch 2. Hose to oil cooler 2.
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Chapter 5 Electrical System ELECTRICAL SCHEMATICS AND ELECTRICAL HARNESS AND CONNECTORS DRAWINGS . . . 2 SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . 3 Starting Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 General Run & Transport Problems . . . . . . . . . . . . 4 Cutting Unit Operating Problems . . . . . . . . . . . . . . 5 ELECTRICAL SYSTEM QUICK CHECKS . . . . . . . .
Electrical Schematics and Electrical Harness and Connectors Drawings The electrical schematics and other electrical drawings for the Groundsmaster 4500--D and Groundsmaster 4700--D are located in Chapter 9 -- Electrical Diagrams. 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, resistance, or voltage.
Troubleshooting For effective troubleshooting and repairs, you must have 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 troubleshooting and safety.
Starting Problems (continued) Problem Possible Causes Engine cranks, but does not start. Engine is not cranking fast enough. Engine run solenoid, circuit wiring, or fuel pump is faulty. The problem is not electrical (see Chapter 3 -- Kubota Engines). Starter cranks, but should not when the traction pedal is depressed. The traction neutral switch is out of adjustment. The traction neutral switch or circuit wiring is faulty.
Cutting Unit Operating Problems Cutting units run, but should not, when raised. Units shut off with PTO switch. The cutting deck position switch or circuit wiring is faulty. The cutting deck lift/lower switch or circuit wiring is faulty. Cutting units run, but should not, when raised. Units do The deck position switch, cutting deck lift/lower switch, not shut off with the PTO 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. Set multimeter to the DC volts setting. The battery should be at a temperature of 60 to 100oF (16 to 38oC). The ignition key should be off and all accessories turned off. Connect the positive (+) meter lead to the positive battery post and the negative (--) meter lead to the negative battery post. Voltage Measured Battery Charge Level 12.
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 doing a continuity check). NOTE: For engine component testing information, see the Kubota Workshop Manual, Diesel Engine, V2003--T Series at the end of Chapter 3 -- Kubota Diesel Engine.
Fuses The fuse block is located under the operator’s control panel. Machines with serial numbers below 220999999 have four (4) fuses (Fig. 5). Machines with serial numbers above 230000000 have six (6) fuses (Fig. 6). 1 Identification, Function, and Wiring The fuses are held in the fuse block. Use Figure 7 to identify each individual fuse and its correct amperage. Each fuse holder has the following functions and wire connected to it. 2 Fuse 1 (15 Amp) A. Supplies power to ignition switch terminal B.
Indicator Lights Testing Indicator Lights 2 3 1. Apply 12 VDC to terminals 1A and 2A. 2. Ground terminals 1B and 2B. 1 4 3. Both indicator lights should light. Engine Oil Pressure Light The oil pressure light should come on when the ignition switch is in the ON position with the engine not running. Also, it should light with the engine running if the engine oil pressure drops below 7 PSI (0.5 kg/cm2).
PTO and Hi--Lo Speed Control Switches The PTO and Hi--Lo Speed Control Switches are located on the control console (Fig. 10). These rocker switches have common switching logic. The switch terminals are marked as shown in Figure 11. The circuitry of these switches is shown in the chart below. With the use of a multimeter (ohms setting), the switch functions may be tested to determine whether continuity exists between the various terminals for each switch position. Verify continuity between switch terminals.
Seat Switch The seat switch is normally open and closes when the operator is on the seat. If the traction system or PTO switch is engaged when the operator raises out of the seat, the engine will stop. The seat switch and its electrical connector are located directly under the seat. Testing of the switch can be done without seat removal by disconnecting the seat wire from the machine wiring harness. 1 2 1. Make sure the engine is off. 2. Disconnect electrical connector for the seat switch. 3.
Cutting Deck Position Switch The cutting deck position switch is a normally open proximity switch that is located on the traction unit frame (Fig. 14). The sensing plate is located on the cutting deck lift arm. The GM 4500--D uses two cutting deck position switches: for decks 4 and 5. There are four deck position switches on the GM 4700--D: for decks 4, 5, 6, and 7. 3 1 2 When the cutting deck is raised, the sensing plate is moved away from the position switch and the switch opens.
Cutting Deck Lift/Lower Switch The lift/lower switch is a normally open proximity switch that is closed when a lift lever is in the neutral position. When a lift lever is moved to raise, the lift/lower switch opens. Each lift lever is equipped with a cutting deck lift/ lower switch. 2 When the machine operator engages the cutting decks (PTO switch ON and decks lowered), the cutting deck lift/lower switch and circuit board diode D1--C provide a latching circuit to keep the PTO relay energized (Fig. 18).
Ramp--up Module The ramp--up module is located under the console cover (Fig. 19). 1 The ramp--up module is used to prevent hydraulic spikes that could affect cutting system hydraulic components. As the PTO relay for decks #1 to #5 is energized, the ramp--up module provides a gradual, increasing current flow to the cutting deck solenoid valves. Solenoid ramp--up time occurs in 1.75 seconds. The Ramp--up module has no affect on operation of decks #6 and #7 on the GM 4700--D.
Hour Meter The meter is located on the control console next to the operator seat. 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.
Start, Neutral, Seat, Cutting Deck, Parking Brake, and High Temperature Relays The relays are located under the console cover (Fig. 23). The wiring harness is tagged to identify each relay. 1 NOTE: Machines with serial numbers above 230000000 use a standard control module to monitor several switches. These machines do not use a start, neutral, seat, parking brake or high temperature relay. 3 4 2 5 6 NOTE: The relays may be manufactured by one of two different manufacturers.
Hydraulic Valve Solenoids The Groundsmaster 4500--D has three hydraulic valve solenoids: one on each cutting deck manifold and one on the traction manifold. The Groundsmaster 4700--D has five solenoids: two on each cutting deck manifold and one on the traction manifold. Testing of these solenoids can be done with the solenoid on the hydraulic valve. NOTE: Prior to taking small resistance readings with a digital multimeter, short the meter test leads together.
Engine Run Solenoid The engine run solenoid must be energized for the engine to run. The solenoid is mounted on the engine block near the injection pump. 2 1 In Place Testing 3 NOTE: Prior to taking small resistance readings with a digital multimeter, short the meter test leads together. The meter will display a small resistance value (usually 0.5 ohms or less). This resistance is due to the internal resistance of the meter and test leads.
Fuel Pump The fuel pump is attached to the frame near the fuel pre-filter (Fig. 29). IMPORTANT: When testing fuel pump, make sure that pump is not operated without fuel. 1 2 3 Fuel Pump Capacity Test 1. Park machine on a level surface, lower cutting units, stop engine, and engage parking brake. 2. Disconnect electrical connector from the engine run solenoid to prevent the engine from firing. 4. Make sure fuel hoses attached to the fuel pump are free of obstructions. 5.
Glow Controller The glow controller is located under the console cover. 2 NOTE: Refer to Chapter 9 -- Electrical Schematics and Diagrams when troubleshooting the controller. Controller Operation 1. When the ignition switch is placed in the ON position, the controller energizes the glow plugs and lights up the glow lamp for 7 to 10 seconds. 2. When the ignition switch is held in the START position, the glow plugs will energize and the glow lamp will not light. 2.
Temperature Sender The temperature sender is located near the alternator on the water flange attached to the engine cylinder head (Fig. 31). There is a gray wire attached to the terminal of the switch. 1 Temperature Sender Test 1. Lower coolant level in the engine and remove the temperature sender from water flange. 2. Put switch in a container of oil with a thermometer and slowly heat the oil (Fig. 32). 2 CAUTION Figure 31 1. Temperature sender 2.
Temperature Gauge The temperature gauge can be tested using a new gauge as a substitute or by the use of a DC voltage source and a variable resistance box. Temperature Gauge Test CAUTION VARIABLE RESISTANCE Make sure the voltage source is turned OFF before connecting it to the electrical circuit to avoid electrical shock and prevent damaging the gauge. 14 VDC + 0.01 VDC + -- 1. Connect temperature gauge to the variable resistance and DC voltage source (Fig. 33).
High Temperature Shutdown Switch The high temperature shutdown switch is located near the glow plug connection on the engine cylinder head (Fig. 36). There is a blue/white wire attached to the switch. The high temperature shutdown switch is designed to shut the engine off when engine coolant temperature reaches an unsafe level. If problems with the switch system are encountered, the following procedure can be used to determine if the problem is related to the switch or the switch circuit: 2 1.
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. Test the switch by disconnecting the wires from the switch terminals and connecting a continuity tester across the two switch terminals. With the engine turned off, slowly push the traction pedal in a forward or reverse direction while watching the continuity tester.
Diode Circuit Board The diode circuit board contains four diodes (Fig. 40) and is located under the console housing. Diode D1--A provide logic for the interlock switches. Diodes D1--C, D1--B (GM 4700--D right deck), and D1--D (GM 4700--D left deck) are used for circuit protection from voltage spikes when PTO relays are de--energized. H G D1--D F D1--A D1--C The diodes can be individually tested using a digital multimeter (ohms setting) and the table to the right.
Standard Control Module Groundsmaster 4500--D and 4700--D machines with Serial Numbers above 230000000 are equipped with a Standard Control Module to monitor and control electrical components required for safe operation. This Module is located under the console cover. 1 Inputs from the neutral, parking brake, PTO, start (ignition), and high temperature switches are monitored by the Module.
Service and Repairs NOTE: For more component repair information, see the Kubota Workshop Manual, Diesel Engine, V2003--T Series 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). 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. 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: 1.265 corrected to 80oF (26.
H. Using the table below, determine the minimum voltage for the cell temperature reading: Minimum Voltage Battery Electrolyte Temperature 9.6 70oF (and up) 21.1oC (and up) 9.5 60oF 15.6oC 9.4 50oF 10.0oC 3. Perform a high--discharge test with an adjustable load tester. 9.3 40oF 4.4oC 9.1 30oF --1.1oC This is one of the most reliable means of testing a battery as it simulates the cold--cranking test. A commercial battery load tester is required to perform this test. 8.9 20oF --6.7oC 8.
2. Determine the charging time and rate using the manufacturer’s battery charger instructions or the following table. Battery Reserve Capacity (Minutes) 3. Following the manufacturer’s instructions, connect the charger cables to the battery. Make sure a good connection is made. 4. Charge the battery following the manufacturer’s instructions. Battery Charge Level (Percent of Fully Charged) 75% 50% 25% 0% 80 or less 3.8 hrs @ 3 amps 7.5 hrs @ 3 amps 11.3 hrs @ 3 amps 15 hrs @ 3 amps 81 to 125 5.
Chapter 6 Axles, Planetaries, and Brakes Table of Contents Rear Axle Assembly . . . . . . . . . . . . . . . . . . . . . . . . Bevel Gear Case and Axle Case . . . . . . . . . . . . . Differential Shafts . . . . . . . . . . . . . . . . . . . . . . . . . . Axle Shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Input Shaft/Pinion Gear . . . . . . . . . . . . . . . . . . . . . Differential Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . Pinion Gear to Ring Gear Engagement . . . .
Specifications Item Specification Wheel lug nut torque (front and rear) 85 to 100 ft--lb (115 to 135 N--m) Steering cylinder bolt torque 100 to 125 ft--lb (135 to 169 N--m) Planetary brake housing and wheel motor mounting screw torque 75 to 85 ft--lb (101 to 115 N--m) Rear wheel toe--in .125 in (3.2 mm) Tire pressure (front and rear) 20 psi (1.4 bar) Planetary gear drive lubricant Planetary gear lube capacity (each wheel) SAE 85W--140 wt. gear lube 16 fl oz (.
Adjustments Axles, Planetaries, and Brakes See Traction Unit Operator’s Manual for adjustment procedures for Groundsmaster 4500--D and Groundsmaster 4700--D axles, planetaries, and brakes. Groundsmaster 4500--D/4700--D Page 6 -- 3 Axles, Planetaries, and Brakes (Rev.
Service and Repairs Brake Assembly 1 2 18 3 6 17 17 19 15 14 RIGHT FRONT 1. 2. 3. 4. 5. 6. 7. 9 16 13 12 11 8 5 10 75 to 85 ft--lb (101 to 115 N--m) Flange head screw Splined brake shaft Planetary assembly Tire and wheel assembly Lug nut Retaining ring Spring plate 7 4 85 to 100 ft--lb (115 to 135 N--m) 8. 9. 10. 11. 12. 13. Axles, Planetaries, and Brakes (Rev. B) Figure 1 Compression spring Jam nut LH Brake assembly Flange head screw Hex plug Piston motor Page 6 -- 4 14. 15. 16.
1. Park machine on a level surface and raise cutting units to allow easier access to front brake assembly. Stop engine, engage parking brake, and remove key from the ignition switch. 2. Drain oil from planetary wheel drive/brake assembly (see Traction Unit Operator’s Manual). CAUTION When changing attachments, tires, or performing other service, use correct blocks, hoists, and jacks. Make sure machine is parked on a solid, level surface such as a concrete floor.
Brake Inspection and Repair 3 2 1 4 5 6 7 8 9 15 14 10 13 12 1. 2. 3. 4. 5. 11 Brake housing (LH shown) Seal Pull rod Clevis pin Link 6. 7. 8. 9. 10. Figure 4 Hitch pin Stationary disc Rotating disc Retaining ring Gasket 11. 12. 13. 14. 15. Rotating actuator Extension spring Ball Plug O--ring Brake Inspection and Repair (Fig. 4) 6. Remove seal (2) from brake housing. 1. Scrape gasket material (10) from brake housing and planetary wheel drive mounting surfaces. 7.
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Planetary Wheel Drive Assembly 75 to 85 ft--lb (101 to 115 N--m) 1 2 18 3 6 17 17 15 14 RIGHT FRONT 1. 2. 3. 4. 5. 6. 9 16 13 12 11 8 5 10 75 to 85 ft--lb (101 to 115 N--m) Flange head screw Splined brake shaft Planetary assembly Tire and wheel assembly Lug nut Retaining ring 7 4 85 to 100 ft--lb (115 to 135 N--m) 7. 8. 9. 10. 11. 12. Figure 5 Spring plate Compression spring Jam nut LH Brake assembly Flange head screw Hex plug 13. 14. 15. 16. 17. 18.
3. Chock rear wheels and jack up front of machine (see Jacking Instructions in Chapter 1 -- Safety). Support machine with jack stands or solid wood blocks. 1 4. Remove front wheel assembly. 5. Remove flange head screws that secure brake assembly to planetary assembly (see Brake Assembly). 2 6. Support planetary assembly to prevent it from falling. Loosen and remove flange head screws that secure planetary assembly to frame. Remove planetary assembly from machine.
Planetary Wheel Drive Service 3 118 to 144 in--lb (13.3 to 16.3 N--m) 4 7 8 9 11 12 1 13 2 5 14 15 16 6 10 28 20 27 19 18 26 17 25 24 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. Spindle Boot seal Oil seal Bearing cone Bearing cup Wheel stud Socket head screw Lock washer Housing Dowel pin 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 23 22 21 29 Figure 7 Bearing cup Bearing cone O--ring Bearing shim Snap ring Ring gear Retaining ring Plug End cap O--ring 21. 22. 23. 24. 25. 26. 27. 28. 29.
Planetary Wheel Drive Assembly (Figure 7) NOTE: Use new seal kit when assembling planetary wheel drive. 1. Clean parts in solvent. Inspect parts for damage or excessive wear and replace as necessary. 8. Install secondary carrier (28), secondary gear (27), and primary carrier (26). 9. Install drive shaft (25) and primary gear (24). Secure gear with retaining ring (23). 10.Install thrust washer (22) and thrust plug (21). 11. Install o--ring (20) and end cap (19). Secure end cap with retaining ring (17). 2.
Rear Axle Assembly 6 7 70 ft--lb (94 N--m) maximum 8 1 3 5 4 2 16 15 14 13 12 11 10 9 24 22 23 17 5 RIGHT 21 20 85 to 100 ft--lb (115 to 135 N--m) 19 FRONT 18 Figure 8 1. 2. 3. 4. 5. 6. 7. 8. Steering cylinder Needle bearing External snap ring External snap ring Thrust washer Flat washer Lock nut Grease fitting 9. 10. 11. 12. 13. 14. 15. 16. Cap screw Flat washer Piston motor O--ring Pinion gear Gear Cap screw Lock washer Remove Rear Axle 1.
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. If required, remove tie rod ends from steering arms on rear axle (Fig. 9). Remove the cotter pins and castle nuts from the tie rod ball joints. Use a ball joint fork and remove the tie rod ends from the axle steering arms. 12.Clean the rear axle pivot pin and pivot bushings. Inspect the pin and bushings for wear or damage.
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 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. 11). 4 6 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. 1.
5. Remove the knuckle pin mounting screws and the knuckle pin. Remove the gasket and any remaining gasket material from either mating surface (Fig. 14). 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. 16). 3 2 1 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. 17). Tighten cover screws from 17 to 20 ft-lb (23 to 27 N--m). Figure 16 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. 20). 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 4 3 1. Remove the axle cover mounting screws. Remove the axle cover from the axle case as an assembly (Fig. 23). 2. Use a bearing puller to remove the bearing and bevel gear as shown (Fig. 24). 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 1 35 to 41 ft--lb (47 to 56 N--m) 9 7 8 6 5 3 2 18 17 4 18 15 10 9 16 14 10 13 11 35 to 41 ft--lb (47 to 56 N--m) 12 Figure 26 1. 2. 3. 4. 5. 6. Nut Lockwasher Stud Locknut Stake washer Oil seal 7. 8. 9. 10. 11. 12. O-ring Seal collar Bearing O-ring Input shaft/Pinion gear Bearing case 13. 14. 15. 16. 17. 18. Shim Screw Gear case Gasket Cover plate Dowel pin The following procedures assume the rear axle assembly has been removed from the machine.
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 locknut 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. 0.04 in. (1.0 mm) 7. Secure the lock nut with the stake washer. 2 1 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) 5 Removal 1 2 6 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. 7 4 2. Mark and pull the differential shaft assemblies from the axle support. 3.
Inspection 1. Measure the differential side gear O.D. and the differential case I.D. to determine the side gear to case clearance (Fig. 33). 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. 37): 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. 40): A. Install thicker or additional bearing case shim(s) to move pinion shaft toward ring gear. Figure 40 B. Install thinner or remove differential bearing shim(s) to move ring gear backward. C.
Chapter 7 Chassis Table of Contents GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . Cutting Deck Identification . . . . . . . . . . . . . . . . . . . . SERVICE AND REPAIRS . . . . . . . . . . . . . . . . . . . . . . Steering Tower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lift Arms For Cutting Decks #1, #4, and #5 . . . . . 1 1 2 2 4 Lift Arms For Cutting Decks #2 and #3 . . . . . . . . . 6 Lift Arms For Cutting Decks #6 and #7 (Groundsmaster 4700--D only) . . . . . . . .
Service and Repairs Steering Tower 20 to 26 ft--lb (28 to 35 N--m) 1 20 21 22 19 18 45 44 2 3 23 5 4 24 25 26 6 11 7 31 27 29 8 48 47 46 9 10 28 11 30 13 42 41 32 24 RIGHT 33 34 35 FRONT 38 15 39 40 43 14 13 12 16 34 17 36 37 Figure 2 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16.
Disassembly Assembly 1. Park machine on a level surface, lower cutting units, stop engine, engage parking brake, and remove key from the ignition switch. 1. Assemble steering tower using Figure 2 as a guide. Chassis 2. Disassemble steering tower as needed using Figure 2 as a guide.
Lift Arms for Cutting Decks #1, #4, and #5 30 38 6 37 5 4 3 2 1 7 8 9 36 10 32 2 13 15 14 34 33 5 RIGHT 11 12 32 10 4 14 16 35 17 31 FRONT 19 32 29 28 25 18 26 27 19 24 23 22 21 16 20 Figure 3 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. Lock nut Flange nut Lift arm (#1 deck) Lift cylinder pin Flange head screw Hydraulic fitting Cap screw Lift cylinder (#4 and #5 decks) Lift cylinder (#1 deck) Thrust washer Lock nut Pivot pin Slotted roll pin 14. 15. 16. 17. 18. 19. 20.
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. #4 Deck #1 Deck #5 Deck 7. Remove lift arm from machine. 8. Clean lift arm and pivot pin. Inspect lift arm flange bushings and pivot pin for damage or wear. Installation #6 Deck 1. Position lift arm to frame (Fig. 3). Fit thrust washer between rear of lift arm and frame. Slide pivot pin into frame and lift arm.
Lift Arms for Cutting Decks #2 and #3 5 29 3 4 1 2 20 19 30 15 17 16 18 15 29 14 21 RIGHT 31 29 25 30 FRONT 6 Thread--locking Compound 7 10 8 24 13 28 27 11 26 23 13 22 12 9 Figure 6 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. Flange nut Bulkhead bracket Hydraulic t--fitting Flange head screw Lock nut Slotted roll pin Pivot pin Bumper Thrust washer Rebound washer Deck pivot shaft Chassis 12. 13. 14. 15. 16. 17. 18. 19. 20. 21.
Removal 1. Park machine on a level surface, lower cutting units, 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 Unit Operator’s Manual). 3. Remove lift cylinder pin that secures lift cylinder to lift arm. #6 Deck (GM4700) 4. Loosen and remove lock nut from pivot pin. #2 Deck #3 Deck #7 Deck (GM4700) 5. Support lift arm and pull lift arm pivot pin from lift arm and frame.
Lift Arms for Cutting Decks #6 and #7 (Groundsmaster 4700--D only) 1 2 3 41 34 4 40 6 5 4 27 1 31 6 33 7 8 9 10 30 37 36 34 32 14 13 1 11 12 39 15 20 19 18 17 16 39 RIGHT FRONT 1 27 38 28 35 22 21 10 23 15 29 24 25 26 42 Figure 8 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14.
Removal 1. Park machine on a level surface, lower cutting units, 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 Unit Operator’s Manual). 3. Remove pin that secures lift links (10) to lift arm. #6 Deck 4. Loosen and remove lock nut from pivot pin. (GM4700) #2 Deck #3 Deck #7 Deck (GM4700) 5. Support lift arm and pull lift arm pivot pin from lift arm and support arm.
Hood 8 6 32 2 1 31 48 49 9 7 9 10 13 11 3 4 51 5 18 17 16 14 10 15 44 46 12 19 21 20 50 22 23 24 25 26 27 46 47 28 45 29 30 17 13 37 36 RIGHT 38 39 40 41 42 FRONT 43 35 34 33 22 Figure 10 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. RH hood frame tube Front hood tube Front shroud Shroud divider Hair pin Screen Keeper Hood Flat washer Lock nut Pop rivet RH tube cover Lock nut Cap screw Cap screw RH support Flange nut Chassis 18. 19. 20. 21. 22. 23. 24.
Removal 1. Park machine on a level surface, lower cutting units, stop engine, engage parking brake, and remove key from the ignition switch. 1 2. Release hood latches (Fig. 11) and raise hood. 3. Unhook lanyard from hood lock pin, remove pin, and slide hood tubes rearward off guides (Fig. 12). Installation 1. Slide hood tubes onto guides, install hood lock pin, and hook lanyard to hood pin (Fig. 12). 2. Secure hood to frame with latches (Fig. 11). Figure 11 1. 3.
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Chapter 8 Cutting Units Table of Contents 2 3 3 4 5 5 6 SERVICE AND REPAIRS . . . . . . . . . . . . . . . . . . . . . . 8 Blade Spindle Assembly . . . . . . . . . . . . . . . . . . . . . 8 Blade Spindle Service . . . . . . . . . . . . . . . . . . . . . . 10 Rear Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Rear Roller Service (Non--Greasable Bearings) 13 Rear Roller Service (Greasable Bearings with Retaining Ring) . . . . . . . . . . . . . . . . . . . . . . . . . .
Specifications MOUNTING: All cutting units are supported by independent lift arms and are interchangeable to any cutting unit positions. The Groundsmaster 4700--D (shown above) uses 7 cutting units. The Groundsmaster 4500--D uses 5 cutting units. CONSTRUCTION: Deck chamber is welded 7, 10, and 12 gauge steel. Deck frame is welded 1--1/2 inch square tubing with 7 gauge side supports. HEIGHT--OF--CUT RANGE: 3/4 to 4 inch (1.91 to 10.16 cm) in 1/4 inch (.64 cm) increments.
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 these special tools from your Toro Distributor. Cutting Unit Tool Kit -- TOR4070 This tool kit includes special tools used to assemble the cutting unit rear roller that has greasable bearings with a grease fitting on the ends of the roller shaft.
Adjustments CAUTION Never install or work on the cutting units or lift arms with the engine running. Always stop engine and remove key first. See the Cutting Unit Operator’s Manual for adjustment procedures for cutting units on the Groundsmaster 4500--D and Groundsmaster 4700--D. Blade Stopping Time The blades of the cutting deck are to come to a complete stop in approximately 5 seconds after the cutting deck engagement switch is shut down.
Blade Plane Inspection and Adjustment If a solid object is struck by the cutting deck, the blade plane of the deck should be inspected. Blade Plane Inspection 1. Remove cutting unit to be inspected (see Cutting Unit Operator’s Manual). 2. Use hoist (or minimum of two people) and place cutting deck on flat table. 3. Mark one end of blade with paint pen or marker. Use this end of blade to check all heights. 4. Position cutting edge of marked end of blade at 12 o’clock (straight ahead in direction of mowing).
Cutting Units This page is intentionally blank. Groundsmaster 4500--D/4700--D Page 8 -- 7 Cutting Units (Rev.
Service and Repairs CAUTION Never install or work on the cutting units or lift arms with the engine running. Always stop engine and remove key first. Blade Spindle Assembly 1 2 13 12 3 11 4 5 RIGHT 6 FRONT 7 85 to 110 ft--lb (115 to 149 N--m) 8 9 10 Figure 3 1. 2. 3. 4. 5. Flange nut Socket head screw (motor mounting) Spindle plate Cutting deck O--ring Cutting Units (Rev. B) 6. 7. 8. 9. Spindle assembly Cap screw Cutting blade Anti--scalp cup Page 8 -- 8 10. 11. 12. 13.
Removal 2 1. Park machine on a level surface, lower cutting units, stop engine, engage parking brake, and remove key from the ignition switch. 2. Remove two socket head screws that secure hydraulic motor to the cutting unit (Fig. 4). Remove hydraulic motor and O--ring from deck. 1 1 3. Cover top of spindle to prevent contamination. Spindle plug (Toro Part No. 94--2703) can be used to cover spindle. 4. Start the engine and raise the cutting unit. Stop engine and remove key from the ignition switch.
Blade Spindle Service Disassembly 2 1. Remove blade spindle from cutting deck (see Blade Spindle Removal). 6 4 130 to 160 ft--lb (177 to 216 N--m) 2. Loosen and remove spindle nut from top of spindle shaft. 11 10 3. Press the spindle shaft out of the spindle housing using an arbor press. The shaft spacer remains on the spindle shaft as the shaft is being removed. 9 12 8 7 4. Remove seals from spindle housing. 1 5.
5. Install lower bearing and seal into bottom of spindle housing. Note: The bottom seal must have the lip facing out (down) (Fig. 7). 2 6. Slide spacer ring and inside spacer into spindle housing, then install upper bearing and seal into top of housing. Note: The upper seal must have the lip facing out (up) (Fig. 7). 7. Inspect the spindle shaft to make sure it is free of burrs or nicks that could possibly damage the seals. Lubricate the shaft with grease. 8. Install spindle spacer onto shaft.
Rear Roller Three types of rear rollers have been used on the Groundsmaster 4500--D and 4700--D. One roller design has sealed bearings with no grease fittings on the roller shaft. The second design has grease fittings in the roller shaft ends. The third design has grease fittings incorporated into the roller fasteners. Removal and installation of the rear roller from the cutting deck is the same, regardless of roller type. 10 6 5 4 9 7 1 8 6 7 Removal (Fig. 8) 3 1.
Rear Roller Service (Non--Greasable Bearings) Seal Removal (Fig. 9) 1. Using a 1/4 inch thick, 3” X 3” square piece of steel, make a seal removal tool as shown in Figure 10. 2. Slide seal removal tool over roller shaft. 5. Install second spiral retaining ring onto roller shaft to secure second bearing. 6. Install new seals to .030 inch (.76 mm) recessed into roller. 3. Using the tool as a template, locate, mark, and drill two 7/64 inch (.109 inch diameter) holes in outer face of seal. 2 3 4 4.
Rear Roller Service (Greasable Bearings with Retaining Ring) 9 8 7 2 10 4 6 1 1 2 3 4 5 3 5 10 9 7 8 6 Figure 11 1. 2. 3. 4. Roller shaft Outer seal Retaining ring Outer oil seal Cutting Units (Rev. B) 5. 6. 7. Grease fitting Washer Inner seal Page 8 -- 14 Rev. D 8. Ball bearing 9. Inner oil seal 10.
Roller Disassembly (Fig. 11) 3. Use tool TOR4068 to install inner seal. 1. Remove retaining ring from both ends of roller. 4. Use tool TOR4069 to install outer seal. 2. Hit end of roller shaft with a soft face hammer to remove seals and bearing from one end of roller. Hit other end of roller shaft to remove seals and bearing from other end of roller. Be careful not to drop roller shaft. 5. Install retaining ring so that side with sharp edges faces end of roller (out). 3. Discard seals and bearings.
Rear Roller Service (Greasable Bearings with Bearing Nut) Disassembly (Fig. 12) 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. 18) 1. Remove roller mounting bolt. 2. Remove roller assembly from carrier frame. 1 3. To remove bearings and spacer: 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 B. Remove spacer. Remove second bearing from roller using a press. 4. Inspect roller housing, bearings, and bearing spacer for damage or wear.
Cutting Units This page is intentionally blank. Groundsmaster 4500--D/4700--D Page 8 -- 19 Rev. D Cutting Units (Rev.
Cutting Deck Carrier Frame Decks #2 and #3 Decks #1, #4, and #5 9 8 3 1 7 6 1 5 Decks #6 and #7 3 4 14 2 13 RIGHT 3 FRONT 12 1 11 10 Figure 19 1. 2. 3. 4. 5. Carrier frame Lynch pin Thrust washer Pivot shaft Lift arm (#4 shown) Cutting Units (Rev. B) 6. 7. 8. 9. 10. Cap screw Rebound washer Pivot shaft Lift arm (#2 shown) Lock nut Page 8 -- 20 Rev. D 11. 12. 13. 14.
Installation 1 Each cutting deck is suspended from a carrier frame. Decks should be attached to the carrier frame using the lower hole in deck bracket (Fig. 20). 3 The cutting deck carrier frame is attached to the lift arm and allows the cutting deck to pivot on the lift arm pivot shaft. Carrier frames are secured to lift arms as follows: 2 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.
This page is intentionally blank. Cutting Units (Rev. B) Page 8 -- 22 Rev.
Chapter 9 Electrical Diagrams Table of Contents Groundsmaster 4500--D/4700--D Page 9 - 1 Rev. D Electrical Diagrams (Rev. A) Electrical Diagrams ELECTRICAL SCHEMATICS . . . . . . . . . . . . . . . . . . . 3 Groundsmaster 4500--D Serial Number Below 220999999 . . . . . . . . . . . . 3 Serial Number From 230000001 to 260000600 4 Serial Number Above 260000600 . . . . . . . . . . . 5 Groundsmaster 4700--D Serial Number Below 220999999 . . . . . . . . . . . .
This page is intentionally blank. Electrical Diagrams (Rev.
GLOW OVER TEMP BU/W OR CLUSTER GAUGE GLOW RELAY ALTERNATOR W LOW OIL PRESSURE GN CONTROLLER GLOW PLUG KUBOTA (IN 4WD) START RELAY K5 (OFF) (SEAT VACANT) DECK UP (IN CENTER POSITION) FRONT PTO (DECKS 2, 3, 5) FRONT DECK POSITION (DECK RAISED) FRONT DECK POSITION (DECK RAISED) FRONT PTO (DECKS 1,4) (NOT IN NEUTRAL) Groundsmaster 4500--D Electrical Schematic Serial Number Below 220999999 All relays and solenoids are shown as de-- energized. All ground wires are black.
GLOW RELAY Groundsmaster 4500--D Electrical Schematic Serial Number From 230000001 to 260000600 All relays and solenoids are shown as de-- energized. All ground wires are black. Page 9 - 4 Rev.
Groundsmaster 4500--D Electrical Schematic Serial Number Above 260000600 All relays and solenoids are shown as de-- energized. All ground wires are black. Page 9 - 5 Rev.
GLOW OVER TEMP LOW OIL PRESSURE CLUSTER GAUGE GLOW RELAY ALTERNATOR GN CONTROLLER GLOW PLUG KUBOTA (IN 4WD) START RELAY K5 (OFF) DECK UP (IN CENTER POSITION) LEFT PTO (DECK 6) (SEAT VACANT) LEFT DECK POSITION (DECK RAISED) DECK UP (IN CENTER POSITION) FRONT PTO (DECKS 2, 3, 5) FRONT DECK POSITION (DECK RAISED) FRONT DECK POSITION (DECK RAISED) FRONT PTO (DECKS 1,4) DECK UP (IN CENTER POSITION) (NOT IN NEUTRAL) RIGHT PTO (DECK 7) RIGHT DECK POSITION (DECK RAISED) Groundsmaster 4700--D Electr
GLOW RELAY Groundsmaster 4700--D Electrical Schematic Serial Number From 230000001 to 260000600 All relays and solenoids are shown as de-- energized. All ground wires are black. Page 9 - 7 Rev.
Groundsmaster 4700--D Electrical Schematic Serial Number Above 260000600 All relays and solenoids are shown as de-- energized. All ground wires are black. Page 9 - 8 Rev.
GLOW OVER TEMP BU/W OR CLUSTER GAUGE GLOW RELAY ALTERNATOR W LOW OIL PRESSURE GN NOTE: The wire harness and relays of the GM 4500-- D and GM 4700-- D are the same. The drawing on this page uses the GM 4500-- D Schematic (Serial Number Below 220999999) to show the operational circuits.
GLOW OVER TEMP BU/W OR CLUSTER GAUGE GLOW RELAY ALTERNATOR W LOW OIL PRESSURE GN NOTE: The wire harness and relays of the GM 4500-- D and GM 4700-- D are the same. The drawing on this page uses the GM 4500-- D Schematic (Serial Number Below 220999999) to show the operational circuits.
GLOW OVER TEMP BU/W OR CLUSTER GAUGE GLOW RELAY ALTERNATOR W LOW OIL PRESSURE GN NOTE: The wire harness and relays of the GM 4500-- D and GM 4700-- D are the same. The drawing on this page uses the GM 4500-- D Schematic (Serial Number Below 220999999) to show the operational circuits.
GLOW OVER TEMP BU/W OR CLUSTER GAUGE GLOW RELAY ALTERNATOR W LOW OIL PRESSURE GN NOTE: The wire harness and relays of the GM 4500-- D and GM 4700-- D are the same. The drawing on this page uses the GM 4500-- D Schematic (Serial Number Below 220999999) to show the operational circuits.
This page is intentionally blank. Page 9 - 13 Rev.
ORANGE P4 GRAY P5 BLUE/WHITE YELLOW INTERCONNECT TO ENGINE PARKING BRAKE P17 NEUTRAL SWITCH P6 RED/BLACK SEAT SWITCH P15 BLACK ALT. B+ J3 J2 BLACK J1 BLACK P3 BLACK GLOW RELAY RED/BLACK oil pressure WARNING LIGHTS P1 alt ”L” P20 FUEL PUMP YELLOW GREEN YELLOW WHITE YELLOW over temp.
J3 ALTERNATOR B+ P15 SEAT SWITCH P27 DIODE 3 B A J2 GLOW RELAY P18 STARTER B+ P10 2WD COIL 1 P19 IGNITION SWITCH 2 P14 CENTER DECK (1, 4) 1 5 4 2 P30 INTERCONNECT TO 4700 P23 INTERCONNECT TO CONSOLE 3 SP4 P2 WARNING LIGHTS (OVER TEMP) SP6 SP5 P1 WARNING LIGHTS (OIL PRESSURE/ALT ”L”) J1 GLOW RELAY SP2 SP7 J4 IGNITION SWITCH 1 SP1 P23 INTERCONNECT TO ENGINE P6 NEUTRAL SWITCH P17 PARKING BRAKE P13 CENTER DECK PTO (2, 3, 5) P3 GLOW RELAY P20 FUEL PUMP 2 SP3 P4 INTERCONNECT TO
GRAY RED/BLACK BLUE/WHITE BLACK BLACK BLACK BLACK PINK ORANGE RED/BLACK PINK GREEN PINK WHITE PINK PINK PINK BLUE/WHITE PINK BROWN RED BLACK BLUE RED BROWN ORANGE RED GRAY ORANGE GREEN BLUE/WHITE BLACK RED/BLACK GREEN YELLOW ORANGE GREEN VIOLET YELLOW BLACK WHITE BLACK BROWN GREEN TAN BLUE ORANGE YELLOW WHITE BLACK BROWN BLACK BLUE GREEN BLACK CABLE SHIELD BROWN BLACK Groundsmaster 4500--D/4700--D Serial Number From 230000001 to 260000600 Main Wire Harness Page 9 - 16 Rev.
Groundsmaster 4500--D/4700--D Serial Number From 230000001 to 260000600 Main Wire Harness Page 9 - 17 Rev.
GRAY RED/BLACK BLUE/WHITE BLACK BLACK BLACK BLACK ORANGE PINK RED/BLACK PINK GREEN PINK WHITE PINK PINK PINK BLUE/WHITE PINK BROWN RED BLACK BLUE RED BROWN ORANGE RED GRAY ORANGE GREEN BLUE/WHITE BLACK RED/BLACK GREEN YELLOW ORANGE GREEN VIOLET YELLOW BLACK WHITE BLACK BROWN GREEN TAN BLUE ORANGE YELLOW WHITE BLACK BROWN BLACK BLUE GREEN BLACK CABLE SHIELD BROWN BLACK Groundsmaster 4500--D/4700--D Serial Number Above 260000600 Main Wire Harness Page 9 - 18 Rev.
SN 280000001 AND UP Groundsmaster 4500--D/4700--D Serial Number Above 260000600 Main Wire Harness Page 9 - 19 Rev.
PTO SWITCH P5 K7 PARKING BRAKE P14 VIOLET P15 YELLOW YELLOW PINK BLACK YELLOW K6 HIGH TEMP BLACK BLUE GREEN VIOLET PINK VIOLET BLUE BLUE K2 RELAY CENTER PTO RAMP--UP MODULE SHIELDED CABLE BROWN BLACK P28 ORANGE YELLOW P7 GREEN K1 RELAY LEFT PTO BLACK RED WHITE GND P4 YELLOW 2WD/4WD SWITCH P3 GREEN GLOW CONTROLLER J1 BLACK P2 PINK TEMPERATURE GAUGE BLACK P8 BLUE BLACK BLACK ORANGE BLUE K3 RELAY RIGHT PTO TAN P9 ORANGE GREEN BLUE/WHITE BLACK BLUE VIOLET GREEN YEL
P9 K3 RELAY: RIGHT PTO P15 K7 PARKING BRAKE 1 4 2 3 P11 K5 RELAY: START P14 K6 HIGH TEMP 1 5 P8 K2 RELAY: CENTER PTO P12 FUSE BLOCK #1 P7 K1 RELAY: LEFT PTO 3 2 P1 HOUR METER P28 RAMP UP MODULE J3 CAPACITOR J2 CAPACITOR P13 OPT.
BLUE BLACK PINK BLACK PINK GND BLACK BLACK RED WHITE GREEN ORANGE SHIELDED CABLE PINK BROWN TAN PINK BLACK PINK BLUE BLUE BLACK BROWN BLACK BLACK BLUE BLUE ORANGE GRAY VIOLET ORANGE GREEN BLUE/WHITE GREEN PINK BLACK BLACK GREEN YELLOW YELLOW ORANGE ORANGE WHITE/BLACK GREEN YELLOW PINK RED TAN GRAY PINK BLUE YELLOW BLACK WHITE VIOLET PINK YELLOW RED GREEN VIOLET RED/BLACK PINK RED WHITE RED ORANGE BROWN PINK VIOLET PINK BLACK ORANGE PINK WHITE BLACK GREEN
Groundsmaster 4500--D/4700--D Serial Number From 230000001 to 260000600 Console Wire Harness Page 9 - 23 Rev.
PINK BROWN BLACK PINK BLACK BLACK RED WHITE GREEN GND BLACK BROWN ORANGE TAN PINK SHIELDED CABLE PINK BLACK BROWN BROWN BROWN BLACK BLACK BLACK BLUE ORANGE VIOLET BROWN GRAY ORANGE GREEN BLACK PINK BLACK BLUE/WHITE GREEN GREEN YELLOW YELLOW ORANGE ORANGE WHITE/BLACK GREEN YELLOW PINK RED TAN GRAY PINK BLUE ORANGE YELLOW BLACK VIOLET YELLOW GREEN RED/BLACK PINK RED PINK WHITE VIOLET RED RED WHITE BROWN PINK VIOLET PINK BLACK YELLOW ORANGE GREEN PINK WHITE BLACK
Groundsmaster 4500--D/4700--D Serial Number Above 260000600 Console Wire Harness Page 9 - 25 Rev.
RUN SOLENOID P1 OVER TEMPERATURE J4 J5 BLUE/WHITE BLACK RED/BLACK HOLD PULL GROUND OIL PRESSURE WHITE FUSIBLE LINK P2 STARTER ”G” WHITE GREEN INTERCONNECT P4 TO MAIN HARNESS BLUE GRAY J3 BLACK GROUND BLACK ORANGE YELLOW BLACK BLUE INTERCONNECT P5 TO MAIN HARNESS J2 J1 P7 J6 GLOW TEMPERATURE SENDER DIODE STARTER R L P6 ALTERNATOR Groundsmaster 4500--D/4700--D Serial Number Below 220999999 Engine Wire Harness Page 9 - 26 Rev.
P1 FUEL SOLENOID J5 TEMPERATURE SWITCH B J2 GLOW PLUGS SP2 A P5 TO MAIN HARNESS SP1 J1 TEMPERATURE SENDER P4 TO MAIN HARNESS P2 STARTER ”G” J4 OIL PRESSURE J6 STARTER ”S” P6 ALTERNATOR 2 1 P7 DIODE J3 GROUND Groundsmaster 4500--D/4700--D Serial Number Below 220999999 Engine Wire Harness Page 9 - 27 Rev.
BLUE/WHITE BLACK RED/BLACK WHITE FUSIBLE LINK WHITE GREEN BLUE GRAY BLACK ORANGE PINK BLACK Groundsmaster 4500--D/4700--D Serial Number Above 230000000 Engine Wire Harness Page 9 - 28 Rev.
Groundsmaster 4500--D/4700--D Serial Number Above 230000000 Engine Wire Harness Page 9 - 29 Rev.
PINK GREEN PINK VIOLET YELLOW PINK BLACK ORANGE BLACK VIOLET BLACK YELLOW BLACK BLACK Groundsmaster 4700--D Deck 6 and 7 Wire Harness Page 9 - 30 Rev.
