Form No.
Revision History Revision Date -- 2014 Initial Issue. A 2016 Updated Engine chapter. B 02/2018 Updated Engine chapter, Electrical chapter and Foldout Drawings. Added revision history. C 05/2018 Added VA02 series planetary information. D 03/2019 Updated Hydraulic chapter. E 06/2019 Updated rear axle service drawings. F 06/2020 Updated Electrical chapter and Foldout Drawings. G 06/2021 Updated Foldout Drawings.
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.
NOTES _
Part No. 14205SL Rev. G Service Manual (Models 30873, 30874, 30881 and 30882) 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 (Models 30873 and 30881) and 4700--D (Models 30874 and 30882). REFER TO THE TRACTION UNIT AND CUTTING UNIT OPERATOR’S MANUALS FOR OPERATING, MAINTENANCE AND ADJUSTMENT INSTRUCTIONS.
This page is intentionally blank.
Chapter 5 -- Electrical System General Safety Instructions . . . . . . . . . . . . . . . . . . 1 -- 2 Jacking Instructions . . . . . . . . . . . . . . . . . . . . . . . . . 1 -- 5 Safety and Instruction Decals . . . . . . . . . . . . . . . . 1 -- 6 General Information . . . . . . . . . . . . . . . . . . . . . . . . 5 -- 2 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 -- 6 InfoCenter Display . . . . . . . . . . . . . . . . . . . . . . . . . . 5 -- 8 Troubleshooting . . . . . .
This page is intentionally blank.
Safety Table of Contents GENERAL SAFETY INSTRUCTIONS . . . . . . . . . . . . Before Operating . . . . . . . . . . . . . . . . . . . . . . . . . . . . While Operating . . . . . . . . . . . . . . . . . . . . . . . . . . . . Maintenance and Service . . . . . . . . . . . . . . . . . . . . JACKING INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . SAFETY AND INSTRUCTION DECALS . . . . . . . . . .
General Safety Instructions The Groundsmaster 4500-D and 4700--D have been tested and certified by TORO for compliance with existing safety standards and specifications. Although hazard control and accident prevention partially are dependent upon the design and configuration of the machine, these factors are also dependent upon the awareness, concern and proper training of the personnel involved in the operation, transport, maintenance and storage of the machine.
1. Sit on the seat when starting and operating the machine. Safety While Operating 5. Before getting off the seat: A. Ensure that traction pedal is in neutral. 2. Before starting the engine: B. Fully lower and disengage cutting decks. Wait for deck blades to stop. A. Engage the parking brake. B. Make sure traction pedal is in neutral and the PTO switch is OFF (disengaged). C. After engine is started, release parking brake and keep foot off traction pedal. Machine must not move.
Maintenance and Service 1. The Traction Unit and Cutting Deck Operator’s Manuals provide information regarding the operation, general maintenance and maintenance intervals for your Groundsmaster machine. Refer to these publications for additional information when servicing the machine. 13.Disconnect battery before servicing the machine. Disconnect negative battery cable first and positive cable last. If battery voltage is required for troubleshooting or test procedures, temporarily connect the battery.
Safety Jacking Instructions Jacking the Rear End CAUTION 1. Apply parking brake and chock both front tires to prevent the machine from moving. When changing attachments, tires or performing other service, use correct jacks and supports. Make sure machine is parked on a solid, level surface such as a concrete floor. Prior to raising machine, remove any attachments that may interfere with the safe and proper raising of the machine. Always chock or block wheels.
Safety and Instruction Decals Numerous safety and instruction decals are affixed to the Groundsmaster 4500--D and 4700--D. If any decal becomes illegible or damaged, install a new decal. Decal part numbers are listed in your Parts Catalog.
Product Records and Maintenance Table of Contents PRODUCT RECORDS . . . . . . . . . . . . . . . . . . . . . . . . . MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EQUIVALENTS AND CONVERSIONS . . . . . . . . . . . Decimal and Millimeter Equivalents . . . . . . . . . . . . U.S. to Metric Conversions . . . . . . . . . . . . . . . . . . . TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . Fastener Identification . . . . . . . . . . . . . . . . . . . . . . .
Equivalents and Conversions 0.
Recommended fastener torque values are listed in the following tables. For critical applications, as determined by Toro, either the recommended torque or a torque that is unique to the application is clearly identified and specified in this Service Manual. These Torque Specifications for the installation and tightening of fasteners shall apply to all fasteners which do not have a specific requirement identified in this Service Manual.
Standard Torque for Dry, Zinc Plated and Steel Fasteners (Inch Series) Thread Size # 6 -- 32 UNC Grade 1, 5 & 8 with Thin Height Nuts SAE Grade 1 Bolts, Screws, Studs & Sems with Regular Height Nuts (SAE J995 Grade 2 or Stronger Nuts) in--lb in--lb N--cm 10 + 2 13 + 2 147 + 23 # 6 -- 40 UNF # 8 -- 32 UNC 13 + 2 25 + 5 282 + 30 # 8 -- 36 UNF # 10 -- 24 UNC 18 + 2 30 + 5 339 + 56 # 10 -- 32 UNF SAE Grade 5 Bolts, Screws, Studs & Sems with Regular Height Nuts (SAE J995 Grade 2 or Stronger N
Thread Size Class 8.8 Bolts, Screws and Studs with Regular Height Nuts (Class 8 or Stronger Nuts) Class 10.9 Bolts, Screws and Studs with Regular Height Nuts (Class 10 or Stronger Nuts) M5 X 0.8 57 + 6 in--lb 644 + 68 N--cm 78 + 8 in--lb 881 + 90 N--cm M6 X 1.0 96 + 10 in--lb 1085 + 113 N--cm 133 + 14 in--lb 1503 + 158 N--cm M8 X 1.25 19 + 2 ft--lb 26 + 3 N--m 28 + 3 ft--lb 38 + 4 N--m M10 X 1.5 38 + 4 ft--lb 52 + 5 N--m 54 + 6 ft--lb 73 + 8 N--m M12 X 1.
Other Torque Specifications SAE Grade 8 Steel Set Screws Wheel Bolts and Lug Nuts Recommended Torque Thread Size Thread Size Square Head Hex Socket 1/4 -- 20 UNC 140 + 20 in--lb 73 + 12 in--lb 5/16 -- 18 UNC 215 + 35 in--lb 145 + 20 in--lb 3/8 -- 16 UNC 35 + 10 ft--lb 18 + 3 ft--lb 1/2 -- 13 UNC 75 + 15 ft--lb 50 + 10 ft--lb Recommended Torque** 7/16 -- 20 UNF Grade 5 65 + 10 ft--lb 88 + 14 N--m 1/2 -- 20 UNF Grade 5 80 + 10 ft--lb 108 + 14 N--m M12 X 1.25 Class 8.
Chapter 3 Yanmar Diesel Engine Table of Contents Groundsmaster 4500−D/4700−D Page 3 − 1 Yanmar Diesel Engine SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Models 30873 and 30874 . . . . . . . . . . . . . . . . . . . . 2 Models 30881 and 30882 . . . . . . . . . . . . . . . . . . . . 3 GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . 4 Operator’s Manuals . . . . . . . . . . . . . . . . . . . . . . . . . 4 Yanmar Service and Troubleshooting Manuals . .
Specifications (Models 30873 and 30874) Item Description Make / Designation Yanmar Model 4TNV84T−ZMTR: 4−Cycle, 4 Cylinder, Water Cooled, Turbocharged, Tier 4i Diesel Engine Bore 3.307 in (84 mm) Stroke 3.543 in (90 mm) 121.7 in3 (1995 cc) Total Displacement 1 (closest to flywheel end) − 3 − 4 (farthest from flywheel) − 2 Firing Order Direction of Rotation Counterclockwise (viewed from flywheel) Fuel Diesel or Biodiesel (up to B20) Fuel with Low or Ultra Low Sulfur Content Fuel Capacity 22 U.
Specifications (Models 30881 and 30882) Item Description Make / Designation Yanmar Model 4TNV86CT−DTR: 4−Cycle, 4 Cylinder, Water Cooled, Turbocharged, Tier 4 Diesel Engine Bore 3.386 in (86 mm) Stroke 3.543 in (90 mm) 1 (closest to flywheel end) − 3 − 4 (farthest from flywheel) − 2 Firing Order Direction of Rotation Counterclockwise (viewed from flywheel) Fuel Diesel or Biodiesel (up to B7) Fuel with Ultra Low Sulfur Content Fuel Capacity 22 U.S.
General Information This Chapter gives information about specifications and repair of the diesel engine used in the Groundsmaster 4500−D and 4700−D. General maintenance procedures are described in your Traction Unit Operator’s Manual. Information on engine troubleshooting, testing, disassembly and assembly is identified in the Yanmar Workshop Manual. Most repairs and adjustments require tools which are commonly available in many service shops. Special tools are described in the Yanmar Workshop Manual.
Engine Electronic Control Unit (ECU) The Yanmar engine that powers your Groundsmaster uses an electronic control unit (ECU) for engine management and also to communicate with the machine TEC controllers and the operator Info Center display on the machine. All wire harness electrical connectors should be plugged into the ECU before the machine ignition switch is moved from the OFF position to either the ON or START position. 2 1 Yanmar Diesel Engine The engine electrical components (e.g.
Yanmar Engine: Models 30873 and 30874 The engine used on Groundsmaster models 30873 and 30874 is a Yanmar TNV Series, turbocharged, diesel engine that complies with EPA interim Tier 4 emission regulations. Engine features include an electronic control unit (ECU) controlled direct fuel injection and electronic governor. An air heater in the intake system is used to assist starting the engine.
Yanmar Engine: Models 30881 and 30882 Yanmar Diesel Engine The engine used on Groundsmaster models 30881 and 30882 is a Yanmar TNV Series, turbocharged, diesel engine that complies with EPA Tier 4 emission regulations.
Types of regeneration that are performed automatically (while the machine is operating) Type Conditions Description Passive Occurs during normal operation of the machine at high engine speed or high engine load. The DPF processes high heat exhaust gasses, oxidizing harmful emissions and incinerating soot to ash. The InfoCenter does not display an icon during passive regeneration.
Type Conditions Description Parked Occurs when exhaust back pressure in the DPF increases due to continued soot buildup. May be caused by prolonged operation at low engine speed, low engine load, or the use of incorrect fuel or engine oil. May occur if the InfoCenter is set to inhibit regen (preventing a Reset Regeneration) and machine operation is continued. Can be initiated when prompted by the engine ECU or after a minimum of 50 hours of engine operation.
Soot Accumulation If the types of regeneration that are performed automatically (while the machine is operating) are bypassed or not allowed to complete before shutting off the engine, soot will continue to accumulate in the soot filter. When enough soot accumulates, the engine ECU will generate an engine fault to prompt a parked or recovery regeneration. In addition to an engine fault appearing on the InfoCenter, the engine output power will be reduced.
Yanmar Diesel Engine This page is intentionally left blank.
Service and Repairs Air Cleaner System 12 to 15 in−lb (1.4 to 1.6 N−m) 20 11 10 7 6 12 3 5 4 19 13 15 9 8 14 RIGHT 1 FRONT 2 16 VACUATOR DIRECTION 16 18 17 MODELS 30881 and 30882 MODELS 30873 and 30874 Figure 5 1. 2. 3. 4. 5. 6. 7. Air cleaner assembly Air cleaner mount Indicator Adapter Air cleaner strap Socket head screw (2 used) Flat washer (2 used) Yanmar Diesel Engine 8. 9. 10. 11. 12. 13. 14.
Removal (Fig. 5) 1. Park machine on a level surface, lower cutting decks, stop engine, apply parking brake and remove key from the ignition switch. 2 4 2. Raise and support hood. 1 3. Remove air cleaner components as needed using Figure 5 as a guide. Installation (Fig. 5) 3 IMPORTANT: Any leaks in the air filter system will cause serious engine damage. Make sure that all air cleaner components are in good condition and are properly secured during assembly. Figure 6 1. Air cleaner housing 2.
Fuel System 8 1 4 8 5 3 8 7 7 16 2 8 13 20 19 21 8 23 18 24 3 6 25 8 17 8 10 22 RIGHT FRONT MODEL 30881/30882 SHOWN 11 9 14 12 15 Figure 8 1. 2. 3. 4. 5. 6. 7. 8. 9. Fuel suction tube Fuel gauge Fuel hose (supply) Return fitting Fuel hose (return) Fuel tank cap Bushing (2 used) Hose clamp (6 used) Fuel tank Yanmar Diesel Engine 10. 11. 12. 13. 14. 15. 16. 17.
Fuel Tank Installation (Fig. 8) Because diesel fuel is highly flammable, use caution when storing or handling it. Do not smoke while filling the fuel tank. Do not fill fuel tank while engine is running, hot or when machine is in an enclosed area. Always fill fuel tank outside and wipe up any spilled diesel fuel before starting the engine. Store fuel in a clean, safety−approved container and keep cap in place. Use diesel fuel for the engine only; not for any other purpose. 1.
Radiator and Oil Cooler Assembly 28 15 15 26 32 RIGHT 46 8 FRONT 25 24 15 29 20 11 41 42 1 47 7 44 26 15 13 29 32 28 22 14 16 21 32 6 30 16 9 10 51 19 5 37 38 14 43 32 25 24 33 11 2 42 18 7 27 10 6 17 36 34 3 18 15 17 50 31 4 42 35 23 45 15 31 36 39 48 42 40 12 49 15 Figure 10 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17.
Removal (Fig. 10) 1. Park machine on a level surface, lower cutting decks, stop engine, engage parking brake and remove key from the ignition switch. 4 1 4 2. Remove hood from the machine (see Hood Removal in the Service and Repairs section of Chapter 7 − Chassis). CAUTION 5 7 3 5 6 Ethylene−glycol antifreeze is poisonous. Dispose of coolant properly or store it in a properly labeled container away from children and pets. 7 2 3. Remove radiator cap.
13.Plug all radiator/oil cooler and hose openings to prevent contamination. 14.If necessary, remove draincock (item 7 in Fig. 12), plug (item 6 in Fig. 12) and hydraulic plug (item 8 in Fig. 12) from radiator/oil cooler. 15.If hydraulic fittings (item 3 in Fig. 12) are to be removed from oil cooler, mark fitting orientation to allow correct assembly. Remove fittings from cooler and discard O−rings. Installation (Fig. 10) 1. If hydraulic fittings (item 3 in Fig.
Yanmar Diesel Engine This page is intentionally blank.
Engine 16 MODEL 30881/30882 SHOWN 15 13 20 21 14 6 5 12 4 2 8 19 16 22 7 9 8 7 12 10 3 5 11 18 10 9 17 6 12 1 9 8 7 5 6 8 7 RIGHT 10 9 FRONT 9 10 9 Figure 13 1. 2. 3. 4. 5. 6. 7. 8. LH front engine mount bracket RH front engine mount bracket LH rear engine mount bracket RH rear engine mount bracket Lock washer (16 used) Cap screw (16 used) Engine mount (4 used) Flange head screw (8 used) Yanmar Diesel Engine 9. 10. 11. 12. 13. 14. 15.
Engine Removal (Fig. 13) MODELS 30881 & 30882 1. Park machine on a level surface, lower cutting decks, stop engine, engage parking brake and remove key from the ignition switch. 3. Remove battery cover. Disconnect negative battery cable from the battery first and then disconnect positive battery cable. 2 4 6 5 1 3 Yanmar Diesel Engine 2. Remove hood from the machine (see Hood Removal in the Service and Repairs section of Chapter 7 − Chassis).
10.Support hydraulic pump assembly to prevent it from shifting or falling. Remove fasteners that secure piston (traction) pump to engine (see Piston (Traction) Pump in the Service and Repairs section of Chapter 4 − Hydraulic System). 11. Make sure all cable ties securing the wire harness, fuel lines and hydraulic hoses to the engine are removed. 12.Connect lift or hoist to the lift brackets on engine. 13.
13.Check position of wires, fuel lines and hydraulic hoses for proper clearance with rotating, high temperature and moving components. 14.Connect positive battery cable to battery first and then negative battery cable. Secure battery cover to machine. 15.Check and adjust engine oil level as needed. 18.Start engine and operate hydraulic controls to properly fill hydraulic system (see Charge Hydraulic System in the Service and Repairs section of Chapter 4 − Hydraulic Systems). 19.
Pump Adapter Plate 7 RIGHT FRONT 29 to 33 ft−lb (40 to 44 N−m) 3 6 4 Boss 1 2 5 29 to 33 ft−lb (40 to 44 N−m) Figure 16 1. Flywheel plate 2. Hardened washer (8 used) 3. Spring coupler Yanmar Diesel Engine 4. Cap screw (8 used) 5. Cap screw with patchlock (8 used) Page 3 − 24 6. Hardened washer (8 used) 7.
Coupler Removal (Fig. 16) NOTE: The hydraulic pump assembly needs to be removed from engine before coupler can be removed. Engine Side Hydraulic Pump Side 1. If engine is in machine, remove hydraulic pump assembly (see Piston (Traction) Pump in the Service and Repairs section of Chapter 4 − Hydraulic System). 1 2. Remove flywheel plate and spring coupler from engine using Figure 16 as a guide. 1. Position spring coupler to engine flywheel and align mounting holes.
Exhaust System (Models 30881 and 30882) 7 40 41 19 to 29 ft−lb (25 to 40 N−m) 39 37 8 35 16 31 18 22 11 31 29 36 38 26 17 34 25 32 10 5 28 27 30 16 20 15 27 25 12 34 33 18 4 9 16 23 18 1 18 3 14 18 23 15 44 21 23 16 13 RIGHT 42 FRONT 19 6 24 2 43 Figure 18 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15.
The diesel particulate filter (DPF) is cleaned periodically through a regenerative process that is controlled by the engine ECU (see Yanmar Engine: Models 30881 and 30882 in the General Information section of this chapter). The InfoCenter display will identify the status of DPF regeneration. At recommended intervals, DPF reconditioning is necessary which will require exhaust system disassembly, DPF removal and DPF reconditioning by a company that has the necessary equipment.
This page is intentionally blank.
Chapter 4 Hydraulic System SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . 3 Operator’s Manual . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Check Hydraulic Fluid . . . . . . . . . . . . . . . . . . . . . . . 3 Towing Traction Unit . . . . . . . . . . . . . . . . . . . . . . . . . 4 Relieving Hydraulic System Pressure . . . . . . . . . . 5 Traction Circuit Component Failure . . . . . . . . . . . .
Specifications Item Description Piston (Traction) Pump Maximum Displacement (per revolution) System Relief Pressure: Forward System Relief Pressure: Reverse Charge Pressure Sauer--Danfoss Variable Displacement Axial Piston Pump 2.75 in3 (45 cc) 4350 PSI (300 bar) 5000 PSI (345 bar) 250 PSI (17 bar) Front Wheel Motors Displacement (per revolution) Sauer--Danfoss 2--Position Axial Piston Motors 1.83 in3 (30 cc) Maximum / 0.89 in3 (14.
General Information Operator’s Manual The Operator’s Manual provides information regarding the operation, general maintenance and maintenance intervals for your Groundsmaster machine. Refer to that publication for additional information when servicing the machine. Check Hydraulic Fluid 1 2 Figure 1 1. Hydraulic reservoir Groundsmaster 4500--D/4700--D Page 4 -- 3 2.
Towing Traction Unit IMPORTANT: If towing limits are exceeded, severe damage to the piston pump may occur. 1 If it becomes necessary to tow (or push) the machine, tow (or push) in a forward direction only, at a speed below 3 mph (4.8 kph) and for a distance less than 1/4 mile (0.4 km). The piston (traction) pump is equipped with two (2) bypass valves that need to be turned three (3) turns counterclockwise before towing or pushing the machine. The bypass valves are on the top of the piston pump (Fig. 2).
Relieving Hydraulic System Pressure Before disconnecting or performing any work on the hydraulic system, all pressure in the hydraulic system must be relieved. Park machine on a level surface, make sure that PTO switch is OFF, lower cutting decks fully, stop engine and engage parking brake. Wait for all moving parts to come to a complete stop. System pressure in lift circuit is relieved when the cutting decks are fully lowered. System pressure in mow circuit is relieved when the PTO switch is disengaged.
Hydraulic Hoses Hydraulic hoses are subject to extreme conditions such as pressure differentials during operation and exposure to weather, sun, chemicals, very warm storage conditions or mishandling during operation and maintenance. These conditions can cause hose damage and deterioration. Some hoses are more susceptible to these conditions than others.
Hydraulic Hose and Tube Installation (O--Ring Face Seal Fitting) 1. Make sure threads and sealing surfaces of the hose/ tube and the fitting are free of burrs, nicks, scratches or any foreign material. C. Use a second wrench to tighten the nut to the correct Flats From Wrench Resistance (F.F.W.R.). The markings on the nut and fitting body will verify that the connection has been properly tightened. 2.
Hydraulic Fitting Installation (SAE Straight Thread O--Ring Fitting into Component Port) Non--Adjustable Fitting (Fig. 6) 1. Make sure all threads and sealing surfaces of fitting and component port are free of burrs, nicks, scratches or any foreign material. 5. If a torque wrench is not available, or if space at the port prevents use of a torque wrench, an alternate method of assembly is the Flats From Finger Tight (F.F.F.T.) method. 2.
Adjustable Fitting (Fig. 8) 1. Make sure all threads and sealing surfaces of fitting and component port are free of burrs, nicks, scratches or any foreign material. 2. As a preventative measure against leakage, it is recommended that the O--ring be replaced any time the connection is opened. Lock Nut 3. Lightly lubricate the O--ring with clean hydraulic oil. Fitting threads should be clean with no lubricant applied. Back--up Washer 4. Turn back the lock nut as far as possible.
Hydraulic System Page 4 -- 10 FRONT CENTER FRONT RIGHT 1.16 CID M1 REAR M2 LEFT 1.16 CID REAR RIGHT 1.16 CID G4 1.16 M4 CID FRONT LEFT 1.16 CID G2 RV8 LC2 LC1 1500 PSI RV09 1500 PSI 3500 PSI T1 T2 P1 G1 DECK CONTROL MANIFOLD 3500 PRV1 PSI PRV2 P2 G3 50 PSI 6.2 GPM P1 PRV CV M2 11.4 GPM S1 M1 11.4 GPM G1 G2 NOTE: A larger hydraulic schematic is included in Chapter 9 -- Foldout Drawings #2 #3 #5 #4 #1 M3 T L L T 0.56 0.56 1.03 1.
Groundsmaster 4500--D/4700--D Page 4 -- 11 Hydraulic System #7 #2 #3 #5 #6 #4 #1 G5 M6 RIGHT WING G2 M5 REARM2 LEFT REAR RIGHT M1 FRONT RIGHT M8 G6 LEFT WING M7 G4 FRONTM4 LEFT FRONT CENTER 1500 PSI LC1 RV8 PRV2 LC3 3500 PSI 3500 PSI PRV1 SV1 DECK CONTROL MANIFOLD RV10 1500 PSI LC4 RV11 1500 PSI LC2 SV2 RV09 1500 PSI T1 T2 P1 G1 P2 50 PSI S1 P1 PRV CV M2 11.4 GPM 11.
Hydraulic System Page 4 -- 12 #2 #3 #5 #4 #1 FRONT CENTER FRONT RIGHT 1.16 CID M1 REAR M2 LEFT 1.16 CID REAR RIGHT 1.16 CID G4 1.16 M4 CID FRONT LEFT 1.16 CID M3 G2 RV8 LC2 LC1 1500 PSI RV09 1500 PSI 3500 PSI T1 T2 P1 G1 DECK CONTROL MANIFOLD 3500 PRV1 PSI PRV2 P2 G3 50 PSI 11.4 GPM G1 G2 6.2 GPM P1 PRV CV M2 11.4 GPM S1 M1 T 50/50 FLOW DIVIDER FD ST 3.1 GPM P 1050 PSI 6.1 CIR L L T 0.56 0.56 1.03 1.03 CID CID CID CID E STEERING CYLINDER 6.
Traction Circuit: LOW Speed (Mow) Front wheel and rear axle motors are positive displacement, two speed variable motors. The dual displacement wheel and axle motors allow operation in either LOW (mow) or HI (transport) speed. The motors are spring biased to maximum displacement for LOW speed and are hydraulically shifted to minimum displacement for HI speed. The rear axle motor includes a flushing valve that bleeds off a small amount of hydraulic oil for cooling of the closed loop traction circuit.
Hydraulic System Page 4 -- 14 Groundsmaster 4500--D/4700--D #2 #3 #5 #4 #1 FRONT RIGHT 1.16 CID REAR M2 LEFT M1 G4 FRONT M4 LEFT FRONT CENTER 1.16 CID REAR RIGHT 1.16 CID 1.16 CID 1.16 CID M3 G2 RV8 LC2 LC1 1500 PSI RV09 1500 PSI 3500 PSI T1 T2 P1 G1 DECK CONTROL MANIFOLD 3500 PRV1 PSI PRV2 P2 G3 50 PSI 11.4 GPM G1 G2 6.2 GPM P1 PRV CV M2 11.4 GPM S1 M1 T L L T 0.56 0.56 1.03 1.03 CID CID CID CID E STEERING CYLINDER 6.
Traction Circuit: HI Speed (Transport) Front wheel and rear axle motors are positive displacement, two speed variable motors. The dual displacement wheel and axle motors allow operation in either LOW (mow) or HI (transport) speed. The motors are spring biased to maximum displacement for LOW speed and are hydraulically shifted to minimum displacement for HI speed. The rear axle motor includes a flushing valve that bleeds off a small amount of hydraulic oil for cooling of the closed loop traction circuit.
Hydraulic System Page 4 -- 16 Groundsmaster 4500--D/4700--D #2 #3 #5 #4 #1 FRONT RIGHT 1.16 CID REAR M2 LEFT M1 G4 FRONT M4 LEFT FRONT CENTER 1.16 CID REAR RIGHT 1.16 CID 1.16 CID 1.16 CID M3 G2 RV8 LC2 LC1 1500 PSI RV09 1500 PSI 3500 PSI T1 T2 P1 G1 DECK CONTROL MANIFOLD 3500 PRV1 PSI PRV2 P2 G3 50 PSI 11.4 GPM G1 G2 6.2 GPM P1 PRV CV M2 11.4 GPM S1 M1 T 0.56 CID L L T 0.56 CID 1.03 1.03 CID CID E STEERING CYLINDER 6.
Lower Cutting Decks: Groundsmaster 4500--D On the Groundsmaster 4500--D, a single lift switch on the console arm is used to raise and lower the five (5) cutting decks (Fig. 10). When the cutting decks are in a stationary position (not raising or lowering), lift circuit flow from the third gear pump section bypasses the lift cylinders through the lift control manifold solenoid valve S5 (de--energized) and proportional relief valve TS.
Hydraulic System Page 4 -- 18 Groundsmaster 4500--D/4700--D #7 #2 #3 #5 #6 #4 #1 1.16 CID 1.16 CID 1.16 CID 1.16 CID 1.16 CID 1.16 CID 1.16 CID G5 M6 RIGHT WING G2 M5 REARM2 LEFT REAR RIGHT M1 FRONT RIGHT M8 G6 LEFT WING M7 G4 FRONTM4 LEFT FRONT CENTER M3 1500 PSI LC1 RV8 PRV2 LC3 3500 PSI 3500 PSI PRV1 SV1 DECK CONTROL MANIFOLD RV10 1500 PSI LC4 RV11 1500 PSI LC2 SV2 RV09 1500 PSI T1 T2 P1 G1 P2 G3 50 PSI P1 PRV CV M2 11.4 GPM 11.
Lower Cutting Decks: Groundsmaster 4700--D The Groundsmaster 4700--D has three (3) lift switches to control the cutting decks (Fig. 12). The center switch is for the five (5) center decks, the left switch controls the left, rear deck (#6) and the right switch controls the right, rear deck (#7) (Fig. 13).
Hydraulic System Page 4 -- 20 Groundsmaster 4500--D/4700--D #2 #3 #5 #4 #1 FRONT RIGHT 1.16 CID REAR M2 LEFT M1 G4 FRONT M4 LEFT FRONT CENTER 1.16 CID REAR RIGHT 1.16 CID 1.16 CID 1.16 CID M3 G2 RV8 LC2 LC1 1500 PSI RV09 1500 PSI 3500 PSI T1 T2 P1 G1 DECK CONTROL MANIFOLD 3500 PRV1 PSI PRV2 P2 G3 50 PSI 11.4 GPM G1 G2 6.2 GPM P1 PRV CV M2 11.4 GPM S1 M1 T 0.56 CID L L T 0.56 CID 1.03 1.03 CID CID E STEERING CYLINDER 6.
Raise Cutting Decks: Groundsmaster 4500- D On the Groundsmaster 4500- D, a single lift switch on the console arm is used to raise and lower the five (5) cutting decks (Fig. 14). 2 1 Figure 14 1. Console arm When the cutting decks are in a stationary position (not raising or lowering), lift circuit flow from the third gear pump section bypasses the lift cylinders through the lift control manifold solenoid valve S5 and proportional relief valve TS which are de- energized.
Hydraulic System Page 4 -- 22 Groundsmaster 4500--D/4700--D #7 #2 #3 #5 #6 #4 #1 1.16 CID 1.16 CID 1.16 CID 1.16 CID 1.16 CID 1.16 CID 1.16 CID G5 M6 RIGHT WING G2 M5 REARM2 LEFT REAR RIGHT M1 FRONT RIGHT M8 G6 LEFT WING M7 G4 FRONTM4 LEFT FRONT CENTER M3 1500 PSI LC1 RV8 PRV2 LC3 3500 PSI 3500 PSI PRV1 SV1 DECK CONTROL MANIFOLD RV10 1500 PSI LC4 RV11 1500 PSI LC2 SV2 RV09 1500 PSI T1 T2 P1 G1 P2 G3 50 PSI S1 P1 PRV CV M2 11.4 GPM 11.
Raise Cutting Decks: Groundsmaster 4700- D A four section gear pump is coupled to the piston (traction) pump. The third gear pump section supplies hydraulic flow to both the lift control manifold and the steering control valve. Hydraulic flow from this pump section is delivered to the circuits through a proportional flow divider located in the fan control manifold. Maximum lift/lower circuit pressure is limited to 1600 PSI (110 bar) by a relief valve (R1) in the lift control manifold.
Hydraulic System Page 4 -- 24 Groundsmaster 4500--D/4700--D #2 #3 #5 #4 #1 FRONT CENTER 1.16 CID 1.16 CID 1.16 CID M1 REAR LEFT M2 REAR RIGHT FRONT RIGHT G4 1.16 CID FRONT M4 LEFT 1.16 CID M3 G2 RV8 LC2 LC1 1500 PSI RV09 1500 PSI 3500 PSI T1 T2 P1 G1 DECK CONTROL MANIFOLD 3500 PRV1 PSI PRV2 P2 G3 50 PSI 11.4 GPM G1 G2 6.2 GPM P1 PRV CV M2 11.4 GPM S1 M1 T 0.56 CID L 0.56 CID 1.03 CID L T 1.03 CID E STEERING CYLINDER 6.
Mow Circuit Hydraulic flow for the mow circuit is supplied by the first two (2) sections of the gear pump. The first gear pump section P1 supplies hydraulic flow to decks 5, 3 and 2 (also deck 7 on the GM 4700--D), while the second gear pump section supplies decks 1 and 4 (also deck 6 on the GM 4700--D).
Cutting Deck Blade Braking When the operator turns the PTO switch OFF (or if the decks are raised), deck manifold solenoid valves (PRV1, PRV2, SV1 and SV2) are de--energized. The valves will shift to direct oil away from the deck motors and toward the oil cooler and filter. Hydraulic pressure is reduced to the cutting deck motors which slows the cutting blades and also allows the deck manifold relief valve (RV) to shift.
Hydraulic System This page is intentionally blank.
Hydraulic System Page 4 -- 28 Groundsmaster 4500--D/4700--D #2 #3 #5 #4 #1 FRONT RIGHT 1.16 CID REAR M2 LEFT M1 G4 FRONT M4 LEFT FRONT CENTER 1.16 CID REAR RIGHT 1.16 CID 1.16 CID 1.16 CID M3 G2 RV8 LC2 LC1 1500 PSI RV09 1500 PSI 3500 PSI T1 T2 P1 G1 DECK CONTROL MANIFOLD 3500 PRV1 PSI PRV2 P2 G3 50 PSI 11.4 GPM G1 G2 6.2 GPM P1 PRV CV M2 11.4 GPM S1 M1 T 0.56 CID L L T 0.56 CID 1.03 1.03 CID CID E STEERING CYLINDER 6.
Steering Circuit A four section gear pump is coupled to the piston (traction) pump. The third gear pump section supplies hydraulic flow to the steering control valve and the lift/lower control valve. Pump hydraulic flow is delivered to the two circuits through a proportional flow divider located in the fan control manifold. Steering circuit pressure is limited to 1050 PSI (72 bar) by a relief valve located in the steering control valve. ing cylinder for a right turn.
Hydraulic System Page 4 -- 30 Groundsmaster 4500--D/4700--D #2 #3 #5 #4 #1 FRONT RIGHT 1.16 CID REAR M2 LEFT M1 G4 FRONT M4 LEFT FRONT CENTER 1.16 CID REAR RIGHT 1.16 CID 1.16 CID 1.16 CID M3 G2 RV8 LC2 LC1 1500 PSI RV09 1500 PSI 3500 PSI T1 T2 P1 G1 DECK CONTROL MANIFOLD 3500 PRV1 PSI PRV2 P2 G3 50 PSI 11.4 GPM G1 G2 6.2 GPM P1 PRV CV M2 11.4 GPM S1 M1 T 0.56 CID L L T 0.56 CID 1.03 CID 1.03 CID E STEERING CYLINDER 6.
Engine Cooling Fan Circuit The fan control manifold controls the operation of the hydraulic motor that drives the engine cooling fan in addition to including the flow divider for the steering and lift circuits. The electronically controlled proportional relief valve (PRV) in the manifold controls the oil flow to the fan motor. The fan control manifold controls the speed and direction of the fan motor based on electrical output from the TEC--5002 controller.
Special Tools Order these special tools from your Toro Distributor. Hydraulic Pressure Test Kit Use to take various pressure readings for diagnostic tests. Quick disconnect fittings provided attach directly to mating fittings on machine test ports without tools. A high pressure hose is provided for remote readings. Contains one each: 1000 PSI (70 Bar), 5000 PSI (350 Bar) and 10000 PSI (700 Bar) gauges. Use gauges as recommended in Testing section of this chapter.
40 GPM Hydraulic Tester (Pressure and Flow) Use to test hydraulic circuits and components for flow and pressure capacities as recommended in the Testing section of this chapter. This tester includes the following: 1. LOAD VALVE: A simulated working load is created in the circuit by turning the valve to restrict flow. 2. PRESSURE GAUGE: Glycerine filled 0 to 5000 PSI gauge to provide operating circuit pressure. 3.
High Flow Hydraulic Filter Kit The high flow hydraulic filter kit is designed with large flow (40 GPM/150 LPM) and high pressure (5000 PSI/345 bar) capabilities. This kit provides for bi--directional filtration which prevents filtered debris from being allowed back into the circuit regardless of flow direction. If a component failure occurs in the closed loop traction circuit, contamination from the failed part will remain in the circuit until removed.
Hydraulic Test Fitting Kit This kit includes a variety of O--ring Face Seal fittings to enable you to connect test gauges into the system. The kit includes: tee’s, unions, reducers, plugs, caps and male test fittings. Toro Part Number: TOR4079 Figure 32 Measuring Container Hydraulic System Use this container for doing hydraulic motor efficiency testing (motors with case drain lines only).
Remote Starter Switch After flushing the hydraulic system or replacing a hydraulic component (e.g. gear pump, piston pump, wheel motor), it is necessary to prime the hydraulic pumps. A remote starter switch (Fig. 35) can be used for this purpose. Obtain a remote starter switch locally. IMPORTANT: When using a remote starter switch, it is highly recommended to include a 20 amp inline fuse between the battery and switch connector for circuit protection.
Troubleshooting The charts that follow contain information to assist in hydraulic system troubleshooting. There may possibly be more than one cause for a machine malfunction. Refer to the Testing section of this Chapter for precautions and specific testing procedures. General Hydraulic System Problems Problem Possible Cause Hydraulic system operates hot. Engine RPM is too low.
Traction Circuit Problems NOTE: When troubleshooting traction circuit problems, if a problem exists in both low (mow) and high (transport) speeds, consider a faulty component that affects the entire traction circuit (e.g. charge circuit, traction circuit relief valves, piston pump). If the problem exists in LOW speed (mow) but not in HI speed (transport), consider a problem that only exists in mow (e.g.
Mow Circuit Problems Problem Possible Cause None of the cutting decks will operate. Cutting decks are not fully lowered to ground. NOTE: To engage the mow circuit, the seat must be occupied, the cutting deck(s) must be fully lowered, the traction speed must be in the LOW (mow) position and the PTO switch must be ON. PTO switch is not in engaged position. Operator seat is unoccupied. Traction system is in HI speed (transport).
Mow Circuit Problems (Continued) Problem Possible Cause All cutting decks operate slowly. Engine RPM is low. Deck motor is damaged. First and second gear pump sections are worn or damaged. Cutting deck stops under load. Relief valve in deck control manifold is bypassing. Traction speed and cutting conditions (e.g. very tall or wet grass) exceed deck capacity. Deck motor relief valve is stuck or damaged. Deck motor has internal leakage (bypassing oil).
Lift/Lower Circuit Problems Problem Possible Cause Cutting decks will not raise. Operator seat is unoccupied. NOTE: Operator must be in seat in order to raise the cutting decks. Hydraulic oil level in reservoir is low. Electrical problem exists that prevents lift control manifold solenoid valve operation (see Chapter 5 -- Electrical System). Lift cylinder(s) is (are) damaged. Lift arm pivots are binding. Lift/lower circuit relief valve in lift control manifold is stuck open.
Engine Cooling Fan Circuit Problems Problem Possible Cause Cooling fan runs only in forward direction (fan does not run in reverse direction). Fan control manifold solenoid cartridge valve (S1) is faulty. Cooling fan does not rotate. Fan motor is worn or damaged. Electrical problem exists that prevents fan control manifold solenoid valve (S1) operation (see Chapter 5 -- Electrical System). Last gear pump section is worn or damaged. Cooling fan always rotates at slow speed.
Hydraulic System This page is intentionally blank.
Testing The most effective method for isolating problems in the hydraulic system is by using hydraulic test equipment such as pressure gauges and flow meters in the circuits during various operational checks (See the Special Tools section in this chapter). IMPORTANT: All obvious areas such as hydraulic oil supply, oil filters, binding components, loose fasteners or improper adjustments must be checked before assuming that a hydraulic component is the source of the problem. 1.
Which Hydraulic Tests Are Necessary? Before beginning any hydraulic test, identify if the problem is related to the traction circuit, cutting (mow) circuit, lift/lower circuit, steering circuit or engine cooling fan circuit. Once the faulty system has been identified, perform tests that relate to that circuit. 1.
Hydraulic System Page 4 -- 46 #2 #3 #5 #4 #1 1.16 CID M1 REAR M2 LEFT 1.16 CID REAR RIGHT 1.16 CID FRONT RIGHT G4 1.16 M4 CID FRONT LEFT 1.16 FRONT CID CENTER M3 G2 RV8 LC1 1500 PSI LC2 RV09 1500 PSI 3500 PSI T1 T2 P1 G1 DECK CONTROL MANIFOLD 3500 PRV1 PSI PRV2 P2 G3 50 PSI 6.2 GPM P1 PRV CV M2 11.4 GPM S1 11.4 GPM G1 G2 M1 T L T 50/50 FLOW DIVIDER FD L ST 3.1 GPM P 1050 PSI 6.1 CIR R E 0.56 0.56 1.03 1.03 CID CID CID CID 6.
Procedure for Traction Circuit Charge Pressure Test CAUTION Prevent personal injury and/or damage to equipment. Read all WARNINGS, CAUTIONS and Precautions for Hydraulic Testing at the beginning of this section. 1. Make sure hydraulic oil is at normal operating temperature by operating the machine for approximately ten (10) minutes. Make sure the hydraulic reservoir is full. 2. Park machine on a level surface with the cutting decks lowered and off.
Hydraulic System Page 4 -- 48 #2 #3 #5 #4 #1 1.16 CID M1 REAR M2 LEFT 1.16 CID REAR RIGHT 1.16 CID FRONT RIGHT G4 1.16 M4 CID FRONT LEFT 1.16 FRONT CID CENTER M3 G2 RV8 LC1 1500 PSI LC2 RV09 1500 PSI 3500 PSI 50 PSI 11.4 GPM 6.2 GPM P1 PRV CV 11.4 GPM S1 M2 T T E 0.56 0.56 1.03 1.03 CID CID CID CID 6.2 GPM FAN CONTROL P2 MANIFOLD 50/50 FLOW DIVIDER FD L ST L 2.75 CID 3.1 GPM G1 1600 PSI P RV S5 S6 50 PSI 250 PSI CV .
Procedure for Traction Circuit Relief Pressure Test CAUTION Prevent personal injury and/or damage to equipment. Read all WARNINGS, CAUTIONS and Precautions for Hydraulic Testing at the beginning of this section. 1. Make sure hydraulic oil is at normal operating temperature by operating the machine for approximately ten (10) minutes. Make sure the hydraulic reservoir is full. CAUTION 7. Release traction pedal and stop engine. Record test results. 8.
Hydraulic System Page 4 -- 50 #2 #3 #5 #4 #1 FRONT CENTER 1.16 CID M1 REAR M2 LEFT 1.16 CID REAR RIGHT 1.16 FRONT CID RIGHT G4 1.16 M4 CID FRONT LEFT 1.16 CID M3 G2 RV8 LC1 1500 PSI LC2 RV09 1500 PSI 3500 PSI T1 T2 P1 G1 DECK CONTROL MANIFOLD 3500 PRV1 PSI PRV2 P2 G3 50 PSI 6.2 GPM P1 PRV CV M2 11.4 GPM S1 11.4 GPM G1 G2 M1 T L T 50/50 FLOW DIVIDER FD L ST 3.1 GPM P 1050 PSI 6.1 CIR R E 0.56 0.56 1.03 1.03 CID CID CID CID 6.
Procedure for Reverse Traction Circuit Reducing Valve (PR) Pressure Test NOTE: When in reverse, pressure reducing valve (PR) limits the pressure to the rear axle motor to 450 PSI (31 bar) so the rear wheels will not scuff the turf. CAUTION Prevent personal injury and/or damage to equipment. Read all WARNINGS, CAUTIONS and Precautions for Hydraulic Testing at the beginning of this section. 1.
Hydraulic System Page 4 -- 52 #2 #3 #5 #4 #1 FRONT CENTER FRONT RIGHT 1.16 CID M1 REAR M2 LEFT 1.16 CID REAR RIGHT 1.16 CID G4 1.16 M4 CID FRONT LEFT 1.16 CID M3 G2 RV8 LC1 1500 PSI LC2 RV09 1500 PSI 3500 PSI T1 T2 P1 G1 DECK CONTROL MANIFOLD 3500 PRV1 PSI PRV2 P2 G3 50 PSI 6.2 GPM P1 PRV CV M2 11.4 GPM S1 11.4 GPM G1 G2 M1 T 50/50 FLOW DIVIDER FD ST 3.1 GPM P 1050 PSI 6.1 CIR R L L T E 0.56 0.56 1.03 1.03 CID CID CID CID 6.
NOTE: Adjustable relief valve (RV) in the rear traction control manifold reduces rear axle motor pressure created in down hill, dynamic braking conditions to prevent rear wheel lock up. CAUTION Prevent personal injury and/or damage to equipment. Read all WARNINGS, CAUTIONS and Precautions for Hydraulic Testing at the beginning of this section. 1. Make sure hydraulic oil is at normal operating temperature by operating the machine for approximately ten (10) minutes. Make sure the hydraulic reservoir is full.
Hydraulic System Page 4 -- 54 REAR DECK & COOLING FAN MOTOR CASE DRAIN FRONT DECK MOTOR CASE DRAIN 50 PSI 0.56 CID 0.56 CID TO FAN CONTROL MANIFOLD PORT P2 TO FAN CONTROL MANIFOLD PORT P1 1.03 CID 1.03 CID 2.
Procedure for Piston (Traction) Pump Flow Test This test measures piston (traction) pump output (flow). During this test, pump load is created at the flow meter using the adjustable load valve on the tester. NOTE: Before performing piston pump flow test, make sure that traction speed is set to 100% using the InfoCenter settings menu. IMPORTANT: Traction circuit flow for the Groundsmaster 4500/4700 is approximately 30 GPM (113.5 LPM).
Hydraulic System Page 4 -- 56 #2 1.16 CID 1.16 CID REAR LEFT REAR RIGHT FRONT RIGHT M2 M1 G4 FRONT M4 LEFT FRONT CENTER G2 RV8 RV09 LC1 1500 PSI LC2 1500 PSI 3500 PSI 3500 PSI T1 T2 P1 G1 DECK CONTROL MANIFOLD PRV1 PRV2 P2 50 PSI 11.4 GPM FROM FAN CONTROL MANIFOLD PORT T 11.4 GPM 6.2 GPM 0.56 CID 0.56 CID TO FAN CONTROL MANIFOLD PORT P2 TO FAN CONTROL MANIFOLD PORT P1 1.03 CID 1.03 CID 2.
Procedure for Cutting Deck Circuit Pressure Test GM 4500--D CAUTION 1 Prevent personal injury and/or damage to equipment. Read all WARNINGS, CAUTIONS and Precautions for Hydraulic Testing at the beginning of this section. 1. Make sure hydraulic oil is at normal operating temperature by operating the machine for approximately ten (10) minutes. Make sure the hydraulic reservoir is full. 2 FRONT 2. Park machine on a level surface with the cutting decks lowered and off.
Hydraulic System Page 4 -- 58 #2 1.16 CID 1.16 CID 1.16 CID 1.16 CID 1.16 CID REAR LEFT REAR RIGHT FRONT RIGHT FRONT LEFT FRONT CENTER M2 M1 G4 M4 G2 RV8 RV09 LC1 1500 PSI LC2 1500 PSI 3500 PSI 3500 PSI T1 T2 P1 G1 DECK CONTROL MANIFOLD PRV1 PRV2 P2 G3 50 PSI FROM FAN CONTROL MANIFOLD PORT T 11.4 GPM 11.4 GPM 6.2 GPM 0.56 CID 0.56 CID TO FAN CONTROL MANIFOLD PORT P2 TO FAN CONTROL MANIFOLD PORT P1 1.03 CID 1.03 CID 2.
Procedure for Cutting Deck Circuit Relief Pressure Test 9. As the circuit relief valve lifts, system pressure should be from 3400 to 3750 PSI (235 to 258 bar). 10.Open the tester flow control valve, disengage cutting decks and stop the engine. Record test results. Prevent personal injury and/or damage to equipment. Read all WARNINGS, CAUTIONS and Precautions for Hydraulic Testing at the beginning of this section. 1.
Hydraulic System STEEL CAP Page 4 -- 60 #2 #3 1.16 CID 1.16 CID FRONT CENTER REAR LEFT REAR RIGHT FRONT RIGHT FRONT LEFT M2 M1 G4 M4 G2 RV8 RV09 LC1 PSI 1500 LC2 1500 PSI PSI 3500 3500 PSI DECK CONTROL MANIFOLD PRV1 PRV2 T1 T2 P1 G1 P2 50 PSI FROM ENGINE COOLING MOTOR TO GEAR PUMP SUCTION FROM FAN CONTROL MANIFOLD PORT T CIRCUIT FLOW CIRCUIT FLOW TEST FOR GM4500--D DECK MOTOR #1 SHOWN CID 1.16 1.16 CID 1.
Procedure for Deck Motor Case Drain Leakage Test NOTE: Over a period of time, a deck motor can wear internally. A worn motor may bypass oil to its case drain causing the motor to be less efficient. Eventually, enough oil loss will cause the deck motor to stall under heavy cutting conditions. Continued operation with a worn, inefficient motor can generate excessive heat, cause damage to seals and other components in the hydraulic system and affect quality of cut.
Hydraulic System Page 4 -- 62 #2 1.16 CID M1 REAR M2 LEFT 1.16 CID REAR RIGHT 1.16 CID FRONT RIGHT G2 RV8 LC1 1500 PSI LC2 RV09 3500 PSI T1 T2 P1 G1 P2 DECK CONTROL MANIFOLD 3500 PRV1 PSI PRV2 50 PSI 11.4 GPM G1 G2 6.2 GPM P1 PRV CV M2 11.4 GPM S1 M1 T L T E 0.56 0.56 1.03 1.03 CID CID CID CID 6.2 GPM FAN CONTROL P2 MANIFOLD 50/50 FLOW DIVIDER FD ST 3.1 GPM P 1050 PSI L 2.75 CID 3.1 GPM G1 RV S5 S6 1600 PSI P 50 PSI 250 PSI CV .
The steering circuit relief pressure test should be performed to make sure that the steering circuit relief pressure is correct. CAUTION Prevent personal injury and/or damage to equipment. Read all WARNINGS, CAUTIONS and Precautions for Hydraulic Testing at the beginning of this section. 1. Make sure hydraulic oil is at normal operating temperature by operating the machine for approximately ten (10) minutes. Make sure the hydraulic reservoir is full. 9.
Steering Cylinder Internal Leakage CYLINDER FULLY EXTENDED STEERING CYLINDER LOOK FOR LEAKAGE STEEL CAP R STEERING WHEEL TURNED FOR RIGHT TURN L 6.
Procedure for Steering Cylinder Internal Leakage Test NOTE: Steering circuit operation will be affected by rear tire pressure, binding of steering cylinder, extra weight on the vehicle and/or binding of rear axle steering components. Make sure that these items are checked before proceeding with steering cylinder internal leakage test. CAUTION Prevent personal injury and/or damage to equipment. Read all WARNINGS, CAUTIONS and Precautions for Hydraulic Testing at the beginning of this section. 1.
Hydraulic System Page 4 -- 66 #2 #3 #5 FRONT CENTER 1.16 CID M1 REAR M2 LEFT 1.16 CID REAR RIGHT 1.16 FRONT CID RIGHT G4 1.16 M4 CID FRONT LEFT 1.16 CID G2 RV8 LC1 1500 PSI LC2 RV09 1500 PSI 3500 PSI T1 T2 P1 G1 P2 50 PSI 11.4 GPM G1 G2 6.2 GPM P1 PRV CV M2 11.4 GPM S1 M1 T P L T E 2.75 CID 3.1 GPM 0.56 0.56 1.03 1.03 CID CID CID CID 6.2 GPM FAN CONTROL P2 MANIFOLD 50/50 FLOW DIVIDER FD ST 3.1 GPM L RV S5 S6 50 PSI 1600 PSI G1 P 250 PSI CV .
The lift/lower circuit relief pressure test should be performed to make sure that the cutting unit lift and lower circuit relief pressure is correct. CAUTION Prevent personal injury and/or damage to equipment. Read all WARNINGS, CAUTIONS and Precautions for Hydraulic Testing at the beginning of this section. 1. Make sure hydraulic oil is at normal operating temperature by operating the machine for approximately ten (10) minutes. Make sure the hydraulic reservoir is full. 2.
Hydraulic System Page 4 -- 68 #2 #3 #5 #4 #1 FRONT CENTER 1.16 CID M1 REAR M2 LEFT 1.16 CID REAR RIGHT 1.16 FRONT CID RIGHT G4 1.16 M4 CID FRONT LEFT 1.16 CID M3 G2 RV8 LC1 1500 PSI LC2 RV09 1500 PSI 3500 PSI T1 T2 P1 G1 P2 50 PSI 11.4 GPM G1 G2 6.2 GPM P1 PRV CV M2 T 50/50 FLOW DIVIDER FD ST L L T E 2.75 CID 3.1 GPM 0.56 0.56 1.03 1.03 CID CID CID CID 6.2 GPM FAN CONTROL P2 MANIFOLD PRESSURE GAUGE 11.4 GPM S1 M1 3.1 GPM P 1050 PSI 6.
The engine cooling fan circuit test should be performed to make sure that the engine cooling fan circuit has the correct system pressure and fan speed. CAUTION 7. If pressure rises to approximately 3000 PSI (207 bar) but fan speed is low, consider that the hydraulic fan motor is worn or damaged. If pressure and fan speed are both low, consider that final gear pump section is worn or damaged (see Gear Pump Flow Test in this section). Prevent personal injury and/or damage to equipment.
FROM WHEEL MOTOR CASE DRAIN FROM REAR TRACTION VALVE 5000 PSI 4350 PSI The gear pump flow test should be performed to make sure that the mow, steering, lift/lower, cooling fan and traction charge circuits have adequate hydraulic flow. Gear pump sections are illustrated in Figure 57. The first gear pump section provides hydraulic flow for cutting decks 2, 3 and 5 (also deck 7 on the GM 4700--D).
12.After testing is completed, disconnect flow tester from hydraulic hose and fitting in gear pump section. Reconnect hose to the pump fitting. Procedure for Gear Pump Flow Test CAUTION 13.Lower and secure operator seat. Prevent personal injury and/or damage to equipment. Read all WARNINGS, CAUTIONS and Precautions for Hydraulic Testing at the beginning of this section. 4 1 2 3 1. Make sure hydraulic oil is at normal operating temperature by operating the machine for approximately ten (10) minutes.
Adjustments Adjust Control Manifold Relief Valves Several of the hydraulic control manifolds on your Groundsmaster include adjustable relief valves. The following procedure can be used to adjust these relief valves. Refer to the Testing section of this chapter for information on testing relief pressure. NOTE: Do not remove relief valve from the hydraulic manifold for adjustment. 1 1. Locate relief valve on control manifold. 2. Remove cap on relief valve with an allen wrench. 3.
Service and Repairs General Precautions for Removing and Installing Hydraulic System Components Before Repair or Replacement of Components After Repair or Replacement of Components 1. Before removing any parts from the hydraulic system, park machine on a level surface, engage parking brake, lower cutting decks and stop engine. Remove key from the ignition switch. 1. Check oil level in the hydraulic reservoir and add correct oil if necessary.
Check Hydraulic Lines and Hoses WARNING Keep body and hands away from pin hole leaks or nozzles that eject hydraulic fluid under high pressure. Use paper or cardboard, not hands, to search for leaks. Hydraulic fluid escaping under pressure can have sufficient force to penetrate the skin and cause serious injury. If fluid is injected into the skin, it must be surgically removed within a few hours by a doctor familiar with this type of injury. Gangrene may result from such an injury.
Flush Hydraulic System IMPORTANT: Flush the hydraulic system any time there is a severe component failure or the system is contaminated (oil appears milky, black or contains metal particles). IMPORTANT: Flush hydraulic system when changIng from petroleum base hydraulic fluid to a biodegradable fluid. Operate machine under normal operating conditions for at least four (4) hours before draining. 1. Park machine on a level surface. Lower cutting decks, stop engine and engage parking brake.
Filtering Closed- Loop Traction Circuit Filtering of a closed- loop hydraulic system after a major component failure (e.g. traction (piston) pump, front wheel motor or rear axle motor) is a requirement to prevent debris from transmitting throughout the system. If a closed- loop hydraulic system filtering tool is not used to ensure system cleanliness, repeat failures, as well as subsequent damage to other hydraulic components in the affected system, will occur.
Charge Hydraulic System IMPORTANT: Change hydraulic oil filter whenever hydraulic components are repaired or replaced. 8. After the hydraulic system starts to show signs of fill, actuate lift control switch until the lift cylinders move in and out several times. If the cylinders do not move after 15 seconds or the pump emits abnormal sounds, shut the engine off immediately and determine cause or problem. Inspect for the following: A. Loose hydraulic filter or suction lines. 1.
Gear Pump 9 7 2 RIGHT 13 FRONT 4 7 5 1 12 21 18 19 17 15 3 16 7 2 6 14 20 8 11 7 12 10 Figure 63 1. 2. 3. 4. 5. 6. 7. Piston pump assembly Flat washer (4 used) Gear pump assembly 90o hydraulic fitting (2 used) 90o hydraulic fitting (2 used) 90o hydraulic fitting O--ring Hydraulic System 8. 9. 10. 11. 12. 13. 14. Hydraulic tee fitting 90o hydraulic fitting 45o hydraulic fitting Straight fitting O--ring Cap screw (2 used) Cap screw (2 used) Page 4 -- 78 15. 16. 17. 18. 19. 20. 21.
Removal (Fig. 63) Remove plugs before installing gear pump to piston pump 1. Park machine on a level surface, lower cutting decks, stop engine, engage parking brake and remove key from the ignition switch. 1 2. Gain access to gear pump from below the machine. 3. Drain the hydraulic reservoir into a suitable container (see Hydraulic Reservoir in this section). 4.
5. Remove caps and plugs from hydraulic lines and fittings. Install hydraulic lines to gear pump (see Hydraulic Hose and Tube Installation in the General Information section of this chapter). 6. Replace hydraulic oil filter and fill hydraulic reservoir with new hydraulic oil. 7. Fill piston pump housing through case drain (90o barbed fitting) with new hydraulic oil (Fig. 65). This will ensure that internal pump components have adequate lubrication during initial operation. Hydraulic System 8.
Hydraulic System This page is intentionally blank.
Gear Pump Service 18 6 9 12 10 13 14 15 17 16 5 3 19 4 11 24 21 9 11 1 2 7 8 21 26 25 22 23 33 ft--lb (45 N--m) 22 20 Figure 66 1. 2. 3. 4. 5. 6. 7. 8. 9. Dust seal Retaining ring Flange washer Shaft seal Front cover Dowel pin (16 used) Pressure seal Back--up gasket Thrust plate (8 used) 10. 11. 12. 13. 14. 15. 16. 17. 18. Seal (8 used) Idler gear Drive shaft Back--up gasket Pressure seal Front body (first pump section) Splined connecting shaft (3 used) Flange Drive gear 19. 20.
3. Secure the front cover of the pump in a vise with the drive shaft pointing down. 4. Loosen the four (4) cap screws that secure pump assembly. 5. Remove pump from vise and remove fasteners. 6. Support the pump assembly and gently tap the pump case with a soft face hammer to loosen the pump sections. Be careful to not drop parts or disengage gear mesh. IMPORTANT: Mark the relative positions of the gear teeth and the thrust plates so they can be reassembled in the same position.
Piston (Traction) Pump 9 7 RIGHT 2 13 FRONT 4 7 5 1 12 21 18 19 17 15 3 16 7 2 6 14 20 1 8 11 FOR MACHINE SERIAL NUMBER ABOVE: 401110001 7 12 10 Figure 68 1. 2. 3. 4. 5. 6. 7. Piston pump assembly Flat washer (4 used) Gear pump assembly 90o hydraulic fitting (2 used) 90o hydraulic fitting (2 used) 90o hydraulic fitting O- ring 8. 9. 10. 11. 12. 13. 14.
5. For assembly purposes, label all hydraulic lines connected to gear pump and traction pump fittings. 6. Put a drain pan below the pump assembly. Remove hydraulic hoses connected to piston and gear pumps. Put plugs or caps on disconnected hydraulic hoses and fittings to prevent contamination of the system. 2 7. Remove gear pump from machine (see Gear Pump in this section). NOTE: A case drain exists in the piston (traction) pump and a suction port is near the input shaft of the gear pump (Fig. 70).
IMPORTANT: A case drain exists in the piston (traction) pump and a suction port is near the input shaft of the gear pump (Fig. 70). Before the gear pump is installed to the piston pump, make sure that plugs placed in both of these ports are removed. Failure to remove plugs will cause excessive pressure in the piston pump and damage seals. Also, before securing gear pump to piston pump, fill piston pump housing with clean hydraulic oil through case drain hole. 10.
Piston (Traction) Pump Service (For machine serial number below: 401110001) 43 41 51 42 52 45 53 42 46 44 45 46 47 48 42 55 42 41 39 49 37 50 34 33 35 3 2 8 30 44 36 7 15 13 40 38 1 14 25 3 34 7 29 2 31 6 33 32 29 25 10 10 54 10 24 28 4 23 11 16 5 18 17 27 26 20 12 21 22 19 9 10 Figure 72 Groundsmaster 4500- D/4700- D Page 4 - 87 Hydraulic System
Figure 72 (Continued) 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. Screen (2 used) Plug with O- ring (2 used) Plug with O- ring (2 used) Cylinder block assembly Valve plate Servo piston Screw (4 used) Orifice (2 used) Screw (4 used) Plug with O- ring (4 used) Screw (2 used) Plug Shaft Bearing assembly Retaining ring Gasket Adapter Adapter seal Coupling 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 31. 32. 33. 34. 35. 36. 37.
Piston (Traction) Pump Service (For machine serial number above: 401110001) Figure 73 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. Control kit (12 volt) Coil kit Charge relief kit Shaft Ball bearing Retaining ring Retaining ring Lip seal Valve plate O- ring O- ring 13. O- ring 14. Screw 15. Plug assembly 16. Seal nut 17. Screw 18. Control gasket 19. Locking ring 20. Screen 21. Screw 22. Screw 23. O- ring 24. Shim kit 25. 26. 27. 28. 29. 30. 31. 32. 33. 34. 35.
Rear Traction Control Manifold 19 5 20 21 18 3 4 RIGHT 17 22 16 14 9 6 11 15 13 12 7 FRONT 20 1 8 10 2 11 Figure 73 1. 2. 3. 4. 5. 6. 7. 8. Rear traction control manifold Cap screw (2 used) Flange nut (2 used) HI/LOW range control manifold Lift circuit junction manifold Hydraulic tube O--ring Hydraulic straight fitting Hydraulic System 9. 10. 11. 12. 13. 14. 15. O--ring Hydraulic tube O--ring Hydraulic straight fitting O--ring Hydraulic hose Hydraulic tube Page 4 -- 90 16. 17.
Removal (Fig. 73) Installation (Fig. 73) NOTE: The ports on the rear traction control manifold are marked for easy identification of components. Refer to the Hydraulic Schematics in Chapter 9 -- Foldout Drawings to identify the function of the hydraulic lines and cartridge valves at each port. 1. If fittings were removed from control manifold, lubricate and place new O--rings onto fittings. Install fittings into manifold ports using marks made during the removal process to properly orientate fittings.
Rear Traction Control Manifold Service 3 25 ft- lb (34 N- m) 2 50 ft- lb (67 N- m) 20 ft- lb (27 N- m) 4 1 7 115 ft- lb (156 N- m) 25 ft- lb (34 N- m) 5 6 Figure 74 1. Rear traction manifold body 2. Relief valve (port RV) 3. Pressure reducing valve (port PR) 4. #4 zero leak plug with O- ring 5. #6 zero leak plug with O- ring NOTE: The ports on the rear traction manifold are marked for easy identification of components.
Control Manifold Cartridge Valve Service 2. If cartridge valve is solenoid operated, remove nut securing solenoid coil to the cartridge valve. Carefully slide coil off the valve. IMPORTANT: Use care when handling the cartridge valve. Slight bending or distortion of the stem tube can cause binding and malfunction. When removing cartridge valve from manifold, make sure that deep well socket fully engages the valve base. 3. Remove cartridge valve from manifold using a deep socket wrench.
HI/LOW Range Control Manifold 3 5 4 8 1 7 6 RIGHT 9 13 FRONT 11 10 2 12 Figure 75 1. 2. 3. 4. 5. HI/LOW range control manifold Cap screw (2 used) Flange nut (2 used) Rear traction control manifold Lift circuit junction manifold 6. 7. 8. 9. Hydraulic tube O--ring Hydraulic tube O--ring 10. 11. 12. 13. Hydraulic tube O--ring O--ring Hydraulic tube NOTE: The ports on the HI/LOW range control manifold are marked for easy identification of components.
Removal (Fig. 75) 25 ft--lb (34 N--m) 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. To prevent contamination of hydraulic system during manifold removal, thoroughly clean exterior of HI/LOW range control manifold. 30 in--lb (3.4 N--m) 6 5 4 25 ft--lb (34 N--m) 3. Label all hydraulic lines for assembly purposes. 4.
Rear Axle Motor 5 8 1 7 2 6 4 7 13 17 14 3 16 10 12 11 9 15 RIGHT FRONT Figure 78 1. 2. 3. 4. 5. 6. Rear axle motor O--ring Pinion gear External snap ring (2 used) O--ring Hydraulic fitting Hydraulic System 7. 8. 9. 10. 11. 12. O--ring 90o hydraulic fitting Cap screw (2 used) Flat washer (2 used) O--ring 90o hydraulic fitting Page 4 -- 96 13. 14. 15. 16. 17.
Removal (Fig. 78) Installation (Fig. 78) 1. Park machine on a level surface, lower cutting decks, stop engine, engage parking brake and remove key from the ignition switch. 1. If fittings were removed from axle motor, lubricate and place new O--rings onto fittings. Install fittings into motor ports using marks made during the removal process to properly orientate fittings. Tighten fittings (see Hydraulic Fitting Installation in the General Information section of this chapter). 3.
Front Wheel Motors 17 1 2 6 3 16 8 7 15 14 9 4 6 13 11 5 RIGHT 10 12 FRONT Figure 79 1. 2. 3. 4. 5. 6. Flange head screw (6 per planetary) Splined brake shaft Planetary assembly Wheel assembly Lug nut (8 per wheel) Retaining ring 7. 8. 9. 10. 11. 12. Spring plate Compression spring Jam nut Brake assembly (LH shown) Flange head screw (4 per brake) Gasket Removal (Fig. 79) 1.
7. Remove and discard O--ring (item 16) from flange of wheel motor. LEFT WHEEL 8. If hydraulic fittings are to be removed from wheel motor, mark fitting orientation to allow correct assembly (Figs. 80 and 81). Remove fittings from motor and discard O--rings. Installation (Fig. 79) 1. If fittings were removed from wheel motor, lubricate and place new O--rings onto fittings. Install fittings into motor ports using marks made during the removal process to properly orientate fittings (Figs. 80 and 81).
Rear Axle and Front Wheel Motor Service 1 2 3 4 24 5 6 8 25 9 10 7 12 13 11 14 16 24 15 25 17 16 20 21 22 23 21 18 19 Figure 82 1. 2. 3. 4. 5. 6. 7. 8. 9. Plug with O--ring Minimum angle stop Bias spring Servo piston O--ring O--ring Socket head screw (5 used) Endcap Dowel Hydraulic System 10. 11. 12. 13. 14. 15. 16. 17. Dowel pin Bearing Gasket Valve plate Cylinder block kit Swashplate Swashplate bearing assembly Output shaft Page 4 -- 100 18. 19. 20. 21. 22. 23. 24. 25.
NOTE: The front wheel motors are identical (shown in Figure 82). The rear axle motor includes a flushing valve for cooling of the closed loop traction circuit and therefore has some differences from the front motors (Fig. 83). Service of the wheel and axle motors uses the same procedure. REAR AXLE MOTOR FLUSHING VALVE 3 10 NOTE: For service of the wheel motors, see the Sauer-Danfoss K and L Frame Variable Motors Service Manual at the end of this chapter. 1 5 4 4 2 3 9 8 2 7 6 Figure 83 1. 2. 3.
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 decks, stop engine, engage parking brake and remove key from the ignition switch. 1 2. Read the General Precautions for Removing and Installing Hydraulic System Components at the beginning of the Service and Repairs section of this chapter. 3. To prevent contamination of hydraulic system during deck motor removal, thoroughly clean exterior of motor. 4.
Hydraulic System This page is intentionally blank.
Cutting Deck Motor Service 33 ft--lb (45 N--m) 26 ft--lb (35 N--m) 19 18 16 13 9 8 5 6 3 1 17 10 11 2 4 12 14 7 12 15 6 26 ft--lb (35 N--m) 7 10 Figure 86 1. 2. 3. 4. 5. 6. 7. Dust seal (2 used) Retaining ring Flange washer Shaft seal Front flange Pressure seal Backup gasket 8. 9. 10. 11. 12. 13. Front wear plate Drive gear Dowel pin (4 used) Idler gear O--ring Body 14. 15. 16. 17. 18. 19.
6. Separate rear cover from body. Lift rear cover from motor. 7. Carefully remove body. Lift body straight up to remove. Make sure the rear wear plate remains on the drive and idler gear shafts. Remove and discard O-rings from the body. Locate and retrieve dowel pins. IMPORTANT: Note position of the open and closed side of the wear plates before removing. Also, identify wear plates (front and rear) with a marker for proper assembly.
Assembly (Fig. 86) NOTE: When assembling the motor, check the marker line on each part to make sure the parts are properly aligned during assembly. 1. Lubricate O--rings, pressure seals, back--up gaskets and wear plate grooves with a thin coat of petroleum jelly. Lubricate all other internal parts freely with clean hydraulic oil. 2. Install new seals into front flange (Fig. 88): A. Press shaft seal into front flange until it reaches the bottom of the bore. B.
Hydraulic System This page is intentionally blank.
Deck Control Manifold 1 7 2 8 4 9 5 3 6 GROUNDSMASTER 4500--D SHOWN RIGHT FRONT Figure 90 1. Deck control manifold 2. Filter mount bracket 3. Flange head screw (2 used) 4. Hydraulic oil filter assembly 5. Valve mount bracket 6. Flange head screw (2 used) 7. Lift control manifold 8. Flange head screw (2 used) 9. Fan drive manifold NOTE: The deck control manifolds used on Groundsmaster 4500--D and 4700--D are different but they mount to the machine in the same location.
Removal (Fig. 90) 7 6 1 5 4 2 3 1. Park machine on a level surface, lower cutting decks, stop engine, apply parking brake and remove key from the ignition switch. 11 14 2. Read the General Precautions for Removing and Installing Hydraulic System Components at the beginning of the Service and Repairs section of this chapter. 5. Label wire harness electrical connectors that attach to manifold solenoid coils. Disconnect connectors from the solenoid coils. 6.
Deck Control Manifold Service (GM 4500--D) 5 ft--lb (6.8 N--m) 7 3 20 ft--lb (27 N--m) 3 4 25 ft--lb (34 N--m) 25 ft--lb (34 N--m) 2 2 5 20 ft--lb (27 N--m) 4 6 25 ft--lb (34 N--m) 25 ft--lb (34 N--m) 5 8 6 UP 1 50 ft--lb (68 N--m) 8 25 ft--lb (34 N--m) 9 Figure 93 1. Manifold body 2. Proportional relief (PRV1 & PRV2) 3. Solenoid coil 4. Relief valve (RV8 & RV9) 5. Logic valve (LC1 & LC2) 6. Pilot piston 7. Nut 8. Zero leak plug (#6) 9.
For solenoid and control valve service procedures, see Control Manifold Cartridge Valve Service in this section. Refer to Figures 93 and 94 for cartridge valve and plug installation torque. IMPORTANT: A pilot piston (item 6) is placed beneath each of the relief valves in deck control manifold ports RV8 and RV9. If a relief valve is removed from the manifold, make sure to remove pilot piston and label its position for assembly purposes.
Deck Control Manifold Service (GM 4700--D) 5 ft--lb (6.8 N--m) 25 ft--lb (34 N--m) 25 ft--lb (34 N--m) 2 20 ft--lb (27 N--m) 25 ft--lb (34 N--m) 10 6 8 7 5 ft--lb (6.8 N--m) 10 6 20 ft--lb (27 N--m) 2 7 7 9 10 20 ft--lb (27 N--m) 9 11 25 ft--lb (34 N--m) 25 ft--lb (34 N--m) 8 7 20 ft--lb (27 N--m) 3 25 ft--lb (34 N--m) 3 11 3 50 ft--lb (68 N--m) 25 ft--lb (34 N--m) 25 ft--lb (34 N--m) 3 4 1 3 UP 5 20 ft--lb (27 N--m) Figure 95 1. 2. 3. 4.
For solenoid and control valve service procedures, see Control Manifold Cartridge Valve Service in this section. Refer to Figures 95 and 96 for cartridge valve and plug installation torque. 2 20 ft--lb (27 N--m) 20 ft--lb (27 N--m) 1 IMPORTANT: A pilot piston (item 6) is placed beneath each of the relief valves in deck control manifold ports RV8, RV9, RV10 and RV11. If a relief valve is removed from the manifold, make sure to remove pilot piston and label its position for assembly purposes.
Steering Control Valve 1 RIGHT 4 2 FRONT 3 20 to 26 ft--lb (28 to 35 N--m) 7 Antiseize Lubricant 9 10 13 11 14 5 15 7 to 10 ft--lb (9.5 to 13.5 N--m) Antiseize Lubricant 6 8 6 6 12 Figure 97 1. 2. 3. 4. 5. Steering wheel cover Lock nut Steering wheel Flat washer Socket head screw (4 used) 6. 7. 8. 9. 10. Flange head screw (4 used) Steering column Steering control valve Socket head screw (4 used) Flange nut (4 used) Removal (Fig. 97) 1.
6. Lubricate new O--rings and connect hydraulic lines to fittings on steering control valve (see Hydraulic Hose and Tube Installation in the General Information section of this chapter). Before opening hydraulic system, operate all hydraulic controls to relieve system pressure and avoid injury from pressurized hydraulic oil. See Relieving Hydraulic System Pressure in the General Information section of this chapter. 8. Disconnect hydraulic lines from steering control valve.
Steering Control Valve Service 2 3 1 8 4 5 6 5 9 7 10 22 11 12 13 14 13 15 13 16 17 18 19 20 to 24 ft--lb (27 to 33 N--m) 20 21 Figure 100 1. 2. 3. 4. 5. 6. 7. 8. Relief valve assembly Dust seal ring Steering valve housing Shaft seal Thrust washer Bearing race Ring Spring set 9. 10. 11. 12. 13. 14. 15. Cross pin Sleeve Spool Cardan shaft O--ring Distributor plate Outer gearwheel 16. 17. 18. 19. 20. 21. 22.
Hydraulic System This page is intentionally blank.
Steering Cylinder 7 6 9 15 7 4 9 8 2 16 5 4 1 3 10 12 14 11 13 14 RIGHT FRONT 100 to 125 ft--lb (136 to 169 N--m) Figure 101 1. 2. 3. 4. 5. 6. Steering cylinder Ball joint Ball joint Retaining ring Grease fitting Grease fitting Hydraulic System 7. 8. 9. 10. 11. 90o hydraulic fitting O--ring O--ring Drive axle assembly Ball joint spacer Page 4 -- 118 12. 13. 14. 15. 16.
Removal (Fig. 101) Installation (Fig. 101) 1. Park machine on a level surface, lower cutting decks, stop engine, engage parking brake and remove key from the ignition switch. 1. If fittings were removed from steering cylinder, lubricate and place new O--rings onto fittings. Install fittings into cylinder ports using marks made during the removal process to properly orientate fittings. Tighten fittings (see Hydraulic Fitting Installation in the General Information section of this chapter). 3.
Steering Cylinder Service 11 10 9 30 to 36 ft--lb (41 to 48 N--m) 5 13 4 3 2 12 8 1 7 6 2 9 1 5 11 6 3 4 13 7 10 8 12 Figure 102 1. 2. 3. 4. 5. Tube assembly Lock nut Seal O--ring O--ring Hydraulic System 6. 7. 8. 9. Piston O--ring Back--up seal Seal Page 4 -- 120 10. 11. 12. 13.
Disassembly (Fig. 102) Assembly (Fig. 102) 1. Remove oil from steering cylinder into a drain pan by slowly pumping the cylinder shaft. Plug both ports and clean the outside of the cylinder. 1. Make sure all cylinder components are clean before assembly. 2. Mount steering cylinder securely in a vise by clamping on the clevis end of the barrel. Use of a vise with soft jaws is recommended. 3. Loosen head from barrel: A.
Engine Cooling Fan Motor 10 RIGHT FRONT 22 16 21 13 15 17 5 14 18 22 12 14 20 19 9 15 1 12 3 13 7 8 11 4 2 3 7 6 6 8 4 Figure 103 1. 2. 3. 4. 5. 6. 7. 8. Cap screw (4 used) Fan Flange head screw (4 used) Flange nut (4 used) Fan motor and bracket assembly Flange head screw (8 used) Flat washer (8 used) R--clamp (2 used) Hydraulic System 9. 10. 11. 12. 13. 14. 15.
Removal (Fig. 103) 1. Park machine on a level surface, lower cutting decks, stop engine, apply parking brake and remove key from the ignition switch. 2. Read the General Precautions for Removing and Installing Hydraulic System Components at the beginning of the Service and Repairs section of this chapter. 3. Unlatch and raise hood. RIGHT FRONT 2 1 13 27 to 33 ft--lb (37 to 44 N--m) 11 17 16 13 7 4 CAUTION 14 18 12 4. Remove four (4) cap screws and washers used to secure fan (item 2) to fan hub.
4. Install upper radiator shroud (Fig. 103): Installation (Fig. 103) 1. If fittings were removed from fan motor, lubricate and place new O--rings onto fittings. Install fittings into port openings. Tighten fittings (see Hydraulic Fitting Installation in the General Information section of this chapter). 2. Secure fan motor to bracket (Fig. 104): A. Position fan motor to fan motor bracket and secure with two (2) cap screws (item 8), flat washers (item 9) and lock nuts (item 10). B.
Hydraulic System This page is intentionally blank.
Engine Cooling Fan Motor Service 11 10 15 6 3 1 14 7 16 9 8 12 8 5 4 14 33 ft--lb (45 N--m) 9 2 13 Figure 105 1. 2. 3. 4. 5. 6. Flange washer O--ring Front flange Dust seal Retaining ring Front wear plate 7. 8. 9. 10. 11. Shaft seal Backup gasket Pressure seal Rear wear plate Body 12. 13. 14. 15. 16. The engine cooling fan motor has similar construction as the cutting deck motors. The body of the cooling fan motor (item 11 in Fig.
Hydraulic System This page is intentionally blank.
Fan Control Manifold 4 2 5 12 3 13 1 6 10 7 9 8 11 RIGHT FRONT Figure 107 1. 2. 3. 4. 5. Fan control manifold Support bracket Flange head screw (2 used) Battery support Air cleaner mount Hydraulic System 6. 7. 8. 9. Deck manifold (GM 4500--D shown) Hydraulic hose Hydraulic hose Hydraulic tube Page 4 -- 128 10. 11. 12. 13.
Removal (Fig. 107) NOTE: The ports on the fan control manifold are marked for easy identification of components. Example: P1 is the gear pump connection port (see Hydraulic Schematics in Chapter 9 -- Foldout Drawings to identify the function of the hydraulic lines and cartridge valves at each manifold port). 2 UP 2 2 1 50 ft--lb (68 N--m) 2 3 1. Park machine on a level surface, lower cutting decks, stop engine, apply parking brake and remove key from the ignition switch. 2 2.
Fan Control Manifold Service 5 ft--lb (6.8 N--m) 50 ft--lb (68 N--m) 10 5 2 25 ft--lb (34 N--m) 5 ft--lb (6.8 N--m) 7 1 6 6 25 ft--lb (34 N--m) 2 9 2 25 ft--lb (34 N--m) 8 25 ft--lb (34 N--m) 3 UP 4 1 20 ft--lb (27 N--m) UP 20 ft--lb (27 N--m) Figure 109 1. 2. 3. 4. Manifold body Zero leak plug (#6) (3 used) Zero leak plug (#4) (2 used) Check valve (port CV) 5. Flow divider cartridge (port FD) 6. Solenoid coil (2 used) 7.
Hydraulic System This page is intentionally blank.
Lift Control Manifold 1 7 2 8 4 9 5 3 6 GROUNDSMASTER 4500--D SHOWN RIGHT FRONT Figure 110 1. Deck control manifold 2. Filter mount bracket 3. Flange head screw (2 used) 4. Hydraulic oil filter assembly 5. Valve mount bracket 6. Flange head screw (2 used) NOTE: The lift control manifolds used on Groundsmaster 4500--D and 4700--D machines are different but they mount to the machine in the same location. The Groundsmaster 4500--D control manifolds are shown in Figure 110. Hydraulic System 7.
Removal (Fig. 110) 1. Park machine on a level surface, lower cutting decks, stop engine, apply parking brake and remove key from the ignition switch. 4. Connect wire harness electrical connectors to the solenoid valve coils. 5. Lower and secure operator seat. IMPORTANT: To prevent unexpected deck lowering, make sure that cutting decks are fully lowered before loosening hydraulic lines from lift manifold. GROUNDSMASTER 4500--D 3 2.
Lift Control Manifold Service (GM 4500--D) 5 ft--lb (6.8 N--m) 15 8 25 ft--lb (34 N--m) 14 4 20 ft--lb (27 N--m) 25 ft--lb (34 N--m) 5 ft--lb (6.8 N--m) 2 3 7 13 20 ft--lb (27 N--m) 20 ft--lb (27 N--m) 1 UP 7 5 ft--lb (6.8 N--m) 16 4 5 11 6 20 ft--lb (27 N--m) 10 9 12 25 ft--lb (34 N--m) Figure 113 1. 2. 3. 4. 5. 6. Manifold body Proportional relief valve (port TS) Solenoid valve (port S6) Solenoid coil (2 used) Check valve (port CV) Orifice (0.080) 7. 8. 9. 10. 11.
NOTE: The lift control manifold includes several zero leak plugs. These plugs have a tapered sealing surface on the plug head that is designed to resist vibration induced plug loosening. The zero leak plugs also have an O--ring as a secondary seal. If zero leak plug removal is necessary, lightly rap the plug head using a punch and hammer before using an allen wrench to remove the plug: the impact will allow plug removal with less chance of damage to the socket head of the plug.
Lift Control Manifold Service (GM 4700--D) 20 ft--lb (27 N--m) 25 ft--lb (34 N--m) 5 ft--lb (6.8 N--m) 4 7 11 10 20 ft--lb (27 N--m) 5 2 1 20 ft--lb (27 N--m) 3 5 ft--lb (6.8 N--m) 25 ft--lb (34 N--m) 6 10 12 8 UP 11 8 6 20 ft--lb (27 N--m) 10 12 9 11 5 ft--lb (6.8 N--m) 11 12 25 ft--lb (34 N--m) 10 12 20 ft--lb (27 N--m) 5 ft--lb (6.8 N--m) Figure 114 1. 2. 3. 4. Manifold body Nut Zero leak plug (#4) Relief valve (port R1) 5. 6. 7. 8.
NOTE: The lift control manifold uses several zero leak plugs. These plugs have a tapered sealing surface on the plug head that is designed to resist vibration induced plug loosening. The zero leak plugs also have an O--ring as a secondary seal. If zero leak plug removal is necessary, lightly rap the plug head using a punch and hammer before using an allen wrench to remove the plug: the impact will allow plug removal with less chance of damage to the socket head of the plug.
Lift Circuit Junction Manifold 2 1 4 RIGHT FRONT 3 Figure 116 1. Lift circuit junction manifold 2. Flange head screw (2 used) Hydraulic System 3. HI/LOW range control manifold Page 4 -- 138 4.
Removal (Fig. 116) 1. Park machine on a level surface, lower cutting decks, stop engine, engage parking brake and remove key from the ignition switch. 2. Read the General Precautions for Removing and Installing Hydraulic System Components at the beginning of the Service and Repairs section of this chapter. 2. Install hydraulic manifold to the frame using Figure 116 as guide. 3. Remove caps and plugs from fittings and hydraulic lines.
Lift Cylinders: Decks #1, #4 and #5 11 9 10 8 7 6 12 5 4 5 12 5 3 2 2 2 1 4 5 RIGHT FRONT Figure 119 1. 2. 3. 4. Lift arm (deck #4) Flange nut Lift arm (deck #1) Cylinder pin (3 used) 5. 6. 7. 8. Flange head screw O--ring 90o hydraulic fitting (2 per cylinder) O--ring 9. 10. 11. 12. Lift arm (deck #5) Lift cylinder (decks #4 and #5) Lift cylinder (deck #1) Cylinder pin (3 used) NOTE: The lift cylinders for deck 1 and 4 are shown in Figure 119.
Removal (Fig. 119) Installation (Fig. 119) 1. Park machine on a level surface, lower cutting decks, stop engine, engage parking brake and remove key from the ignition switch. 1. If fittings were removed from lift cylinder, lubricate and place new O--rings onto fittings. Install fittings into cylinder openings using marks made during the removal process to properly orientate fittings. Tighten fittings (see Hydraulic Fitting Installation in the General Information section of this chapter). 3.
Lift Cylinders: Decks #2 and #3 5 13 11 10 9 6 8 11 12 2 9 4 1 3 7 RIGHT FRONT Figure 121 1. 2. 3. 4. 5. Flange head screw Flange nut Cylinder pin Lift cylinder Retaining ring Hydraulic System 6. 7. 8. 9. Cylinder pin Lift arm (deck #2) Lift arm (deck #3) O--ring Page 4 -- 142 10. 11. 12. 13.
Removal (Fig. 121) 1. Park machine on a level surface, lower cutting decks, stop engine, engage parking brake and remove key from the ignition switch. 2. Read the General Precautions for Removing and Installing Hydraulic System Components at the beginning of the Service and Repairs section of this chapter. 3. To prevent contamination of hydraulic system during lift cylinder removal, thoroughly clean exterior of lift cylinder. 2.
Lift Cylinders: Decks #6 and #7 (GM 4700--D) 10 6 8 9 1 10 8 12 2 9 3 7 6 11 5 13 13 4 RIGHT FRONT Figure 123 1. 2. 3. 4. 5. Lift cylinder Lock nut (2 used per side) Rear link Link assembly Plastic roller Hydraulic System 6. 7. 8. 9. Retaining ring Cylinder pin 90o hydraulic fitting O--ring Page 4 -- 144 10. 11. 12. 13.
Removal (Fig. 123) 1. Park machine on a level surface, lower cutting decks, stop engine, engage parking brake and remove key from the ignition switch. 2. Read the General Precautions for Removing and Installing Hydraulic System Components at the beginning of the Service and Repairs section of this chapter. 3. To prevent contamination of hydraulic system during lift cylinder removal, thoroughly clean exterior of lift cylinder. WARNING 2.
Lift Cylinder Service See text for torque specification 14 2 5 6 1 10 11 3 13 4 14 7 8 14 9 12 2 3 1 6 7 13 4 9 11 5 8 10 14 12 Figure 125 1. 2. 3. 4. 5. Tube assembly Lock nut Wear ring Seal Piston 6. 7. 8. 9. 10. O--ring O--ring Back--up ring Seal Retaining ring 11. 12. 13. 14. Head Wiper Rod assembly Grease fitting (2 used) NOTE: The lift cylinders used on the Groundsmaster are all very similar regardless of the location on the machine.
Disassembly (Fig. 125) Assembly (Fig. 125) 1. Remove oil from lift cylinder into a drain pan by slowly pumping the cylinder shaft. Plug both ports and clean the outside of the cylinder. 1. Make sure all cylinder components are clean before assembly. 2. Mount lift cylinder securely in a vise by clamping on the clevis end of the barrel. Use of a vise with soft jaws is recommended. 3. Loosen head from barrel: 2. Coat new seal kit components with clean hydraulic oil. A.
Hydraulic Reservoir 2 1 RIGHT FRONT 3 5 4 6 15 18 17 16 19 12 20 13 14 8 7 9 15 21 10 11 22 35 to 47 ft--lb (48 to 63 N--m) 23 Figure 126 1. 2. 3. 4. 5. 6. 7. 8. Plug O--ring Dipstick Breather Screen filter Hydraulic reservoir Reservoir strainer O--ring Hydraulic System 9. 10. 11. 12. 13. 14. 15. 16. O--ring Straight hydraulic fitting O--ring Cap screw (2 used) Flat washer (2 used) Clamp (2 used) Flange nut (3 used) Cap screw Page 4 -- 148 17. 18. 19. 20. 21. 22. 23.
Removal (Fig. 126) Inspection 1. Park machine on a level surface, lower cutting decks, stop engine, engage parking brake and remove key from the ignition switch. 1. Clean hydraulic reservoir and suction strainer with solvent. 3. To prevent contamination of hydraulic system during hydraulic reservoir removal, thoroughly clean exterior of reservoir. 4. To allow draining of hydraulic reservoir, disconnect the hydraulic hose (item 23) from the fitting in the bottom of the reservoir.
Radiator and Oil Cooler Assembly 28 15 15 26 32 46 8 RIGHT 25 FRONT 24 15 29 20 11 41 42 1 47 7 44 26 15 13 29 32 28 22 14 16 21 32 6 30 16 9 10 51 19 5 37 38 14 43 32 25 24 33 11 2 42 18 7 27 10 6 17 36 34 3 18 15 17 50 31 4 42 35 23 45 31 36 39 48 42 40 12 49 15 15 Figure 127 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17.
NOTE: The hydraulic oil cooler on your Groundsmaster is combined with the radiator. See Radiator and Oil Cooler Assembly in the Service and Repairs section of Chapter 3 -- Diesel Engine for information on removal and installation of the radiator/oil cooler assembly. 4 1 4 5 7 3 6 5 6 7 Hydraulic System 2 Figure 128 1. 2. 3. 4. Radiator/oil cooler Hydraulic tube Hydraulic tube Hydraulic hose 5. Bulkhead nut 6. Spacer 7. O--ring 3 2 4 5 1 6 8 2 7 Figure 129 1. 2. 3. 4.
This page is intentionally blank.
Chapter 5 Electrical System Table of Contents Groundsmaster 4500−D/4700−D Headlight Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . Seat Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Parking Brake Switch . . . . . . . . . . . . . . . . . . . . . . . Cutting Deck Position Switches . . . . . . . . . . . . . . Relays with Four (4) Terminals . . . . . . . . . . . . . . . Relays with Five (5) Terminals . . . . . . . . . . . . . . . Traction Pedal Position Sensor . . . . . .
General Information Operator’s Manual The Operator’s Manual provides information regarding the operation, general maintenance and maintenance intervals for your Groundsmaster machine. Refer to the Operator’s Manual for additional information when servicing the machine. Electrical Drawings The electrical schematic and wire harness drawings for Groundsmaster 4500--D and 4700--D machines are located in Chapter 9 -- Foldout Drawings.
Yanmar Engine Electronic Control Unit (ECU) The Yanmar engine that powers the Groundsmaster 4500−D and 4700−D uses an electronic control unit (ECU) for engine management and also to communicate with the TEC controllers and the InfoCenter Display on the machine. All engine ECU electrical connectors should be plugged into the controller before the machine ignition switch is moved from the OFF position to either the ON or START position.
Yanmar Engine Electrical Components When servicing or troubleshooting the engine electrical components, use the correct engine service manual and troubleshooting manual. Also, the Yanmar SMARTASSIST−Direct electronic control diagnostics service system is available to support the error diagnosis and maintenance services of engine electrical control devices.
Electrical System This page is intentionally blank.
Special Tools Order special tools from your Toro distributor. Some tools may also be available from a local supplier. Multimeter The multimeter can test electrical components and circuits for current (amps), resistance (ohms) or voltage. Obtain this tool locally. NOTE: Toro recommends the use of a DIGITAL Volt− Ohm−Amp multimeter when testing electrical circuits.
Battery Hydrometer Use the battery hydrometer when measuring specific gravity of battery electrolyte. Obtain this tool locally.
InfoCenter Display The InfoCenter Display used on your Groundsmaster is a LCD device that is located on the console. The InfoCenter provides information for the machine operator during machine operation, provides electrical system diagnostic assistance for technicians and allows inputs for adjustable machine settings. Power for the InfoCenter is available when energized by the TEC controller (ignition switch in the START or ON position).
Main Information Screens The two (2) InfoCenter main information screens (Figs. 10 and 11) are displayed after the initial splash screens have been displayed for several seconds. During normal machine operation, the main information screens provide machine information for the operator. Toggling between the main information screens is done by pressing the right button on the InfoCenter.
Main Menu Screen The main menu screen can be accessed from the InfoCenter main information or splash screen by pressing and releasing the menu/back button (left button) on the display. Once to the main menu screen (Fig. 12), navigation to the five (5) different menu items can occur. Pressing the move to menu item button (center button) allows a different menu item to be highlighted. Selection of the highlighted item is completed by pressing the choose item button (right button).
Service Screen NOTE: If the protected menu items are available, PIN will be shown in the upper right corner of the InfoCenter display. The options listed for hours include the following: Key On identifies the number of hours that the ignition switch has been in the ON position. Machine Run identifies the number of hours that the engine has been running. PTO On identifies the number of hours that the machine has been operated with the cutting decks engaged.
Diagnostics Screen The diagnostics screen (Fig. 15) lists the various states of machine electrical components. The diagnostics screen should be used to check operation of machine controls and to verify that switches and circuit wiring are functioning correctly. For each of the diagnostics screen items, inputs, qualifiers and outputs are identified. The diagnostics screen includes the following: Left Deck (Groundsmaster 4700−D) identifies machine requirements to allow the left deck to raise and lower.
Settings Screen If either the backlight (brightness) or contrast items are selected, the center button (−) or right button (+) can be used to change the display settings. Protected menus allows the machine PIN to be entered so that hidden machine service screen items can be viewed and modified. The protected service items include traction pedal sensor calibration, cooling fan reversal demonstration and exhaust system DPF regeneration (Tier4 engines).
About Screen The about screen (Fig. 18) identifies the machine model number, serial number and software revisions for the TEC controllers, InfoCenter and engine electronic control unit (if available). The about screen also lists the CAN−bus status. Additional information is identified if the about screen is accessed after the protected menus have been accessed by entering the PIN.
Troubleshooting For effective troubleshooting and repairs, there must be a good understanding of the electrical circuits and components used on this machine. CAUTION Remove all jewelry, especially rings and watches, before doing any electrical troubleshooting or testing. Disconnect the battery cables unless the test requires battery voltage. If the machine has any interlock switches by−passed, reconnect the switches for proper safety and troubleshooting.
Fault Codes The list below identifies the fault codes that are generated by the TEC controller to identify an electrical system malfunction (fault) that occurred during machine operation. Use the InfoCenter Display for fault retrieval. NOTE: The following list of fault codes identifies electrical problems that typically will prevent normal machine operation. The InfoCenter Display will identify existing faults if they should occur. Fault codes 13 through 25 identify problems with inputs (e.g.
Fault Description 33 Forward piston (traction) pump output has open or short to ground 34 Reverse piston (traction) pump output has open or short to ground 35 Reverse engine cooling fan output has open or short to ground 39 LH PTO output has open or short to ground 40 RH PTO output has open or short to ground 41 Solenoid valve S1 (GM 4700−D lift/lower enable) output has open or short to ground 42 Solenoid valve S2 (GM 4700−D LH deck raise) output has open or short to ground 43 Solenoid valve
Starting Problems NOTE: Check InfoCenter Display for possible operator advisories or faults whenever diagnosing machine electrical problems. Problem Possible Causes No electrical power to machine (including gauges). Battery is discharged. Battery cables are loose or corroded. Fuse D−1 (2 Amp) is faulty. Fuse D−2 (2 Amp) is faulty. Ground connection on machine is loose or corroded. The ignition switch or circuit wiring is faulty. Starter solenoid clicks, but starter will not crank.
Starting Problems (continued) Problem Possible Causes Engine cranks, but does not start. Fuel tank is empty. Engine is not cranking fast enough. Fuel pump or circuit wiring is faulty. Engine or fuel system is malfunctioning (see Yanmar Service Manual). Starter cranks, but should not when the traction pedal is depressed. Traction pedal position sensor is out of adjustment. Traction pedal position sensor or circuit wiring is faulty.
Cutting Deck Operating Problems NOTE: Check InfoCenter Display for possible operator advisories or faults whenever diagnosing machine electrical problems. Problem Possible Causes Cutting decks run, but should not, when raised. Decks shut off with PTO switch. The cutting deck position switch or circuit wiring is faulty. Wire harness connections are incorrectly connected to hydraulic solenoid valve coils on hydraulic deck control manifold.
Cutting Deck Lift/Lower Problems NOTE: Check InfoCenter Display for possible operator advisories or faults whenever diagnosing machine electrical problems. NOTE: To lower a cutting deck, the operator must be in the operator seat and the traction speed must be in the LOW speed (mow) position. To raise a cutting deck, the operator must be in the operator seat.
Cutting Deck Lift/Lower Problems (Continued) Problem Possible Causes On Groundsmaster 4700−D, center cutting decks will not raise or lower, but both wing cutting decks will raise and lower. The center deck lift switch or circuit wiring is faulty. Fuse(s) for TEC controller are faulty (fuse C−1). Lift control manifold solenoid coils S5 or S6 or circuit wiring is faulty. A hydraulic problem in the lift/lower circuit exists (see Troubleshooting section in Chapter 4 - Hydraulic System).
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 60o to 100oF (16o 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.
Adjustments Traction Pedal Adjustment The traction pedal includes a neutral assembly that is used to adjust the traction neutral position (Fig. 19). Traction pedal adjustment may be necessary to make sure that traction pedal movement provides the correct full reverse and full forward positions for the traction pedal position sensor. The InfoCenter display can be used to check traction pedal adjustment using the following procedure. 6 3 5 1.
6. After any adjustment of the spring shaft and rod end bearing, use the InfoCenter Display Diagnostics menu to obtain and select the Traction Pedal menu item (see InfoCenter Display in this chapter). Choose Outputs and the InfoCenter display will identify the traction pedal position (Fig. 21). Traction Pedal Forward Range: Neutral Reverse Range: OFF ON OFF A. When the traction pedal is in the neutral position, the InfoCenter should display Neutral as ON and both Forward Range and Reverse Range as OFF.
Traction Pedal Position Sensor Calibration IMPORTANT: A properly installed and calibrated traction pedal position sensor is critical to accurate traction system response and for reliable sensor life. Use care when removing, installing and calibrating the traction pedal position sensor. Calibration of the traction pedal position sensor ensures that the TEC controller can identify the traction neutral, forward and reverse positions. 1.
Component Testing For accurate resistance and/or continuity checks, electrically disconnect the component being tested from the circuit (e.g. unplug the ignition switch connector before checking continuity of the switch terminals). NOTE: For engine component testing information, see the Yanmar Service Manual and Yanmar Troubleshooting Manual. CAUTION When testing electrical components for continuity with a multimeter (ohms setting), make sure that power to the circuit has been disconnected.
Fuses Groundsmaster 4500−D and 4700−D use numerous fuses for circuit protection. The fuses reside in the power center behind the operator’s seat. Fuse Identification and Function (Fig. 27) Fuse A−1 (7.5 Amp) protects TEC−5002 output power supply for engine start, engine run, fuel pump and cooling fan directional solenoid (S1). Fuse A−2 (7.
Fusible Link Harness Your Groundsmaster uses two (2) fusible links for circuit protection. These fusible links are located in a harness that connects the starter B+ terminal to the wire harness (Fig. 28). If either of these links should fail, current to the protected circuits will cease. Refer to wire harness drawings in Chapter 9 − Foldout Drawings for additional fusible link information. 1 2 Testing Make sure that ignition switch is OFF.
PTO Switch The two position PTO switch is located on the console arm (Fig. 30). The PTO switch is pulled up to engage the PTO and pushed in to disengage the PTO. NOTE: To engage the PTO, the seat has to be occupied, traction speed has to be in low range (mow) and the cutting decks have to be fully lowered.
Hi/Low Speed, Engine Speed Request and Cutting Deck Lift Switches The Hi/Low speed, engine speed request and cutting deck lift switches are all identical. These switches are located on the console arm (Fig. 32). The Hi/Low speed switch is used as an input for the TEC controller to select either the Hi (transport) or Low (mow) traction speed. The engine speed request switch is used as an input for the engine control unit (ECU) to raise or lower the engine speed.
Headlight Switch The headlight switch is located on the operator side of the console arm (Fig. 34). This two (2) position rocker switch allows the headlights to be turned on and off. Testing 1. Park machine on a level surface, lower cutting decks, engage parking brake and stop engine. Remove key from ignition switch. 2. Remove console arm covers to gain access to headlight switch (see Console Arm in the Service and Repairs section of Chapter 7 − Chassis). 3.
Seat Switch The seat switch is normally open and closes when the operator is on the seat. The seat switch and its electrical connector are located in the seat assembly. If the traction system or PTO switch is engaged when the operator raises out of the seat, an operator advisory will be displayed on the InfoCenter. Testing of the switch can be done without seat removal by disconnecting the switch wire from the machine wire harness (Fig. 36).
Parking Brake Switch The parking brake switch is a normally open proximity switch. The parking brake switch is attached to the bottom of the RH brake pedal (Fig. 37). When the parking brake is not applied, the parking brake detent is positioned near the target end of the parking brake switch so the switch is closed. The parking brake detent is moved away from the switch when the parking brake is applied causing the switch to open.
Cutting Deck Position Switches The cutting deck position switches are normally open proximity switches that are located on the traction unit frame (Fig. 39). The sensing plate is located on the cutting deck lift arm. The Groundsmaster 4500−D uses two (2) cutting deck position switches: for decks 4 and 5. There are four (4) deck position switches on the Groundsmaster 4700−D: for decks 4, 5, 6 and 7.
Relays with Four (4) Terminals Your Groundsmaster uses a number of electrical relays that have four (4) terminals. A tag near the wire harness relay connector can be used to identify each relay. 1 The main power relay is used to provide current to most of the fuse protected circuits (operator seat, InfoCenter display, engine electronic control unit (ECU), power point and optional electric equipment). The main power relay is energized when the ignition switch is in the ON or START position.
6. Connect multimeter (ohms setting) leads to relay terminals 30 and 87. Ground terminal 86 and apply +12 VDC to terminal 85. The relay should make and break continuity between terminals 30 and 87 as +12 VDC is applied and removed from terminal 85. 7. Disconnect voltage and test leads from the relay terminals. 86 87 30 85 85 30 86 87 8. Secure relay to mounting bracket and connect wire harness connector to relay. 9. Secure all removed components to machine. Figure 43 Electrical System 10.
Relays with Five (5) Terminals Your Groundsmaster uses a number of electrical relays that have five (5) terminals. A tag near the wire harness relay connector can be used to identify each relay. 9. After testing, disconnect voltage and multimeter test leads from the relay terminals. Secure relay to mounting bracket and connect wire harness connector to relay.
Traction Pedal Position Sensor The traction pedal position sensor is connected to the traction pedal assembly (Fig. 46). This position sensor determines the neutral band for the traction pedal, the direction of travel desired by the operator and the traction speed. The position sensor is a single analog, dual digital signal electronic device.
Toro Electronic Controllers (TEC) Groundsmaster 4500−D and 4700−D machines use a Toro Electronic Controller (TEC−5002) to control electrical system operation. Groundsmaster 4700−D machines use an additional TEC−5001 controller for electrical control of the rear cutting decks (PTO and lift/ lower functions). The controllers are microprocessor controlled that sense the condition of various switches and sensors (inputs).
The connection terminal functions for the TEC controllers are shown in Figures 48 (TEC--5002) and 49 (TEC--5001). Note that electrical power for controller outputs is provided through three (3) connector terminals (PWR 2, PWR 3 and PWR 4) each protected with a 7.5 amp fuse. A fifty (50) pin wire harness connector attaches to each controller. The wire harness connector pins are identified in the diagram in Figures 48 and 49.
Hydraulic Solenoid Valve Coils 1 2 3 GROUNDSMASTER 4500−D SHOWN RIGHT FRONT 4 Figure 51 1. Deck control manifold 2. Lift control manifold 3. Fan control manifold Numerous hydraulic solenoid valve coils are used on the hydraulic control manifolds of Groundsmaster 4500−D and 4700−D machines. When energized by the TEC controller, these coils provide hydraulic circuit control. Three (3) different solenoid valve coils are used on your Groundsmaster.
Solenoid Coil Testing 1. Park machine on a level surface, lower cutting decks, stop engine, engage parking brake and remove key from the ignition switch. 2. Locate hydraulic solenoid valve coil to be tested (Fig. 51). 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.
Piston (Traction) Pump Control Solenoid Coils The piston (traction) pump uses an electronic control assembly for swash plate rotation. Electrical outputs from the machine TEC controller are provided to two (2) solenoid coils for pump control. The piston pump control assembly is attached to the left side of the piston pump (Fig. 53). NOTE: To assist in troubleshooting, the piston pump solenoid coils can be exchanged because they are identical.
Hydraulic Oil Temperature Sender A temperature sender is used as an input for the TEC controller to identify if the hydraulic oil temperature has reached an excessive level. The hydraulic oil temperature sender is attached to the rear axle motor at the rear of the machine (Fig. 55). 5. Check resistance of the sender with a multimeter (ohms setting) as the oil temperature increases.
Fuel Pump (Models 30873 and 30874) The fuel pump is attached to the air cleaner mount below the fuel water separator (Fig. 57). FRONT Operational Test 5 1. Park machine on a level surface, lower cutting decks, stop engine and apply parking brake. Raise hood to access fuel pump. 3 2. Disconnect fuel supply hose from the fuel injection pump fitting on the engine (Fig. 57). This hose is the fuel pump discharge. 2 3. Make sure fuel hoses attached to the fuel pump are free of obstructions. 1 4.
Fuel Pump (Models 30881 and 30882) The fuel pump is attached to the air cleaner mount below the fuel water separator (Fig. 58). FRONT Operational Test 1. Park machine on a level surface, lower cutting decks, stop engine and apply parking brake. Raise hood to access fuel pump. 3 2. Disconnect fuel pump discharge hose from the fuel filter attached to the engine (Fig. 58). 5 3. Make sure fuel hoses attached to the fuel pump are free of obstructions. 2 4.
CAN−bus Termination Resistor System communication between electrical components on Groundsmaster 4500−D and 4700−D machines is accomplished on a CAN−bus communication system. Two (2) specially designed, twisted cables form the bus for the network used on the machine. These wires provide the data pathways between machine components. At the end of the twisted pair of bus cables near the InfoCenter display is a 120 ohm termination resistor.
Diode Assemblies The Groundsmaster engine wire harness contains a diode assembly that is used for circuit protection from voltage spikes when the engine starter solenoid is de− energized. This diode assembly plugs into the engine wire harness near the engine starter motor. 1 4 2 Groundsmaster models 30873 and 30874 use an additional diode assembly in the engine wire harness that protects the engine EGR circuit from reverse polarity.
Fan Speed Switch (Machines with Two−Post ROPS Extension Operator Fan Kit) The fan speed switch is attached to the overhead control panel (Fig. 62). The switch is used to select the fan speed (off, low, medium, or high). 1 2 Testing 1. Park the machine on a level surface, lower the cutting decks, and shut off the engine. Remove the key from the key switch. 2. To access the switch, remove the sunshade from the top of the ROPS extension. 3 3. Disconnect the machine wire harness from the fan speed switch.
Resistor Module (Machines with Two−Post ROPS Extension Operator Fan Kit) 1. Operator’s fan 2 2. 3 Figure 64 Fan mount bracket The resistor module is attached to the rear of the fan mounting bracket (Fig. 64). The resistor module is used for operation of the operator’s fan. Testing 1. Park the machine on a level surface, lower the cutting decks, and shut off the engine. Remove the key from the key switch. 3.
Service and Repairs NOTE: For engine component repair information (e.g. starter motor), refer to the Yanmar Service Manual that is correct for your Groundsmaster model. Battery Care 1. The top of the battery must be kept clean. lf the machine is stored in a location where temperatures are extremely high, the battery will discharge more rapidly than if the machine is stored in a location where temperatures are cool. B. Coat battery posts and cable connectors with battery terminal protector (Toro Part No.
Battery Service The battery is the heart of the electrical system. With regular and proper service, battery life can be extended. Additionally, battery and electrical component failure can be prevented. 1 CAUTION 3 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.
Battery Testing C. Make sure battery terminals are free of corrosion. 1. Conduct a hydrometer test of the battery electrolyte. D. Measure the temperature of the center battery cell. IMPORTANT: Make sure the area around the cells is clean before opening the battery caps. A. Measure the specific gravity of each cell with a hydrometer. Draw electrolyte in and out of the hydrometer barrel prior to taking a reading to warm− up the hydrometer. At the same time take the temperature of the cell. B.
Battery Charging CAUTION Follow the battery charger manufacturer’s instructions when using a battery charger. NOTE: Using specific gravity of the battery cells is the most accurate method of determining battery condition. CAUTION Do not charge a frozen battery because it can explode and cause injury. Let the battery warm to 60oF (16oC) before connecting to a charger. Charge the battery in a well−ventilated place to dissipate gases produced from charging.
This page is intentionally blank.
Chapter 6 Axles, Planetaries and Brakes Table of Contents Axles, Planetaries and Brakes SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . 3 Operator’s Manual . . . . . . . . . . . . . . . . . . . . . . . . . . 3 ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Planetary Drive End Play (OPH−2 series planetary drives) . . . . . . . . . . . . . . 4 SERVICE AND REPAIRS . . . . . . . . . . . . . . . .
Specifications Item Specification Tire pressure (front and rear) 20 psi (138 kPa) Rear wheel toe−in 0.125 in (3 mm) Wheel lug nut torque (front and rear) 85 to 100 ft−lb (116 to 135 N−m) Steering cylinder bolt torque 100 to 125 ft−lb (136 to 169 N−m) Planetary, Brake Assembly and Wheel Motor Mounting Screw Torque OPH−2 series planetary VA02 series planetary 60 ft−lb (81 N−m) 75 to 85 ft−lb (101 to 115 N−m) Planetary Drive Lubricant Capacity (each wheel) SAE 85W−140 wt.
General Information Operator’s Manual Axles, Planetaries and Brakes The Traction Unit Operator’s Manual provides information regarding the operation, general maintenance and maintenance intervals for your Groundsmaster machine. Refer to this publication for additional information when servicing the machine.
Adjustments Planetary Drive Endplay (OPH−2 series planetary drives) A front planetary drive assembly that is properly operating should have no endplay. Any endplay in a planetary assembly indicates that there are potential problems with the planetary. Check planetary endplay at intervals specified in your Operator’s Manual. Endplay Checking Procedure OPH−2 series planetary 1. Park machine on a level surface, lower cutting decks, stop engine and remove key from the ignition switch. Figure 1 2.
Axles, Planetaries and Brakes This page is intentionally blank.
Service and Repairs Brake Assembly VA02 series planetary OPH−2 series planetary OPH−2 series planetary = 60 ft−lbs (81 N−m) VA02 series planetary = 75 to 85 ft−lbs (101 to 115 N−m) 1 3 6 RIGHT FRONT 17 2 15 8 9 14 16 7 13 11 5 10 12 OPH−2 series planetary = 60 ft−lbs (81 N−m) VA02 series planetary = 75 to 85 ft−lbs (101 to 115 N−m) 4 85 to 100 ft−lb (116 to 135 N−m) Figure 2 1. 2. 3. 4. 5. 6. 7.
Brake Assembly Removal (Fig. 2) Brake Assembly Installation (Fig. 2) 1. Park machine on a level surface and raise cutting decks to allow easier access to front brake assembly. Stop engine, engage parking brake and remove key from the ignition switch. 3 2. Drain oil from planetary drive and brake assembly; refer to traction unit Operator’s Manual. 2 CAUTION 1 When changing attachments, tires or performing other service, use correct jacks, hoists and jack stands to raise and support machine.
3. Install brake cable to pull rod on brake assembly (Fig. 4). Brake cable end should be completely threaded onto pull rod before tightening jam nut. 7. Check and adjust brake cables for proper brake operation (see machine Operator’s Manual). WARNING 4. Make sure wheel motor O−ring (item 4) is in position and secure wheel motor to planetary with two (2) cap screws and flat washers. For OPH−2 series planetary drives: tighten screws from 60 ft−lb (81 N−m).
Brake Inspection and Repair 3 2 1 4 5 6 7 8 9 15 14 10 13 12 11 1. 2. 3. 4. 5. Brake housing (LH shown) Seal Pull rod Clevis pin (2 used) Link (2 used) 6. 7. 8. 9. 10. Hitch pin (2 used) Stationary disc (4 used) Rotating disc (3 used) Retaining ring Gasket 11. 12. 13. 14. 15. Rotating actuator Extension spring (3 used) Ball (3 used) Plug O−ring Brake Inspection and Repair (Fig. 5) 6. Remove seal (item 2) from brake housing. 1.
Planetary Drive Assembly VA02 series planetary OPH−2 series planetary OPH−2 series planetary = 60 ft−lbs (81 N−m) VA02 series planetary = 75 to 85 ft−lbs (101 to 115 N−m) 1 3 6 RIGHT FRONT 2 17 15 8 9 14 16 7 13 11 5 10 12 OPH−2 series planetary = 60 ft−lbs (81 N−m) VA02 series planetary = 75 to 85 ft−lbs (101 to 115 N−m) 4 85 to 100 ft−lb (116 to 135 N−m) Figure 6 1. 2. 3. 4. 5. 6. 7.
Planetary Drive Removal (Fig. 6) Planetary Drive Installation (Fig. 6) 1. Park machine on a level surface, lower cutting decks, stop engine, engage parking brake and remove key from the ignition switch. 1. Position planetary assembly to machine making sure to engage splined brake shaft with planetary drive shaft. Secure planetary assembly to frame with six (6) flange head screws. 2. Drain the oil from the brake assembly and the Planetary drive; refer to the traction unit Operator’s Manual.
OPH−2 Series Planetary Drive Service 2 118 to 144 in−lb (13.3 to 16.3 N−m) 3 4 7 8 9 11 1 12 13 14 5 15 16 6 10 28 21 13 27 26 17 25 24 23 22 20 OPH−2 series planetary 19 18 Figure 7 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. Spindle Boot seal Oil seal Inner bearing cone Inner bearing cup Wheel stud (8 used) Socket head screw (16 used) Lock washer (16 used) Housing Dowel pin (2 used) Axles, Planetaries and Brakes 11. 12. 13. 14. 15. 16. 17. 18. 19.
NOTE: The planetary drive assembly can be serviced with the planetary installed to machine. If the spindle (item 1) needs to be removed, see Planetary Drive Assembly in this chapter. Disassembly (Figs. 7 and 8) 1. Park machine on a level surface, stop engine and remove key from the ignition switch. 2. Drain oil from planetary drive/brake assembly; refer to traction unit Operator’s Manual. 3. Chock rear wheels and jack up front of machine (see Jacking Instructions in Chapter 1 − Safety).
C. Make sure that seal bore in housing is thoroughly cleaned. If OD of seal (item 3) is not rubber or does not have a sealant coating, apply light coating of silicone sealant to seal bore in housing. Install seal into housing so it is flush with housing face. Lightly grease seal lips. D. Pack boot seal (item 2) with grease and install on housing. E. If ring gear was removed from housing, place dowel pins (item 10) in housing.
Axles, Planetaries and Brakes This page is intentionally blank.
VA02 Series Planetary Drive Service 1 2 3 5 37 N−m (27 ft−lb) VA02 series planetary 7 4 8 9 4 5 11 12 13 14 6 15 10 28 27 20 19 26 24 25 24 23 22 21 18 17 16 G248465 Figure 9 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. Spindle Boot seal Lip seal Inner bearing cup (2) Inner bearing cone (2) Wheel stud (8) Socket head screw (8) Lock washer (8) Housing Dowel pin (4) Axles, Planetaries and Brakes 11. 12. 13. 14. 15. 16. 17. 18. 19.
NOTE: The planetary drive assembly is best serviced with the planetary installed to machine or the spindle firmly secured to a fixture or workbench. If the spindle (item 1) needs to be removed from machine, see Planetary Drive Assembly in this chapter. 2 7 8 13 11 10 14 28 27 15 24 3 16 Disassembly 1. Park machine on a level surface, stop engine and remove key from the ignition switch. 2. Drain oil from planetary drive and brake assembly; refer to traction unit Operator’s Manual.
4. If previously removed, press bearing cups into housing. Cups should be pressed fully to shoulder of the housing bore. 5. Fit inner bearing cone onto spindle. Make sure inner bearing cone seats fully against spindle shoulder. If inner bearing is not seated fully, lightly tap bearing cone on inner hub until it seats properly. 6. Make sure that seal bore in housing is thoroughly cleaned.
Axles, Planetaries and Brakes This page is intentionally blank.
Rear Axle Assembly 39 42 70 ft−lb (94 N−m) maximum 38 5 8 41 1 40 7 2 31 22 6 4 21 19 7 13 25 17 14 3 18 20 24 16 10 12 11 9 15 23 26 27 37 28 34 85 to 100 ft−lb (116 to 135 N−m) 36 32 35 33 RIGHT FRONT 32 30 29 85 to 100 ft−lb (116 to 135 N−m) Figure 11 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14.
Remove Rear Axle (Fig. 11) 1. Park machine on a level surface, lower cutting decks, stop engine, engage parking brake and remove key from the ignition switch. 1 2. Drain oil from rear axle and rear axle gearbox (Figs. 12 and 13). 2 CAUTION Figure 12 When changing attachments, tires or performing other service, use correct jacks, hoists and jack stands to raise and support machine. See Jacking Instructions in Chapter 1 − Safety for additional information and precautions. 1. Outside plug (2 used) 2.
2. If removed, install the tie rod to rear axle (Fig. 14). Tighten ball joint castle nuts and install new cotter pins. 2 3. Support axle under machine with a jack. Position axle assembly to rear frame mount. 4. Install rear axle pivot pin to secure axle to frame. Make sure to install thrust washer (item 42) between axle pivot and frame on both ends of the pivot. With thrust washers installed, there should be from 0.002 to 0.020 inch (0.05 to 0.
Axles, Planetaries and Brakes This page is intentionally blank.
Rear Axle Service 10 11 21 20 19 22 17 18 24 2 23 16 1 25 4 13 15 12 5 26 43 6 7 44 8 45 27 61 33 28 29 46 62 14 3 9 47 8 32 30 31 10 11 48 37 50 63 64 42 22 60 51 38 41 52 8 9 35 36 49 13 34 40 53 59 54 58 39 57 56 55 Figure 17 Axles, Planetaries and Brakes Page 6 - 24 Groundsmaster 4500- D/4700- D
Figure 12 (Continued) 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. LH axle support Flange bushing (2 used) Axle vent Filter Vent extension Cap screw (4 used per gear case) Shim set Seal washer Plug Lock nut Lock washer Grease fitting Ball bearing Screw (2 used per steering arm) Axle case support (LH shown) Bolt (2 used) Stud (2 used) Shim set Differential assembly O−ring Plug O−ring 23. 24. 25. 26. 27. 28. 29. 30. 31. 32. 33. 34. 35. 36. 37. 38. 39. 40. 41. 42. 43.
Bevel Gear Case and Axle Case The following procedures assume the rear axle assembly has been removed from the machine. 35 to 41 ft−lb (47 to 56 N−m) Removal 1 5 6 1. Remove the mounting screws, nuts and lock washers. Remove the bevel gear case/axle case assembly and O-ring from the axle support (Fig. 18). 4 2. Mark both right and left bevel gear case/axle case assemblies. 2 3 35 to 41 ft−lb (47 to 56 N−m) IMPORTANT: Do not interchange right and left bevel gear case/axle case assemblies.
5. Remove the knuckle pin mounting screws and the knuckle pin. Remove the gasket and any remaining gasket material from either mating surface (Fig. 21). 17 to 20 ft−lb (23 to 27 N−m) 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. 7. Pull the bevel gear case from the axle case and remove the upper bevel gear and collar from the gear case. 8. Remove the axle case cover screws, cover and the O-ring from the axle case. 9.
Installation 1. Coat new shaft seal with grease and install in axle case as shown (Fig. 23). 3 2 1 Figure 23 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. 24). Tighten cover screws from 17 to 20 ft-lb (23 to 27 N−m). 3. Shaft seal 7 8 3. Slide the bevel gear case over the bevel gear shaft and install the bevel gear and collar.
5. Determine necessary quantity of support shims. A. Lubricate the axle case support bushing with a thin coat of grease and slide axle case support onto knuckle pin. C. Use dial indicator to measure vertical endplay of axle case (Fig. 25). AXLE CASE ASSEMBLY ENDPLAY: 0.001 to 0.008 in. (0.02 to 0.20 mm) 1 VERTICAL ENDPLAY 6 5 2 3 Figure 25 1. Axle case support 2. Axle case 3. Bevel gearcase D. Adjust endplay by increasing or reducing number of axle case support shims. 1 3 4. Dial indicator 5.
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. 27). 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).
Differential Shafts 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 IMPORTANT: Do not interchange right and left differential shaft assemblies. 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. 28). 4 4. Drive the differential shaft out of the bearings. Remove the bearings and bearing shims.
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) Removal 1 4 1. Remove the axle cover mounting screws. Remove the axle cover from the axle case as an assembly (Fig. 30). 3 2. Use a bearing puller to remove the bearing and bevel gear as shown (Fig. 31). 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.
Axles, Planetaries and Brakes This page is intentionally left blank.
Input Shaft/Pinion Gear 35 to 41 ft−lb (47 to 56 N−m) 3 2 1 18 20 19 9 8 7 6 5 17 4 18 15 10 9 16 14 10 13 11 35 to 41 ft−lb (47 to 56 N−m) 12 Figure 33 1. 2. 3. 4. 5. 6. 7. Nut (2 used) Lock washer (2 used) Stud (2 used) Lock nut Stake washer Oil seal O-ring 8. 9. 10. 11. 12. 13. 14. Seal collar Bearing O-ring Input shaft/pinion gear Bearing case Shim Screw (2 used) The following procedures assume the rear axle assembly has been removed from the machine. Removal (Fig. 33) 1.
5. Install a new stake washer. Install the lock nut finger tight. 6. Set the bearing preload by securing the bearing case in a vise. Thread a M12 x 1.5 hex head cap screw into the splined end of the input shaft/pinion gear and slowly tighten the lock nut until 4 to 6 in-lb (0.4 to 0.7 N−m) of force is required to rotate the input shaft/pinion gear in the bearing case. 0.040 in. (1.0 mm) 2 1 7. Secure the lock nut with the stake washer. 8.
Differential Gear The following procedures assume the rear axle assembly has been removed from the machine. 47 to 56 Nm (35 to 41 ft- lb) 1 Removal 1. Remove bevel gear case/axle case assemblies (see Bevel Gear Case/Axle Case Assembly in this section of this manual). IMPORTANT: Do not interchange right and left differential shafts assemblies. 2. Mark and pull the differential shaft assemblies from the axle support. 3. Remove input shaft/pinion gear assembly, shims and O-ring from the axle support (Fig.
Inspection 1. Measure the differential side gear O.D. and the differential case I.D. to determine the side gear to case clearance (Fig. 40). 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. 44): TOE Toe - the portion of the tooth surface at the end towards the center. 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. 47): A. Install thicker or additional bearing case shim(s) to move pinion shaft toward ring gear. Figure 47 B. Install thinner or remove differential bearing shim(s) to move ring gear backward. C.
Chapter 7 Chassis Table of Contents Chassis GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . 2 Operator’s Manual . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Cutting Deck Identification . . . . . . . . . . . . . . . . . . . . 2 SERVICE AND REPAIRS . . . . . . . . . . . . . . . . . . . . . . 4 Steering Column . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Traction Pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Console Arm . . . . . . . . . . . . . . .
General Information Operator’s Manual The Traction Unit and Cutting Deck Operator’s Manuals provide information regarding the operation, general maintenance and maintenance intervals for your Groundsmaster machine. Refer to these publications for additional information when servicing the machine. Cutting Deck Identification Cutting decks on the Groundsmaster 4500--D and 4700--D are identified as shown in Figure 1.
Chassis This page is intentionally blank.
Service and Repairs Steering Column 1 RIGHT 4 2 FRONT 3 20 to 26 ft--lb (28 to 35 N--m) 7 Antiseize Lubricant 10 9 7 to 10 ft--lb (9.5 to 13.5 N--m) 11 5 Antiseize Lubricant 6 8 6 6 12 Figure 2 1. 2. 3. 4. Steering wheel cover Lock nut Steering wheel Flat washer 5. 6. 7. 8. Socket head screw (4 used) Flange head screw (4 used) Steering column Steering control valve Removal (Fig. 2) 1. Park the machine on a level surface, engage the parking brake, lower the cutting decks and stop the engine.
9. Loosen and remove four (4) socket head screws (item 5) that secure steering control valve to steering column. 1 2 4 10.Loosen and remove four (4) socket head screws (item 9) and flange nuts (item 10) that secure steering column to machine. 3 11. Carefully raise steering column assembly from steering control valve and machine. 4 12.Disassemble steering column assembly as needed using Figure 4 as a guide. 5 6 Installation (Fig. 2) Figure 3 1. Roller support 2. Screw (2 used) 3.
Traction Pedal 5 2 28 4 27 6 20 3 14 1 13 7 8 10 11 12 9 31 21 RIGHT 26 30 29 19 FRONT 22 24 25 18 16 32 15 17 23 33 Figure 5 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. Washer head screw (2 used) Reverse pedal pad Pedal assembly Spring pin Forward pedal pad Accelerator pedal Cap screw Flat washer Jam nut Rod end bearing Slotted roll pin Chassis 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22.
IMPORTANT: A properly assembled and calibrated traction pedal position sensor is critical to accurate traction system response and for reliable sensor life. Use care when removing, assembling and calibrating the traction pedal position sensor. Disassembly (Fig. 5) 1. Park machine on a level surface, lower cutting decks, stop engine, apply parking brake and remove key from the ignition switch. 3. Plug machine wire harness connector into traction pedal position sensor (item 29 in Fig. 5). 4.
Console Arm 14 34 28 12 26 7 31 33 13 3 27 38 8 15 20 30 5 19 4 10 25 39 24 10 35 37 41 42 40 11 21 11 17 10 36 32 9 18 11 10 22 1 2 4 RIGHT FRONT 6 16 29 23 Figure 8 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. Console arm frame LH cover RH cover Washer head screw (10 used) Phillips head screw Lock nut Cover plate Flange head screw (2 used) Mount U--nut (5 used) Flange head screw (5 used) Switch panel Rivet (2 used) Arm rest Chassis 15. 16. 17. 18. 19. 20. 21. 22.
Disassembly (Fig. 8) 1. Park machine on a level surface, lower cutting decks, stop engine and engage parking brake. Remove key from ignition switch. 7 3 2 1 5 10 9 11 12 5. Remove console arm covers from machine. As LH cover (item 2) is removed from console arm, unplug wire harness connector from headlight switch. 7. If necessary, remove console panel and supports from machine using Figures 8 and 9 as guides. 4 9 4.
Lift Arms for Cutting Decks #1, #4 and #5 7 1 17 19 30 22 2 3 4 35 4 8 35 9 5 6 20 32 10 34 34 14 2 10 13 11 12 15 33 10 14 20 4 22 33 7 5 1 21 31 34 10 27 19 29 RIGHT 28 17 26 25 24 23 16 FRONT 33 20 35 18 6 19 Figure 10 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12.
5. Loosen and remove lock nut (item 11) from lift arm pivot pin. #4 Deck 6. Support lift arm and pull lift arm pivot pin from lift arm and frame. Locate and remove thrust washers from both sides of lift arm during pivot pin removal. #1 Deck #5 Deck 7. Remove lift arm from machine. 8. Disassemble lift arm as needed using Figure 10 as a guide. #2 Deck #6 Deck (GM4700) 9. Clean lift arm and pivot pin. Inspect lift arm bushings and pivot pin for damage or wear. Replace worn or damaged components.
Lift Arms for Cutting Decks #2 and #3 5 RIGHT FRONT 17 13 16 14 7 18 4 8 6 10 1 15 2 3 Loctite #242 12 9 11 Figure 13 1. 2. 3. 4. 5. 6. Grease fitting Set screw (2 used per stop) Rotation stop Flange head screw Lock nut Slotted roll pin Chassis 7. 8. 9. 10. 11. 12. Pivot pin Bumper Thrust washer Lift cylinder pin Deck pivot shaft Lift arm (#2 deck shown) Page 7 -- 12 13. 14. 15. 16. 17. 18.
Removal (Fig. 13) 1. Park machine on a level surface, lower cutting decks, stop engine, engage parking brake and remove key from the ignition switch. 2. Remove cutting deck from lift arm (see Cutting Deck Operator’s Manual). 3. Remove lift cylinder pin (item 10) that secures lift cylinder to lift arm. 4. Loosen and remove lock nut (item 17) from pivot pin. 5. 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) 1 2 3 135 to 165 ft--lb (184 to 223 N--m) 5 7 1 40 37 9 6 27 25 8 10 30 36 39 26 34 6 31 2 1 41 135 to 165 ft--lb (184 to 223 N--m) 32 14 12 13 4 15 15 11 18 33 1 17 19 20 27 10 28 29 4 38 42 35 16 RIGHT 23 21 24 FRONT 42 22 Figure 15 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14.
Removal (Fig. 15) 1. Park machine on a level surface, lower cutting decks, stop engine, engage parking brake and remove key from the ignition switch. #4 Deck #1 Deck #5 Deck 2. Remove cutting deck from lift arm (see Cutting Deck Operator’s Manual). 3. Remove pin (item 27) that secures lift links (item 10) to lift arm. 4. Loosen and remove lock nut (item 19) from pivot pin (item 28). #6 Deck (GM4700) #2 Deck #3 Deck #7 Deck (GM4700) 5.
Operator Seat 23 27 19 30 28 29 31 26 32 28 28 10 22 18 11 14 29 29 20 24 28 11 25 21 11 16 2 7 RIGHT 5 4 FRONT 6 3 17 12 13 8 15 33 9 8 1 29 Figure 17 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. Seat frame Seat plate Torsion spring Seat plate latch Clevis pin Flat washer Cotter pin Hair pin (4 used) Seat frame rod (2 used) R--clamp (2 used) Flat washer (3 used) Chassis 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22.
Removal (Fig. 17) 1. Park machine on a level surface, lower cutting decks, stop engine, apply parking brake and remove key from the ignition switch. 2. Disconnect seat electrical connector from machine wire harness. 3. Support console arm assembly to prevent it from shifting. 4. Remove flange nut (item 29) and carriage screw (item 28) that secure support bracket (item 24) to support channel (item 22). 5. Remove cap screw (item 30) that secures console arm support (item 23) to coupling nut (item 32). 6.
Operator Seat Service 28 7 6 21 1 2 5 13 12 21 29 22 26 25 31 30 18 19 20 11 4 16 14 17 24 3 23 9 8 27 10 15 Figure 19 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. Backrest cushion Seat cushion LH armrest cover LH armrest Bushing (2 used) Backrest Plug (2 used) Cable tie (3 used) LH adjustment rail Bumper (2 used) Washer Chassis 12. 13. 14. 15. 16. 17. 18. 19. 20. 21.
Disassembly (Fig. 19) Assembly (Fig. 19) 1. Remove seat from machine for service (see Operator Seat Removal in this section). 1. Assemble operator seat using Figure 19 as a guide. 2. Install seat to machine (see Operator Seat Installation in this section). Chassis 2. Disassemble operator seat as necessary using Figure 19 as a guide.
Operator Seat Suspension RIGHT 16 17 FRONT 24 22 25 23 5 18 2 19 21 33 1 20 3 39 14 12 7 35 28 30 6 15 38 27 13 31 4 36 8 29 9 10 26 33 11 34 32 37 Figure 20 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. Cover Cover Level control Air control valve Shock absorber Air spring Air tube assembly Wire harness Compressor Bellows Stop Bumper set (2 used) Roller (4 used) Chassis 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26.
NOTE: Most of the seat suspension components can be serviced with the seat suspension base mounted to the seat plate. If the air spring assembly (item 6) requires removal, the seat suspension base will have to be removed from the seat plate. 4 5 3 Disassembly (Fig. 20) 1. Park machine on a level surface, lower cutting decks, stop engine, apply parking brake and remove key from the ignition switch. 1 2. Remove operator seat from seat suspension (see Operator Seat Removal in this section). 2 3.
Hood 5 RIGHT 26 6 FRONT 4 20 27 24 28 29 26 25 25 8 26 21 26 25 22 1 26 23 25 11 7 3 10 2 15 12 9 14 13 16 19 17 18 Figure 22 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. Screen Latch keeper Pop rivet (2 used) Hood Plastic plug (20 used) Hood screen Radiator mount Flange head screw Hair pin (2 used) Rear bumper Chassis 11. 12. 13. 14. 15. 16. 17. 18. 19. 20.
Removal (Fig. 22) Installation (Fig. 22) 1. Park machine on a level surface, lower cutting decks, stop engine, engage parking brake and remove key from the ignition switch. 1. If components were removed from hood, assemble hood using Figure 22 as a guide. 2. Release hood latches and raise hood. 3. Remove hair pins and washers from pivot pins on radiator frame. 4. Remove hood from pivot pins and machine. 2. Slide hood frame onto radiator frame pivot pins. 3.
This page is intentionally blank.
Chapter 8 Cutting Decks Table of Contents Cutting Decks SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . 3 Operator’s Manual . . . . . . . . . . . . . . . . . . . . . . . . . . 3 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . 4 Factors That Can Affect Quality of Cut . . . . . . . . . 4 SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 ADJUSTMENTS . . . . . . . . . . . . . . . .
Specifications Groundsmaster 4500--D Groundsmaster 4700--D MOUNTING: All cutting decks are supported by independent lift arms and are interchangeable to any cutting deck positions. The Groundsmaster 4500--D uses five (5) cutting decks. The Groundsmaster 4700--D uses seven (7) cutting decks. CONSTRUCTION: Deck chamber and frame are welded steel construction reinforced with channels and plates. HEIGHT--OF--CUT RANGE: 3/4 to 4 inch (19 to 101 mm) in 1/4 inch (6.4 mm) increments.
General Information CAUTION Never install or work on the cutting decks or lift arms with the engine running. Always stop engine and remove key from ignition switch first. Operator’s Manual Cutting Decks The Cutting Deck Operator’s Manual provides information regarding the operation, general maintenance and maintenance intervals for the cutting deck on your Groundsmaster machine. Refer to that publication for additional information when servicing the cutting deck.
Troubleshooting There are a number of factors that can contribute to unsatisfactory quality of cut, some of which may be turf conditions. Turf conditions such as excessive thatch, “sponginess”, uneven ground conditions or attempting to cut off too much grass height may not always be overcome by adjusting the machine. It is important to remember that the lower the height--of--cut, the more critical these factors are.
Special Tools Order special tools from your Toro Distributor. Rear Roller Bearing and Seal Installation Tools These tools are used to assemble the cutting deck rear roller.
Adjustments CAUTION Never install or work on the cutting decks or lift arms with the engine running. Always stop engine and remove key from ignition switch first. See the Cutting Deck Operator’s Manual for adjustment procedures for cutting decks on the Groundsmaster 4500--D and Groundsmaster 4700--D. Blade Stopping Time The blades of the cutting decks are to come to a complete stop in approximately five (5) seconds after the PTO is disengaged.
Cutting Decks This page is intentionally blank.
Service and Repairs CAUTION Never install or work on the cutting decks or lift arms with the engine running. Always stop engine and remove key from ignition switch first. Blade Spindle Assembly 11 2 12 1 3 4 6 5 8 7 RIGHT 88 to 108 ft--lb (120 to 146 N--m) FRONT 9 10 Figure 4 1. 2. 3. 4. Flange nut (6 used) Hydraulic deck motor Spindle plate Cutting deck Cutting Decks 5. 6. 7. 8. O--ring Spindle assembly Drive stud (6 used) Cutting blade Page 8 -- 8 9. 10. 11. 12.
Removal (Fig. 4) 1. Park machine on a level surface, lower cutting decks, stop engine, engage parking brake and remove key from the ignition switch. 1 2. Remove two (2) socket head screws and flat washers that secure hydraulic motor to the cutting deck (Fig. 5). Remove hydraulic motor and O--ring from deck. 2 3. Cover top of spindle to prevent debris from entering spindle. A spindle plug (see Special Tools in this chapter) can be used to cover spindle.
Blade Spindle Service Disassembly (Fig. 6) 1. Remove blade spindle from cutting deck (see Blade Spindle Removal in this section). 2 6 2. Loosen and remove spindle nut from top of spindle shaft. 4 131 to 159 ft--lb (178 to 215 N--m) 3. Remove the spindle shaft from the spindle housing which may require the use of an arbor press. The spindle shaft spacer should remain on the spindle shaft as the shaft is being removed. 11 10 9 12 8 7 4.
3. Using an arbor press, push the bearing cups into the top and bottom of the spindle housing. The top bearing cup must contact the outer bearing spacer previously installed, and the bottom bearing cup must contact the large snap ring. Make sure that the assembly is correct by supporting the first bearing cup and pressing the second cup against it (Fig 8). PRESS 4 4. Pack the bearing cones with grease. Apply a film of grease on lips of oil seals. 5.
Rear Roller 2 29 to 35 ft--lb (40 to 47 N--m) 1 3 4 5 6 7 RIGHT FRONT 29 to 35 ft--lb (40 to 47 N--m) 8 Figure 10 1. Deck frame 2. Rear roller assembly 3. Grease fitting Cutting Decks 4. Roller shaft screw 5. Roller mount 6. Flange head screw Page 8 -- 12 7. Skid bracket 8.
Removal (Fig. 10) 30 ft--lb (41 N--m) 1. Park machine on a level surface, lower cutting decks, stop engine, engage parking brake and remove key from the ignition switch. 4 2. If cutting deck is equipped with a roller scraper (Fig. 11), remove fasteners securing left and right scraper rod brackets to roller mounts. Remove scraper rod assembly. 1 3 29 to 35 ft--lb (40 to 47 N--m) 2 3. Remove four (4) flange head screws securing roller mounts to rear of deck frame.
Rear Roller Service Disassembly (Fig. 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. 3. To remove bearings and bearing 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. 1 2 B. Remove bearing spacer. Remove second bearing from roller using a press. 3 4.
Cutting Decks This page is intentionally blank.
Cutting Deck Carrier Frame Decks #2 and #3 Decks #1, #4 and #5 12 3 11 5 1 1 10 9 4 3 2 Decks #6 and #7 17 15 6 RIGHT 16 7 8 3 FRONT 14 1 13 Figure 19 1. 2. 3. 4. 5. 6. Carrier frame Lynch pin Thrust washer Pivot shaft Lift arm (#4 shown) Flange nut (2 used per deck) Cutting Decks 7. 8. 9. 10. 11. 12. Hardened washer (2 used per deck) Cap screw (2 used per deck) Cap screw Rebound washer Pivot shaft Lift arm (#2 shown) Page 8 -- 18 13. 14. 15. 16. 17.
Removal and Installation (Fig. 19) Each cutting deck is suspended from a carrier frame. The cutting deck carrier frame is attached to the lift arm and allows the cutting deck to pivot on the lift arm pivot shaft. Cutting deck positions are identified in Figure 20. #4 Deck #1 Deck #5 Deck Cutting deck carrier frames are secured to lift arms as follows: 1. Carrier frames for the front three cutting decks (#1, #4 and #5) have a thrust washer between the carrier frame and the lift arm.
This page is intentionally blank.
Chapter 9 Foldout Drawings Table of Contents Groundsmaster 4500--D/4700--D Main Wire Harness (Serial Numbers 400000000 to 403450000) . . . . . . . . . . . . . . . . Main Wire Harness (Serial Numbers above 403450001) . . . . . . . . . . . . . . . . . . . . . . . Seat and Console Wire Harness (Serial number below 399999999) . . . . . . . . . . . . . . . . Seat and Console Wire Harness (Serial number 400000000 to 403450000) . . . . . . . . . Seat and Console Wire Harness (Serial number 403450001) . . . . .
Electrical Drawing Designations The following abbreviations are used for wire harness colors on the electrical schematics and wire harness drawings in this chapter. ABBREVIATION COLOR BK BLACK BR or BN BROWN BU BLUE GN GREEN GY GRAY OR ORANGE PK PINK R or RD RED T TAN VIO VIOLET W or WH WHITE Y or YE YELLOW Numerous harness wires used on Groundsmaster 4500 and 4700 machines include a line with an alternate color.
2.00” BORE 4.20” STROKE 0.630” ROD R STEERING CYLINDER 1.500” BORE 7.00” STROKE 0.630” ROD L LIFT CYLINDERS 1.500” BORE 4.00” STROKE 0.630” ROD 1.500” BORE 7.00” STROKE 0.630” ROD C2 .080 JUNCTION MANIFOLD 6.1 CIR S6 STEERING CONTROL VALVE G3 M3 1500 PSI #1 1.16 CID 1050 PSI P2 FRONT CENTER 3.1 GPM PRV2 RV09 P T .030 .055 CV E S5 3500 PSI CHG M1 M2 ST RV S1 FRONT M4 LEFT G2 1600 PSI 50/50 FLOW DIVIDER CV FD G1 L LC2 P 3.1 GPM G2 LIFT CONTROL MANIFOLD 1 G1 G4 1.
2.00” BORE 4.20” STROKE 0.630” ROD R STEERING CYLINDER 1.500” BORE 7.00” STROKE 0.630” ROD L LIFT CYLINDERS 1.500” BORE 4.00” STROKE 0.630” ROD 1.500” BORE 7.00” STROKE 0.630” ROD C2 .080 JUNCTION MANIFOLD 6.1 CIR S6 STEERING CONTROL VALVE G3 P2 M3 1500 PSI #1 1.16 CID 1050 PSI FRONT CENTER 3.1 GPM PRV2 RV09 P T .030 .030 CV E S5 3500 PSI CHG M1 M2 ST RV S1 FRONT M4 LEFT G2 1600 PSI 50/50 FLOW DIVIDER CV FD G1 L LC2 P 3.1 GPM G2 LIFT CONTROL MANIFOLD 1 G1 G4 1.
2.00” BORE 4.20” STROKE 0.630” ROD R 2.00” BORE 9.00” STROKE 0.750” ROD STEERING CYLINDER L 2.00” BORE 9.00” STROKE 0.750” ROD LEFT WING C4 C3 C2 .063 6.1 CIR 1500 PSI #1 1.16 CID FRONT CENTER PRV2 .080 STEERING CONTROL VALVE 1050 PSI 3.1 GPM 3500 PSI P T C6 .030 S2 S3 S7 JUNCTION MANIFOLD S8 S1 1.500” BORE 3.50” STROKE 0.630” ROD SV2 M1 FRONT M4 LEFT ST FD 1500 PSI #6 1600 PSI G1 L LIFT CONTROL MANIFOLD 1 CHG 4 PSI P1 3 T P2 FAN CONTROL MANIFOLD LC4 2 OR8 .
2.00” BORE 4.20” STROKE 0.630” ROD R 2.00” BORE 9.00” STROKE 0.750” ROD STEERING CYLINDER L 2.00” BORE 9.00” STROKE 0.750” ROD LEFT WING C4 C3 C2 .063 6.1 CIR 1500 PSI #1 1.16 CID FRONT CENTER PRV2 .063 .030 STEERING CONTROL VALVE 1050 PSI 3.1 GPM 3500 PSI P T S2 S3 S7 JUNCTION MANIFOLD S8 S1 1.500” BORE 3.50” STROKE 0.630” ROD #4 1.16 CID SV2 M1 FRONT M4 LEFT M2 TS ST S1 LC2 50/50 FLOW DIVIDER CV G2 M7 FD 1500 PSI #6 1 1600 PSI G1 L P G2 3.
NOTE: REFER TO ELECTRICAL DRAWING DESIGNATIONS IN THIS CHAPTER FOR WIRE COLOR ABBREVIATIONS. TRACTION PEDAL POSITION SENSOR RH (#5) DECK LH (#4) DECK TRACTION PEDAL POSITION SENSOR GM4700- D All relays and solenoids are shown as de-- energized. All ground wires are black.
All relays and solenoids are shown as de-- energized. All ground wires are black. NOTE: REFER TO ELECTRICAL DRAWING DESIGNATIONS IN THIS CHAPTER FOR WIRE COLOR ABBREVIATIONS.
NOTE: REFER TO ELECTRICAL DRAWING DESIGNATIONS IN THIS CHAPTER FOR WIRE COLOR ABBREVIATIONS. All relays and solenoids are shown as de energized. All ground wires are black.
NOTE: REFER TO ELECTRICAL DRAWING DESIGNATIONS IN THIS CHAPTER FOR WIRE COLOR ABBREVIATIONS. All relays and solenoids are shown as de energized. All ground wires are black.
NOTE: REFER TO ELECTRICAL DRAWING DESIGNATIONS IN THIS CHAPTER FOR WIRE COLOR ABBREVIATIONS. All relays and solenoids are shown as de energized. All ground wires are black.
NOTE: REFER TO ELECTRICAL DRAWING DESIGNATIONS IN THIS CHAPTER FOR WIRE COLOR ABBREVIATIONS. All relays and solenoids are shown as de energized. All ground wires are black.
NOTE: REFER TO ELECTRICAL DRAWING DESIGNATIONS IN THIS CHAPTER FOR WIRE COLOR ABBREVIATIONS. All relays and solenoids are shown as de energized. All ground wires are black.
NOTE: REFER TO ELECTRICAL DRAWING DESIGNATIONS IN THIS CHAPTER FOR WIRE COLOR ABBREVIATIONS. All relays and solenoids are shown as de energized. All ground wires are black.
NOTE: REFER TO ELECTRICAL DRAWING DESIGNATIONS IN THIS CHAPTER FOR WIRE COLOR ABBREVIATIONS. All relays and solenoids are shown as de--energized.
NOTE: REFER TO ELECTRICAL DRAWING DESIGNATIONS IN THIS CHAPTER FOR WIRE COLOR ABBREVIATIONS. All relays and solenoids are shown as de--energized.
All relays and solenoids are shown as de-- energized. All ground wires are black. NOTE: REFER TO ELECTRICAL DRAWING DESIGNATIONS IN THIS CHAPTER FOR WIRE COLOR ABBREVIATIONS.
All relays and solenoids are shown as de energized. All ground wires are black. Page 9 - 18 NOTE: REFER TO ELECTRICAL DRAWING DESIGNATIONS IN THIS CHAPTER FOR WIRE COLOR ABBREVIATIONS.
P04 HEADLIGHT RH P79 HEADLIGHT LH A B B A B A F E B A B D A C B P01 TRACTION PEDAL POSITION SENSOR P34 HYDRAULIC TEMP SENDER A P12 PARKING BRAKE SWITCH P07 RH (#5) DECK POSITION SWITCH A B P10 FUEL PUMP B P90 INTERCONNECT TO PWR CTR 1 P96 INTERCONNECT TO PWR CTR A P18 RANGE HI/LOW B B 2 A P88 GM4700 INTERCONNECT C B P87 GM4700 INTERCONNECT GROUND A A D P19 C DECK UP S5 B A P28 HYDROSTAT FWD C E A P93 ENGINE GROUND P24 DECK PTO 2 P20 C DECK FLOAT S6 P13 LH (#4) DECK
RH (#5) DECK POSITION SWITCH LH (#4) DECK POSITION SWITCH TRACTION PEDAL POSITION SENSOR NOTE: THIS DRAWING IDENTIFIES WIRE GAUGE SIZE AND WIRE COLOR. REFER TO ELECTRICAL DRAWING DESIGNATIONS IN THIS CHAPTER FOR ADDITIONAL INFORMATION.
122-- 0663 Rev A Groundsmaster 4500-- D/4700-- D Main Wire Harness (Serial Numbers 315000301 to 399999999) CV Page 9 - 21
NOTE: THIS DRAWING IDENTIFIES WIRE GAUGE SIZE AND WIRE COLOR. REFER TO ELECTRICAL DRAWING DESIGNATIONS IN THIS CHAPTER FOR ADDITIONAL INFORMATION.
122-- 0872 Rev B Groundsmaster 4500-- D/4700-- D Main Wire Harness (Serial Numbers 400000000 to 403450000) CV Page 9 - 23
122-- 0872 Rev B Groundsmaster 4500-- D/4700-- D Main Wire Harness (Serial Numbers 400000000 to 403450000) Page 9 - 24 NOTE: THIS DRAWING IDENTIFIES WIRE GAUGE SIZE AND WIRE COLOR. REFER TO ELECTRICAL DRAWING DESIGNATIONS IN THIS CHAPTER FOR ADDITIONAL INFORMATION.
122-- 1528 Rev A Groundsmaster 4500-- D/4700-- D Main Wire Harness (Serial Numbers Above 403450001) CV Page 9 - 25
122-- 1528 Rev A Groundsmaster 4500-- D/4700-- D Main Wire Harness (Serial Numbers Above 403450001) Page 9 - 26 NOTE: THIS DRAWING IDENTIFIES WIRE GAUGE SIZE AND WIRE COLOR. REFER TO ELECTRICAL DRAWING DESIGNATIONS IN THIS CHAPTER FOR ADDITIONAL INFORMATION.
Groundsmaster 4500--D/4700--D Seat and Console Wire Harness (Serial number below 399999999) Page 9 - 27
NOTE: THIS DRAWING IDENTIFIES WIRE GAUGE SIZE AND WIRE COLOR. REFER TO ELECTRICAL DRAWING DESIGNATIONS IN THIS CHAPTER FOR ADDITIONAL INFORMATION.
122-- 0871 Rev B Groundsmaster 4500-- D/4700-- D Seat and Console Wire Harness (Serial Numbers 400000000 to 403450000) CV Page 9 - 29
NOTE: THIS DRAWING IDENTIFIES WIRE GAUGE SIZE AND WIRE COLOR. REFER TO ELECTRICAL DRAWING DESIGNATIONS IN THIS CHAPTER FOR ADDITIONAL INFORMATION.
122-- 1557 Rev A Groundsmaster 4500-- D/4700-- D Seat and Console Wire Harness (Serial Numbers Above 403450001) CV Page 9 - 31
NOTE: THIS DRAWING IDENTIFIES WIRE GAUGE SIZE AND WIRE COLOR. REFER TO ELECTRICAL DRAWING DESIGNATIONS IN THIS CHAPTER FOR ADDITIONAL INFORMATION.
Groundsmaster 4500--D/4700--D Power Center Wire Harness (Serial number below 403450000) Page 9 - 33
NOTE: THIS DRAWING IDENTIFIES WIRE GAUGE SIZE AND WIRE COLOR. REFER TO ELECTRICAL DRAWING DESIGNATIONS IN THIS CHAPTER FOR ADDITIONAL INFORMATION.
122-- 1547 Rev A Groundsmaster 4500-- D/4700-- D Power Center Wire Harness (Serial Numbers Above 403450001) CV Page 9 - 35
NOTE: THIS DRAWING IDENTIFIES WIRE GAUGE SIZE AND WIRE COLOR. REFER TO ELECTRICAL DRAWING DESIGNATIONS IN THIS CHAPTER FOR ADDITIONAL INFORMATION.
RH (#6) DECK POSITION SWITCH LH (#7) DECK POSITION SWITCH 41 PIN AND BACKSHELL ORIENTATION (TEC--5001) 50 40 31 30 21 20 11 10 1 NOTE TAB POSITION Groundsmaster 4700--D Deck 6 and 7 Wire Harness Page 9 - 37
NOTE: THIS DRAWING IDENTIFIES WIRE GAUGE SIZE AND WIRE COLOR. REFER TO ELECTRICAL DRAWING DESIGNATIONS IN THIS CHAPTER FOR ADDITIONAL INFORMATION.
PIN AND BACKSHELL ORIENTATION FOR P01 & P02 Groundsmaster 4500--D/4700--D (Models 30881 and 30882) Engine Wire Harness Drawing (Serial number below 315000000) Page 9 - 39
NOTE: THIS DRAWING IDENTIFIES WIRE GAUGE SIZE AND WIRE COLOR. REFER TO ELECTRICAL DRAWING DESIGNATIONS IN THIS CHAPTER FOR ADDITIONAL INFORMATION.
122-- 0230 Rev C Groundsmaster 4500-- D/4700-- D (Models 30881 and 30882) Engine Wire Harness Drawing (Serial Numbers 315000001 to 408000000) CV Page 9 - 41
NOTE: THIS DRAWING IDENTIFIES WIRE GAUGE SIZE AND WIRE COLOR. REFER TO ELECTRICAL DRAWING DESIGNATIONS IN THIS CHAPTER FOR ADDITIONAL INFORMATION.
122--2132 Rev A Groundsmaster 4500--D/4700--D (Models 30881 and 30882) Engine Wire Harness Drawing (Serial Numbers Above 408000000) CV Page 9 - 43
122--2132 Rev A Groundsmaster 4500--D/4700--D (Models 30881 and 30882) Engine Wire Harness Drawing (Serial Numbers Above 408000000) Page 9 - 44
122--2133 Rev A Groundsmaster 4500--D/4700--D (Models 30881 and 30882) Engine DPF Sub--Wire Harness Drawing (Serial Numbers Above 408000000) CV Page 9 - 45
PIN AND BACKSHELL ORIENTATION FOR P23 Groundsmaster 4500--D/4700--D (Models 30873 and 30874) Engine Wire Harness Drawing Page 9 - 46
NOTE: THIS DRAWING IDENTIFIES WIRE GAUGE SIZE AND WIRE COLOR. REFER TO ELECTRICAL DRAWING DESIGNATIONS IN THIS CHAPTER FOR ADDITIONAL INFORMATION.
6 5 4 3 2 1 D D C C B B A A Drawing Number: 122--0892 Rev.
6 5 4 3 2 1 D D C C B B A A Drawing Number: 122--0892 Rev.
122--1352 Rev A Groundsmaster 4500--D/4700--D Power Harness Kit -- Wiring Diagram CV Page 9 - 50
