Toro 30881 and 30882 manual

(Models 30873, 30874, 30881 and 30882) Part No. 14205SL Service Manual Groundsmaster R 4500 - - D/4700 - - D Preface The pur pose of t his public ation is to pr ovide the serv ice technic ian with i nfor mati on for tr oubleshooting, t est ing and repair of maj or syst ems and co mponents on the Gr oundsmas ter 4500- - D (Models 30873 and 30881) an[...]

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Gr oundsmas ter 4500 - - D/ 4700 - - D T able Of Contents Chapter 1 - - Safety Gener al Safet y I nst ruc tions 1 - - 2 .................. Jackin g Instructions 1 - - 5 ......................... Safet y and I nst ruc tion Dec als 1 - - 6 ................ Cha pter 2 - - Product R ec ords and Maint enanc e Produc t Records 2 - - 1 ...................[...]

Gr oundsmas ter 4500 - - D/ 4700 - - D This page is intent ional ly blank .[...]

Groundsmaster 4500- - D/4700 - -D Page 1 - - 1 Safet y Chapter 1 Safety T able o f Contents GENERAL SAFETY INSTRUCTIONS 2 ............ Before Oper ating 2 ............................ While Operating 3 ............................ Maintenance and Service 4 .................... JACKING INSTRUCTIONS 5 ..................... SAFETY AND INSTRUCTION DECA[...]

Groundsmaster 4500- - D/4700 - -D Page 1 - - 2 Safety General Safety Instructions The Groun dsmaster 4500 -D and 470 0 - - D have bee n tested and certifi ed by TORO for compliance with exist- ing safety standards and spec ifications. Although haz- ard control and accident prevention partially are dependent upon the d esign and configuration of the[...]

Groundsmaster 4500- - D/4700 - -D Page 1 - - 3 Safet y While Operating 1. Sit on the seat when st arting an d operating th e ma- chine. 2. Before starting the eng ine: A. Engage the par king brake. B. Make sure traction pedal i s in neutral and the PTO switch is OFF (dise ngaged). C. After eng ine is start ed, relea se parking b rake and keep foot [...]

Groundsmaster 4500- - D/4700 - -D Page 1 - - 4 Safety Maintenance and Service 1. The T raction Unit and Cutting Deck Operator ’s Manuals provide information r egarding the operation, general main tenance and maintenanc e intervals for your Groundsmaster machin e . Refer to these publica- tions for a dditional infor mation whe n servicing the ma -[...]

Groundsmaster 4500- - D/4700 - -D Page 1 - - 5 Safet y Jacking Instructions CAUTION When changing attachments, tires or perform- ing other servic e, use correct jacks and sup- ports. Make sure machine is park ed on a solid, level surface such as a concre te floor . Prior to raising machine, remove any attac hments that may interfere with the safe a[...]

Groundsmaster 4500- - D/4700 - -D Page 1 - - 6 Safety Safety and Instruction Decals Numerous safe ty and instruction decals are affixed to the Groundsmaster 4500- -D and 4700 - - D. If any decal becomes illegible o r damaged, install a new decal. De- cal part numbers are listed in y our Parts Catalog.[...]

Groundsmaster 4500- - D/4700 - -D Page 2 - - 1 Product Records a nd Maintenance Chapter 2 Product Records and Maintenance T able o f Contents PRODUCT RECORDS 1 ......................... MAINTENANCE 1 .............................. EQUIV ALENTS AND CONVERSIONS 2 ........... Decimal and Millimeter Equivalents 2 ............ U.S. to Metric Conversions[...]

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

Groundsmaster 4500- - D/4700 - -D Page 2 - - 3 Product Records a nd Maintenance T or que Specifications Recommended fastener torque values are listed in the following tables. For critical applications, as determined by T oro, either t he recommended torque or a torque that is unique to the application is clearly iden tified and spe- cified in this [...]

Groundsmaster 4500- - D/4700 - -D Page 2 - - 4 Product Records a nd Maintenance Standard T orque for Dry , Z inc Plate d and Steel Fasteners (Inch Series) Thread Size Grade 1, 5 & 8w i t hT h i n Height Nuts SAE Grade 1 Bolts, Screws, Studs & Sems with Regular Hei ght Nuts (SAE J995 G rade 2 or St ronger Nuts) SAE Grade 5 Bolts, Sc rews, St[...]

Groundsmaster 4500- - D/4700 - - D Page 2 - - 5 Product Records a nd Maintenance Standard T o rque for Dry , Zinc Plated a nd Steel Fasteners (Metric Series) Thre ad 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 [...]

Groundsmaster 4500- - D/4700 - - D Page 2 - - 6 Product Records a nd Maintenance Other T orque Specifications SAE Grade 8 Steel Set Screws Thread Size Recommended T orque 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 + 3f t - - l b[...]

Groundsmaster 4500- - D/4700 - - D Page 3 - - 1 Y anmar Diesel Engine Chapter 3 Y anmar Diesel Engine T able o f Contents SPECIFICA TIONS 2 ............................ Models 3087 3 and 30874 2 .................... Models 3088 1 and 30882 3 .................... GENERAL INFORMA TION 4 ..................... Operator ’s Manu als 4 .................[...]

Groundsmaster 4500- - D/4700 - - D Page 3 - - 2 Y anmar Diesel Engine Specifications (Models 30873 and 30874) Item Description Make / Designation Y anmar Model 4TNV84T- - ZMTR: 4 - - Cycle, 4 Cylinder , W ater C ooled, T urboc harged, T ier 4i Diesel Engine Bore 3.307 in (84 mm) Stroke 3.543 in (90 mm) T o tal Dis place ment 121.7 in 3 (19 95 c c) [...]

Groundsmaster 4500- - D/4700 - - D Page 3 - - 3 Y anmar Diesel Engine Specifications (Models 30881 and 30882) Item Description Make / Designation Y anmar Model 4TNV86CT - - DT R: 4 - - Cycle, 4 Cylinder , W ater Cooled, Turbocharged, T ier 4 Diesel Engine Bore 3.386 in (86 mm) Stroke 3.543 in (90 mm) T otal Displacement 127 .5 in 3 (2090 cc) Firing[...]

Groundsmaster 4500- - D/4700 - - D Page 3 - - 4 Y anmar Diesel Engine General Information This Chapter gives information about specifications and repair of the diese l engine used in the Groundsma ster 4500 - - D and 4 700 - - D. General maintenance pro cedures are described in your T raction Unit Operator ’s Manual. Inform a tion on engine troub[...]

Groundsmaster 4500- - D/4700 - - D Page 3 - - 5 Y anmar Diesel Engine Engine Electronic Control Unit (EC U) The Y anmar engine that powers y our Groundsmaster uses an electronic cont rol unit (ECU) fo r engine man- agement and also to co mmunicate wit h the machine TEC controllers and the operator Info Center display on the mach ine. All wir e harn[...]

Groundsmaster 4500- - D/4700 - - D Page 3 - - 6 Y anmar Diesel Engine Y anmar Engine: Models 3087 3 and 30874 The engine u sed on Groundsmaster mo dels 30873 and 30874 is a Y anm ar TNV Series, tu rbochar ged, diesel engine that complies with EP A interim T ier 4 emission regulations. Engi ne features include an electronic con- trol unit (ECU) cont[...]

Groundsmaster 4500- - D/4700 - - D Page 3 - - 7 Y anmar Diesel Engine Assist regeneration occurs if the engine ECU senses that the DPF b ackpressure has increase d to its max im- um threshold. During assist regener ation, the intake throttle valve limits the air flow into the eng ine while the injectors add additional fuel. This process in creases [...]

Groundsmaster 4500- - D/4700 - - D Page 3 - - 8 Y anmar Diesel Engine Service and Repairs Air Cleaner Sy stem Figure 6 FRONT RIGHT 1. Air cleaner assembly 2. Air cleaner mount 3. Indicator 4. Adapt er 5. Air cleaner strap 6. Socket head screw (2 used) 7. Flat washer (2 used) 8. Flat washer (2 used) 9. Lock nut (2 used) 10. Spring (2 used) 1 1. Cap [...]

Groundsmaster 4500- - D/4700 - - D Page 3 - - 9 Y anmar Diesel Engine Removal (Fig. 6) 1. Park machine on a level s urface, lower cu tting decks, stop engine, apply parking brake and remove key from the ignition switch . 2. Raise and support h ood. 3. Remove air clea ner components as needed using Figure 6 as a guide. Installation (Fig. 6) IMPORT A[...]

Groundsmaster 4500- - D/4700 - - D Page 3 - - 1 0 Y anmar Diesel Engine Fuel System Figure 9 1. Fuel suction tube 2. Fuel gauge 3. Fuel hose (supply) 4. Return fitting 5. Fuel hose (return) 6. Fuel tank cap 7. Bus hing ( 2 used ) 8. Hose clamp (6 used) 9. Fuel tank 10. Cap screw (2 used) 11 . C l a m p ( 2 u s e d ) 12. Flange nut (2 used) 13. Fuel[...]

Groundsmaster 4500- - D/4700 - - D Page 3 - - 1 1 Y anmar Diesel Engine DANGER Because diesel fuel is highly flammable, use cau- tion when storing or handling i t. 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[...]

Groundsmaster 4500- - D/4700 - - D Page 3 - - 1 2 Y anmar Diesel Engine Radiator and Oil Cooler Assem bly 1. Radiator/oil cooler assembly 2. Cap screw (4 used) 3. W asher (4 used) 4. Fan 5. Plenum assembly 6. Cap screw (6 used) 7. Flange nut (6 used) 8. Air intake hose 9. Hose 10. Hose clamp (4 used) 1 1. Upper radiator shroud 12. Lower radiator sh[...]

Groundsmaster 4500- - D/4700 - - D P age 3 - - 13 Y anmar Diesel Engine Removal (Fig. 1 1) 1. Park machine on a level s urface, lower cu tting decks, stop engine, engage parking brake and remove key from the ignition switch . 2. Remove hood fro m the machin e (see Hood Rem oval in the Service and Repairs section of Chapter 7 - - Chas- sis). CAUTION[...]

Groundsmaster 4500- - D/4700 - - D Page 3 - - 1 4 Y anmar Diesel Engine 13. Plug all radiator/oil cooler and hose op enings to pre- vent contamination. 14. If necessary , remove draincock (item 7 in Fig. 13), plug (item 6 in Fig. 13) and hydraulic pl ug (item 8 in Fig. 13) from radiator/oil cooler . 15. If hydraulic fittings (item 3 in Fig. 13) are[...]

Groundsmaster 4500- - D/4700 - - D P age 3 - - 15 Y anmar Diesel Engine This page is intentionally blank. Ya n m a r Diesel Engine[...]

Groundsmaster 4500- - D/4700 - - D Page 3 - - 1 6 Y anmar Diesel Engine Engine Figure 14 1. LH front engine mount br acket 2. RH front engine mount bracket 3. LH rear engine mount b racket 4. RH rear engine mount bracket 5. Lock washer (16 used) 6. Cap scre w (16 u sed) 7. Engine mount (4 used) 8. Flange head screw (8 used) 9. Fl ange n ut (13 used[...]

Groundsmaster 4500- - D/4700 - - D P age 3 - - 17 Y anmar Diesel Engine Engine Removal (Fig. 14) 1. Park machine on a level s urface, lower cu tting decks, stop engine, engage parking brake and remove key from the ignition switch . 2. Remove hood fro m the machin e (see Hood Rem oval in the Service and Repairs section of Chapter 7 - - Chas- sis). 3[...]

Groundsmaster 4500- - D/4700 - - D Page 3 - - 1 8 Y anmar Diesel Engine 10. Support hydraulic pump assembly to prevent it from shifting or falling. Remove fastener s that secure piston (traction) pump to engi ne (see Piston (T raction) Pump in the Service and Repairs section of Chapter 4 - - Hy- draulic System). 1 1. Make sure all cable ties securi[...]

Groundsmaster 4500- - D/4700 - - D P age 3 - - 19 Y anmar Diesel Engine 13. Check position of wires, fuel lines and hyd raulic hoses for proper clearance with rotating, high temp era- ture and moving compone nts. 14. Connect positive battery cable to battery first and then negati ve battery cable. Secur e battery cover to ma- chine. 15. Check and a[...]

Groundsmaster 4500- - D/4700 - - D Page 3 - - 2 0 Y anmar Diesel Engine Pump Ada pter Plate Figure 17 1. Flyw heel p late 2. Hardened washer (8 used) 3. Spring coupler 4. Cap screw (8 used) 5. Cap screw with patchlock (8 used) 6. Hardened washer (8 used) 7. Engine assembly FRON T RIGHT 1 3 5 2 4 6 7 29 to 33 ft - - lb (40 to 44 N - - m) Boss 29 to [...]

Groundsmaster 4500- - D/4700 - - D P age 3 - - 21 Y anmar Diesel Engine Coupler Removal (Fig. 17) NOTE: The hydraulic pump assembly ne eds to be re- moved from engine befor e coupler can be removed . 1. If engine is in machine, remove hydrau lic pump as- sembly (see Piston (T raction) Pump in the Service and Repairs section of Chapter 4 - - Hydraul[...]

Groundsmaster 4500- - D/4700 - - D Page 3 - - 2 2 Y anmar Diesel Engine Exhaust System (Mod els 30881 and 30882) Figure 19 1. Gasket 2. Exhaust assembly stay 3. Exhaust assembly stay 4. Exhaust assembly stay 5. Exhaust assembly stay 6. Nut 7. DOC t emp senso r (inle t) 8. DOC temp sensor (outlet) 9. Nut ( 4 used) 10. DOC assembly 1 1. Nut (3 used) [...]

Groundsmaster 4500- - D/4700 - - D P age 3 - - 23 Y anmar Diesel Engine Groundsmaster models that are powered by a diesel en- gine that complies with EP A T ier 4 emission regulations are equipped with an exhau st system that includes a diesel oxidation catalyst (DOC) and a diesel particulate filter (DPF). These exhau st components require service [...]

Groundsmaster 4500- - D/4700 - - D Page 3 - - 2 4 Y anmar Diesel Engine This page is intentionally blank.[...]

Groundsmaster 4500- - D/4700 - - D Hydraulic System Pa ge 4 - - 1 Chapter 4 Hydraulic System T able o f Contents SPECIFICA TIONS 2 ............................ GENERAL INFORMA TION 3 ..................... Operator ’s Manu al 3 .......................... Check Hydraulic Fluid 3 ....................... T owing T raction Unit 4 .....................[...]

Groundsmaster 4500- - D/4700 - - D Hydraulic System Page 4 - - 2 Specifications Item Description Piston (Traction ) Pump Sauer - - Danfoss V ariable Displacement Axial Piston Pump Maximum Displacement (per revolution) 2.75 in 3 (45 c c) System Relief Pressure: Forward 4350 PSI (300 bar) System Relief Pressure: Re v erse 5000 PSI (345 bar) Charge Pr[...]

Groundsmaster 4500- - D/4700 - - D Hydraulic System Pa ge 4 - - 3 General Information Operator ’ s Manual The Operator ’s Manu al provides info rmation regarding the operation, general main tenance and maintenance intervals for your Ground smaster machine. Refer to that publication for additional information when servicing the machine. Check Hy[...]

Groundsmaster 4500- - D/4700 - - D Hydraulic System Page 4 - - 4 T owing T raction Unit IMPORT ANT : If towing limits a re exceeded, severe damage to the piston pump may occur . If it becomes necessary to tow (or push) the machine, tow (or push) in a forward direc tion only , at a speed below 3 mph (4.8 kph) and for a dis tance less tha n 1/4 mile [...]

Groundsmaster 4500- - D/4700 - - D Hydraulic System Pa ge 4 - - 5 Relieving Hydraulic System Pressu re Before disconnectin g or performin g any work on the hy- draulic system, all pressure in the hydraulic system must be relieved. Park machine on a level surface, make sure that PT O switch is OFF , lower cutting decks fully , stop engine and en gag[...]

Groundsmaster 4500- - D/4700 - - D Hydraulic System Page 4 - - 6 Hydraulic Hoses Hydraulic hoses are subject to extre me conditions su ch as pressure d ifferentials du ring operation and exposure to weather , sun, che micals, very warm s torage cond i- tions or mishandling during operation and mainte nance. These conditions can ca use hose damage a[...]

Groundsmaster 4500- - D/4700 - - D Hydraulic System Pa ge 4 - - 7 Hydraulic Hose and T ube 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. 2. As a preventative measure aga inst leakage, it is rec- ommended that t he f[...]

Groundsmaster 4500- - D/4700 - - D Hydraulic System Page 4 - - 8 Hydraulic Fitting Installation (SAE S traight Thread O - - R ing Fitting into Component Port) Non - - Adjustable Fitting (Fig. 6) 1. Make sure al l threads and sealing surfaces of fitting and component port are free of burrs, nicks, scratches or any foreign m aterial. 2. As a prevent [...]

Groundsmaster 4500- - D/4700 - - D Hydraulic System Pa ge 4 - - 9 Adjustable Fitting (Fi g. 8) 1. Make sure all thr eads and sealing surfa ces of fitting and component port are free of burrs, nicks, scratches or any foreign material. 2. As a preventative measure aga inst leakage, it is rec- ommended that the O- - ring be rep laced any time the conn[...]

Groundsmaster 4500- - D/4700 - - D Hydraulic System Page 4 - - 10 Hydraulic Schematics Hydraulic Schematic Groundsmaster 45 00 - - D All solenoids are shown as de - - energized NOTE: A larger hydraulic schematic is included in Chapter 9 - - F oldout Drawings 0.630” ROD 1050 1600 PSI 6.2 GPM 11 . 4 G P M 3500 PSI 3500 PSI 1500 PSI 1500 PSI P1 P2 T[...]

Groundsmaster 4500- - D/4700 - - D Hydraulic System Page 4 - - 1 1 Hydraulic Schematic Groundsmaster 4700- - D All solenoids are shown as de - - ener giz ed NOTE: A larger hydraulic schematic is included in Cha pter 9 - - Foldout Drawings 0.630 ” ROD 1050 6.2 GPM 11 . 4 G P M T PRV S1 CV FD P2 P1 ST L M1 M2 PE T R 50/50 FLOW DIVID ER FA N C O N T[...]

Groundsmaster 4500- - D/4700 - - D Hydraulic System Page 4 - - 12 Hydraulic Flow Diagrams T raction Circuit: LOW Speed (GM 4500 - - D Forward Shown) Working Pressure Low Pressure (Charge) Return or Suction Flow Groundsmaster 450 0 - - D/4700 - - D 0.630” ROD 1050 1600 PSI 6.2 GPM 11 . 4 G P M 3500 PSI 3500 PSI 1500 PSI 1500 PSI P1 P2 T1 G1 PRV1 P[...]

Groundsmaster 4500- - D/4700 - - D Hydraulic System Page 4 - - 13 T raction Circuit: LOW S peed (Mow) The traction circuit piston pump is a variable d isplace- ment pump that is directly coupled to the en g ine fly- wheel. This pump utilizes an in tegral electro - - hydraulic servo piston assembly that co ntrols the rate and dire c- tion of hydraul[...]

Groundsmaster 4500- - D/4700 - - D Hydraulic System Page 4 - - 14 T raction Circuit: H I Speed (GM 4500 - - D Forward Shown) Working Pressure Low Pr ess ure (C harge) Return or Suction Flow Groundsmaster 450 0 - - D/4700 - - D 0.630” ROD 1050 1600 PSI 6.2 GPM 11 . 4 G P M 3500 PSI 3500 PSI 1500 PSI 1500 PSI P1 P2 T1 G1 PRV1 PRV2 LC1 LC2 M1 M2 M3 [...]

Groundsmaster 4500- - D/4700 - - D Hydraulic System Page 4 - - 15 T raction Circuit: HI Spe ed (T ransport) The traction circuit piston pump is a variable d isplace- ment pump that is directly coupled to the en g ine fly- wheel. This pump utilizes an in tegral electro - - hydraulic servo piston assembly that co ntrols the rate and dire c- tion of h[...]

Groundsmaster 4500- - D/4700 - - D Hydraulic System Page 4 - - 16 Working Pressure Low Pressure (Charge) Return or Suction Flow Ground smaster 4500 - - D Lower Cutting Decks Lift Switch Pressed to Lower Decks 0.630” ROD 1050 1600 PSI 6.2 GPM 11 . 4 G P M 3500 PSI 3500 PSI 1500 PSI 1500 PSI P1 P2 T1 G1 PRV1 PRV2 LC1 LC2 M1 M2 M3 M4 T RV0 9 PRV S1 [...]

Groundsmaster 4500- - D/4700 - - D Hydraulic System Page 4 - - 17 Lower Cutting Decks: Groundsmaste r 4500 - - D A four section gear pump is coupled to the piston ( trac- tion) pump . The third gea r pump sectio n supplies hy - draulic flow to both the lif t control manifold and the steering control valve . Hydraulic flow from this pump section is [...]

Groundsmaster 4500- - D/4700 - - D Hydraulic System Page 4 - - 18 Wo rking Pressure Low Pressure (Charge) Return or Sucti on Flow Groundsmaster 4700- - D Lower Cutting Decks All Lift Switches Pressed to Low er Decks 0.630” ROD 1050 6.2 GPM 11 . 4 G P M T PRV S1 CV FD P2 P1 ST L M1 M2 PE T R 50/50 FL OW DIVIDER FAN CONTROL MANIFOLD MANIFOLD 30.5 G[...]

Groundsmaster 4500- - D/4700 - - D Hydraulic System Page 4 - - 19 Lower Cutting Decks: Groundsmaste r 4700 - - D A four section gear pump is coupled to the piston ( trac- tion) pump . The third gea r pump sectio n supplies hy - draulic flow to both the lif t control manifold and the steering control valve . Hydraulic flow from this pump section is [...]

Groundsmaster 4500- - D/4700 - - D Hydraulic System Page 4 - - 20 Wor king Pressure Low Pressure (Charge) Return or Suction Flow Groundsmaster 4500- - D Raise Cutting Decks Lift Switch Pressed to Raise Decks 0.630” ROD 1050 1600 PSI 6.2 GPM 11 . 4 G P M 3500 PSI 3500 PSI 1500 PSI 1500 PSI P1 P2 T1 G1 PRV1 PRV2 LC1 LC2 M1 M2 M3 M4 T RV09 PRV S1 CV[...]

Groundsmaster 4500- - D/4700 - - D Hydraulic System Page 4 - - 21 Raise Cutting Decks: Groundsmaster 450 0 - - D A four section gear pump is coupled to the piston ( trac- tion) pump . The third gea r pump sectio n supplies hy - draulic flow to both the lif t control manifold and the steering control valve . Hydraulic flow from this pump section is [...]

Groundsmaster 4500- - D/4700 - - D Hydraulic System Page 4 - - 22 Wor ki n g Pr es s u re Low Pressure (Charge) Return or Sucti on Flow Groundsmaster 4700- - D All Lift Switches Pressed to Raise Decks Raise Cutting Decks 0.630” RO D 1050 6.2 GPM 11 . 4 G P M T PRV S1 CV FD P2 P1 ST L M1 M2 PE T R 50/50 FLOW DIVIDE R FAN CONTROL MANIFOLD MANIFOLD [...]

Groundsmaster 4500- - D/4700 - - D Hydraulic System Page 4 - - 23 Raise Cutting Decks: Groundsmaster 470 0 - - D A four section gear pump is coupled to the piston ( trac- tion) pump . The third gea r pump sectio n supplies hy - draulic flow to both the lif t control manifold and the steering control valve . Hydraulic flow from this pump section is [...]

Groundsmaster 4500- - D/4700 - - D Hydraulic System Page 4 - - 24 Mow Circuit (GM 4500 - - D Shown) Wo rking Pressure Low Pressure (Charge) Return or Sucti on Flow Groundsmaster 4500- - D/4700 - - D 0.630” RO D 1050 1600 PSI 6.2 GPM 11 . 4 G P M 3500 PSI 3500 PSI 1500 PSI 1500 PSI P1 P2 T1 G1 PRV1 PRV2 LC1 LC2 M1 M2 M3 M4 T RV09 PRV S1 CV FD P2 P[...]

Groundsmaster 4500- - D/4700 - - D Hydraulic System Page 4 - - 25 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 suppli es hydraulic flow to decks 5, 3 a nd 2 (also deck 7 on the G M 4700 - - D), while the second gear pump section supplies decks 1 and 4 (also[...]

Groundsmaster 4500- - D/4700 - - D Hydraulic System Page 4 - - 26 Cutting Deck Blade Braking When the operator turns th e PTO switch OFF (or if the decks are raised), deck manifold solenoid va lves (PRV1, PRV2, SV1 and SV2) are d e - - ener gized. Th e valves will shift to direct oil away from the deck motors and toward the oi l cooler and filter .[...]

Groundsmaster 4500- - D/4700 - - D Hydraulic System Page 4 - - 27 This page is intentionally blank. Hydraulic System[...]

Groundsmaster 4500- - D/4700 - - D Hydraulic System Page 4 - - 28 Steering Circuit (GM 4500 - - D Right T urn Shown) Working Pressure Low Pr ess ure (C harge) Return or Suction Flow Groundsmaster 450 0 - - D/4700 - - D 0.630” ROD 1050 1600 PSI 6.2 GPM 11 . 4 G P M 3500 PSI 3500 PSI 1500 PSI 1500 PSI P1 P2 T1 G1 PRV1 PRV2 LC1 LC2 M1 M2 M3 M4 T RV0[...]

Groundsmaster 4500- - D/4700 - - D Hydraulic System Page 4 - - 29 Steering Circuit A four section gear pump is coupled to the piston ( trac- tion) pump . The third gea r pump sectio n supplies hy - draulic flow to the ste ering con trol valv e and the lift/lower control valve. Pump h ydraulic flow is delivered to the two circuits through a proporti[...]

Groundsmaster 4500- - D/4700 - - D Hydraulic System Page 4 - - 30 Engine Cooling Fan Circuit (GM 4500 - - D Normal Fan Direction Shown) Working Pressure Low Pressure (Charge) Return or Suction Flow Groundsm aster 4500 - - D /4700 - - D 0.630” ROD 1050 1600 PSI 6.2 GPM 11 . 4 G P M 3500 PSI 3500 PSI 1500 PSI 1500 PSI P1 P2 T1 G1 PRV1 PRV2 LC1 LC2 [...]

Groundsmaster 4500- - D/4700 - - D Hydraulic System Page 4 - - 31 Engine Cooling Fan Circuit A four section gear pump is coupled to the piston ( trac- tion) pump. The fina l gear pump section (farthest from the piston pump) su pplies hydraulic fl ow for the hydrau- lic engine cooling fan m otor . The fan control manifol d controls the operation of [...]

Groundsmaster 4500- - D/4700 - - D Hydraulic System Page 4 - - 32 Special T ools Order these spe cial tools from you r T oro Distribut or . Hydraulic Pressure T est Kit Use to take various pressure read ings for diagnostic tests. Quick disconnect fitti ngs provided attach directly to mating fittings on machine test ports without tools. A high press[...]

Groundsmaster 4500- - D/4700 - - D Hydraulic System Page 4 - - 33 40 GPM Hydraulic T ester (Pressure and Flow) Use to test hydraulic circuits and components for flow and pressure capacities as recommended in the T estin g section of this chapte r . This tester includes the f ollowing: 1. LOAD V AL VE: A simulated working load is create d in the cir[...]

Groundsmaster 4500- - D/4700 - - D Hydraulic System Page 4 - - 34 High Flow Hydraulic Filter Kit The high flow hydraulic filt er kit is designed with large flow (40 GPM/150 LPM) and high pre ssure (5000 PSI/345 bar) capabilities. This kit provides for bi - - direc- tional filtration whi ch prevents filtered debris from being allowed back into the c[...]

Groundsmaster 4500- - D/4700 - - D Hydraulic System Page 4 - - 35 Hydraulic T est Fitting Kit This kit includes a variety of O - - ring Face Seal fittings to enable you to co nnect test gauges in to the system. The kit includes: tee’ s, unions, reducers, plugs, caps and male test fittings. T oro Part Number: TOR407 9 Figure 32 Measuring C ontaine[...]

Groundsmaster 4500- - D/4700 - - D Hydraulic System Page 4 - - 36 Remote Starter Switch After flushing the hydraulic system or replacing a hy- draulic component (e.g. gear pump, pi ston pump, wheel motor), it is nec essary to pr ime the hydr aulic pumps. A remote starter switch (Fig. 35) can be used for this pur- pose. Obtain a remo te starter swit[...]

Groundsmaster 4500- - D/4700 - - D Hydraulic System Page 4 - - 37 T roubleshooting The charts that follow conta in information to assist in hy- draulic system troubleshooting. There may possib ly be more than one cause for a machi ne malfunction. Refer to the T esting section of this Chapter for prec au- tions and specific testing procedures. Gener[...]

Groundsmaster 4500- - D/4700 - - D Hydraulic System Page 4 - - 38 T raction Circuit Pr oblems NOTE: When troubleshooting tra ction circuit problems, if a problem exist s in both low (mow) an d high (transp ort) speeds, consider a faulty component that af fects the en- tire traction circuit (e.g. char ge circuit, traction circuit re- lief valves, pi[...]

Groundsmaster 4500- - D/4700 - - D Hydraulic System Page 4 - - 39 Mow Circuit Problems Problem Possible Cause None of the cutting decks w ill oper- ate. NOTE: T o engage the mow circu it, t h es e a tm u s tb eo c c u p i e d ,t h ec u t - ting deck(s) must be fully lowered, the traction speed m ust be in the LOW (mow) position and the PT O switch [...]

Groundsmaster 4500- - D/4700 - - D Hydraulic System Page 4 - - 40 Mow Circuit Problems (Continued) Problem Possible Cause All cutting decks opera te slowly . Engine RP M is low . Deck motor is damaged. First and second gear pump sections are worn or damaged. Cutting deck stop s under load. Relief valve in deck control manifold is bypassing. T racti[...]

Groundsmaster 4500- - D/4700 - - D Hydraulic System Page 4 - - 41 Lift/Lower Circuit Problems Problem Possible Cause Cutting decks will not raise. NOTE: Operator m ust be in seat in order to raise t he cutting decks. Operator seat is unoccupied. Hydraulic oil level in reservoir is low . Electrical problem exists that preve nts lift control manifold[...]

Groundsmaster 4500- - D/4700 - - D Hydraulic System Page 4 - - 42 Engine Cooling Fan Cir cuit Problems Problem Possible Cause Cooling fan runs on ly in forward di- r e c t i o n( f a nd o e sn o tr u ni nr e v e r s e direction). Fan control manifold so lenoid cartridge valve (S 1) is faulty . Electrical problem exists that prevents fa n control ma[...]

Groundsmaster 4500- - D/4700 - - D Hydraulic System Page 4 - - 43 This page is intentionally blank. Hydraulic System[...]

Groundsmaster 4500- - D/4700 - - D Hydraulic System Page 4 - - 44 Te s t i n g The most effective method for isol ating problems in the hydraulic system is by using hydraulic test equipment such as pressure gauges and flo w m eters in the ci rcuits during vari ous operatio nal checks (S ee the Special T ools section in this chapter). IMPORT ANT : A[...]

Groundsmaster 4500- - D/4700 - - D Hydraulic System Page 4 - - 45 Which Hydraulic T ests Are Necessary? Before begin ning any hydra ulic test, i dentify if t he prob - lem is related to the traction circui t , cutting (mow) circuit, lift/lower circuit, steering circuit o r engine cooling fan cir- cuit. Once the faulty system has been i dentified, p[...]

Groundsmaster 4500- - D/4700 - - D Hydraulic System Page 4 - - 46 T raction Circuit Charge Pre ssure (Using Pressure Gauge) PRESSURE GAUGE 1050 1600 PSI 6.2 GPM 11 . 4 G P M 3500 PSI 3500 PSI 1500 PSI 1500 PSI P1 P2 T1 G1 PRV1 PRV2 LC1 LC2 M1 M2 M3 M4 T RV0 9 PRV S1 CV FD P2 P1 ST L M1 M2 PE T R P CHG G1 C2 TS RV S5 T2 FRONT LEFT FRONT RIGHT REAR L[...]

Groundsmaster 4500- - D/4700 - - D Hydraulic System Page 4 - - 47 NOTE: T h et r a c t i o nc h a r g ec i r c u i ti sd e s i g n e dt or e - place loss of hydraulic fluid fro m the closed loop traction circuit. Procedure for T raction Circuit Charge Pr essure Te s t CAUTION Prevent personal injury and/or damage to equip- ment. Read all W ARNINGS,[...]

Groundsmaster 4500- - D/4700 - - D Hydraulic System Page 4 - - 48 T raction Circuit Relief Pr essure (Using Pressure Gauge) FORW ARD DIRECTION TEST SHOWN PRESSURE GAUGE 1050 1600 PSI 6.2 GPM 11 . 4 G P M 3500 PSI 3500 PSI 1500 PSI 1500 PSI P1 P2 T1 G1 PRV1 PRV2 LC1 LC2 M1 M2 M3 M4 T RV09 PRV S1 CV FD P2 P1 ST L M1 M2 PE T R P CHG G1 C2 TS RV S5 T2 [...]

Groundsmaster 4500- - D/4700 - - D Hydraulic System Page 4 - - 49 Procedure for T raction Circuit Relief Pressure Te s t CAUTION Prevent personal injury and/or damage to equip- ment. Read all W ARNINGS, CAUTIONS and Pre - cautions for Hydraulic T esting at the beginning of this section. 1. Make sure hydrau lic oil is at normal operating te m- perat[...]

Groundsmaster 4500- - D/4700 - - D Hydraulic System Page 4 - - 50 Reverse T raction Circuit Reducing V alve (PR) Pressure (Using Pressu re Gauge) 1050 1600 PSI 6.2 GPM 11 . 4 G P M 3500 PSI 3500 PSI 1500 PSI 1500 PSI P1 P2 T1 G1 PRV1 PRV2 LC1 LC2 M1 M2 M3 M4 T RV09 PRV S1 CV FD P2 P1 ST L M1 M2 PE T R P CHG G1 C2 TS RV S5 T2 FRONT LEFT FRONT RIGHT [...]

Groundsmaster 4500- - D/4700 - - D Hydraulic System Page 4 - - 51 Procedure for Revers e T raction Circuit Reducing Va l v e ( P R ) P r e s s u r e Te s t NOTE: When in reverse, pressure reducing valve (P R) limits the pressure to the rear axle motor to 450 PSI (31 bar) so the rear wheels will no t scuff the t urf. CAUTION Prevent personal injury [...]

Groundsmaster 4500- - D/4700 - - D Hydraulic System Page 4 - - 52 Rear T raction Circuit Re lief (R V) Pressure (Us ing Pressure Gauge) PRESSURE GAUGE 1050 1600 PSI 6.2 GPM 11 . 4 G P M 3500 PSI 3500 PSI 1500 PSI 1500 PSI P1 P2 T1 G1 PRV1 PRV2 LC1 LC2 M1 M2 M3 M4 T RV0 9 PRV S1 CV FD P2 P1 ST L M1 M2 PE T R P CHG G1 C2 TS RV S5 T2 FRONT LEFT FRONT [...]

Groundsmaster 4500- - D/4700 - - D Hydraulic System Page 4 - - 53 Procedure for Rear T raction Circuit Relief V alve (R V) Pressure Te s t NOTE: Adjustable relief valve (RV) in the rear traction control manifo ld reduces rear axle motor pressure created in down hill, dynamic braking conditions to pre- vent rear wheel lock up. CAUTION Prevent person[...]

Groundsmaster 4500- - D/4700 - - D Hydraulic System Page 4 - - 54 Piston (T raction) Pump Flow (Using T ester with Pressur e Gauge & Flow Mete r) TESTER 4350 PSI 250 PSI 5 000 PSI EU - - 2600 / 1200 RPM 0.56 CID 0.56 CID 1.03 CID 1.03 CID 2.75 CID 50 PSI ENGINE T4 - - 2700 / 1200 RPM PISTON PUMP FROM REAR TRACTION MANIFOLD REAR DECK & COOLI[...]

Groundsmaster 4500- - D/4700 - - D Hydraulic System Page 4 - - 55 Procedure for Piston (T raction) Pump Flow Te s t This test me asures pisto n (tractio n) pump ou tput (flow) . During this tes t, pump load is creat ed at the flow meter using the adjustable loa d v alve on the tester . NOTE: Before perfor ming piston pum p flow test, make sure that[...]

Groundsmaster 4500- - D/4700 - - D Hydraulic System Page 4 - - 56 Cutting Deck Circuit Pressure (Using Pressu re Gauge) DECKS 1 AND 4 SHOWN TEST FO R GM4500 - - D PRESSURE GAUGE 6.2 GPM 11 . 4 G P M 3500 PSI 3500 PSI 1500 PSI 1500 PSI P1 P2 T1 G1 PRV1 PRV2 LC1 LC2 M1 M2 M3 M4 RV0 9 T2 FRONT LEFT FRONT RIGHT REAR LEFT RV8 4350 PSI 30.5 GPM 250 PSI 5[...]

Groundsmaster 4500- - D/4700 - - D Hydraulic System Page 4 - - 57 Procedure for Cutting Deck Circuit Pressure Te s t CAUTION Prevent personal injury and/or damage to equip- ment. Read all W ARNINGS, CAUTIONS and Pre - cautions for Hydraulic T esting at the beginning of this section. 1. Make sure hydrau lic oil is at normal operating te m- perature [...]

Groundsmaster 4500- - D/4700 - - D Hydraulic System Page 4 - - 58 Cutting Deck Circuit Relief Pre ssure (Using T ester with Pressure Ga uge & Flow Meter) SECOND PUMP SECTION SHOWN TEST F OR GM4500 - - D TESTER 6.2 GPM 11 . 4 G P M 3500 PSI 3500 PSI 1500 PSI 1500 PSI P1 P2 T1 G1 PRV1 PRV2 LC1 LC2 M1 M2 M3 M4 RV0 9 T2 FRONT LEFT FRONT RIGHT REAR [...]

Groundsmaster 4500- - D/4700 - - D Hydraulic System Page 4 - - 59 Procedure for Cutting Deck Cir cuit Relief Pressure Te s t CAUTION Prevent personal injury and/or damage to equip- ment. Read all W ARNINGS, CAUTIONS and Pre - cautions for Hydraulic T esting at the beginning of this section. 1. Make sure hydrau lic oil is at normal operating te m- p[...]

Groundsmaster 4500- - D/4700 - - D Hydraulic System Page 4 - - 60 Deck Motor Case Drain Leakage (Usin g T es ter with Pressure Gauge & Flow Meter) MEASURING CONT AINER DECK MOTOR #1 SHOWN TEST FOR GM4500 - - D TESTER STEEL CAP 3500 PSI 3500 PSI 1500 PSI 1500 PSI P1 P2 T1 G1 PRV1 PRV2 LC1 LC2 M1 M2 M3 M4 RV0 9 T2 FRONT LEFT FRONT RIGHT REAR LEFT[...]

Groundsmaster 4500- - D/4700 - - D Hydraulic System Page 4 - - 61 Procedure for Deck Motor Case Dr ain Leakage Te s t NOTE: Over a period of time, a de ck motor can wear in- ternally . A worn motor may bypass oil to its case drain causing the motor to be less efficien t. Eventually , enough oil loss will cause the deck motor to stall under heavy cu[...]

Groundsmaster 4500- - D/4700 - - D Hydraulic System Page 4 - - 62 Steering Cir cuit Relief Pressure (Us ing Pressure Gauge) (STEERING WHEEL TURNED TEST FOR GM4500 - - D SHOWN FOR RIGHT TURN) CAP STEEL PRESSURE GAUGE 1050 1600 PSI 6.2 GPM 11 . 4 G P M 3500 PSI 3500 PSI 1500 PSI 1500 PSI P1 P2 T1 G1 PRV1 PRV2 LC1 LC2 M1 M2 M3 M4 T RV09 PRV S1 CV FD P[...]

Groundsmaster 4500- - D/4700 - - D Hydraulic System Page 4 - - 63 Procedure for Steering Circuit Relief Pressure Te s t The steering circuit relief pressure test shou ld be per- formed to make sure that the ste ering circuit relief pres- sure is correct. CAUTION Prevent personal injury and/or damage to equip- ment. Read all W ARNINGS, CAUTIONS and [...]

Groundsmaster 4500- - D/4700 - - D Hydraulic System Page 4 - - 64 Steeri ng Cylinder Inter nal Leakage 1050 PE T R STEERING CYLINDER 6.1 CIR L CONTROL VA LV E STEERING PSI FROM COMBINA TION MANIFOLD TO GEAR CYLINDER FULL Y EXTEN DED LOOK FOR LEAKAGE STEEL CAP STEERING WHEEL TURNED FOR RIGHT TURN PUMP INLET TO TR ACTION CHARGE CIRCUIT[...]

Groundsmaster 4500- - D/4700 - - D Hydraulic System Page 4 - - 65 The steering cy linder intern al leakage test should be performed if a steering problem is identified. This test will determine if the steering cylinder is faulty . Procedure for Steering Cylinder Inter nal Leakage Te s t NOTE: Steering circuit operat ion will be affected by rear tir[...]

Groundsmaster 4500- - D/4700 - - D Hydraulic System Page 4 - - 66 Lift/Lower Circuit Relief Press ure (Using P ressure Gauge) GM 4500 - - D SHOWN PRESSURE GAUGE 1050 1600 PSI 6.2 GPM 11 . 4 G P M 3500 PSI 3500 PSI 1500 PSI 1500 PSI P1 P2 T1 G1 PRV1 PRV2 LC1 LC2 M1 M2 M3 M4 T RV0 9 PRV S1 CV FD P2 P1 ST L M1 M2 PE T R P CHG G1 C2 TS RV S5 T2 FRONT L[...]

Groundsmaster 4500- - D/4700 - - D Hydraulic System Page 4 - - 67 Procedure for Lift/Lower Circuit Relief Pressure Te s t The lift/lower circuit relief pressure test should be per- formed to make sure that the cutting unit lift and lower circuit relief pressure is correct. CAUTION Prevent personal injury and/or damage to equip- ment. Read all W ARN[...]

Groundsmaster 4500- - D/4700 - - D Hydraulic System Page 4 - - 68 Engine Cool ing Fan Circuit (Using Pr essure Gauge and Phototac) GM 4500 - - D SHOWN PRESSURE GAUGE 1050 1600 PSI 6.2 GPM 11 . 4 G P M 3500 PSI 3500 PSI 1500 PSI 1500 PSI P1 P2 T1 G1 PRV1 PRV2 LC1 LC2 M1 M2 M3 M4 T RV0 9 PRV S1 CV FD P2 P1 ST L M1 M2 PE T R P CHG G1 C2 TS RV S5 T2 FR[...]

Groundsmaster 4500- - D/4700 - - D Hydraulic System Page 4 - - 69 Procedure for Engine Cooling Fan Circuit T est The engine cooling fan circui t test should be performed to make sure that the engine cooling fan circuit has the correct system pressure and fan speed. CAUTION Prevent personal injury and/or damage to equip- ment. Read all W ARNINGS, CA[...]

Groundsmaster 4500- - D/4700 - - D Hydraulic System Page 4 - - 70 Gear Pump Flow (Using T ester with Pressure Gauge & Flow Meter) SECOND GEAR PUMP SECTION TESTER 4350 PSI 250 PSI 5000 PSI EU - - 2600 / 1200 RPM 0.56 CID 0.56 CID 1.03 CID 1.03 CID 2.75 CID 50 PSI ENGINE T4 - - 2700 / 1200 RPM PISTON PUMP FROM REAR TRACTI ON V AL VE REAR DECK &am[...]

Groundsmaster 4500- - D/4700 - - D Hydraulic System Page 4 - - 71 Procedure for Gear Pump Flow Te s t CAUTION Prevent personal injury and/or damage to equip- ment. Read all W ARNINGS, CAUTIONS and Pre - cautions for Hydraulic T esting at the beginning of this section. 1. Make sure hydrau lic oil is at normal operating te m- perature by operating th[...]

Groundsmaster 4500- - D/4700 - - D Hydraulic System Page 4 - - 72 Adjustments Adjust Control Ma nifold Relie f V alves Several of the hydraulic control manifolds on your Groundsmaster include a djustable relief valves. The fol- lowing procedure can be used to adjust th ese r elief valves. Refer to the T es ting section of this chapter for in- forma[...]

Groundsmaster 4500- - D/4700 - - D Hydraulic System Page 4 - - 73 Service and Repairs General Precautions for R emoving and In stalling Hydraulic System Components Before Repair or Re placement of Components 1. Before removing any pa r ts from the hydraulic sys- tem, park machine on a level surface, engage parking brake, lower cutting decks and sto[...]

Groundsmaster 4500- - D/4700 - - D Hydraulic System Page 4 - - 74 Check Hydraulic Li nes and Hoses W ARNING Keep body and hands away from pin hole leaks or nozzles that eject hydraulic fluid under high pressure. Use pape r or cardboard, not hands, to search fo r leaks. Hydraulic f luid escapi ng und er pressure can h ave suff icient fo rce to pene [...]

Groundsmaster 4500- - D/4700 - - D Hydraulic System Page 4 - - 75 Flush Hydraulic Sy stem IMPORT ANT : Flush the hydraulic system any time there is a severe com p onent failure or the system is contaminated (oil appear s milky , black or contains metal particles). IMPORT ANT : Flush hydraulic s ystem when chang - Ing from petroleum base hydraulic f[...]

Groundsmaster 4500- - D/4700 - - D Hydraulic System Page 4 - - 76 Filtering Closed - - Loop T raction Circuit Filtering of a closed - - loop hydraulic system after a major component failure ( e.g. traction (piston) pump, front wheel motor o r rear axle mot or) is a req uiremen t to pre- vent debris from transmitting throughout the syst em. If a clo[...]

Groundsmaster 4500- - D/4700 - - D Hydraulic System Page 4 - - 77 Charge Hydraul ic System NOTE: When initially starting the hydraulic syst em with new or rebuilt compon ents such as pumps, motors or lift cylinders, it is important that the hydraulic system be charged properly . Air must be purged from the system and its components to re duce the c[...]

Groundsmaster 4500- - D/4700 - - D Hydraulic System Page 4 - - 78 Gear Pump 1. Piston pump assembly 2. Flat washer (4 used) 3. Gear pump assembly 4. 90 o hydraulic fitting (2 used) 5. 90 o hydraulic fitting (2 used) 6. 90 o hydraulic fitting 7. O - - ring 8. Hydraulic tee fitting 9. 90 o hydraulic fitting 10. 45 o hydraulic fitt ing 11 . S t r a i [...]

Groundsmaster 4500- - D/4700 - - D Hydraulic System Page 4 - - 79 Removal (Fig. 63) 1. Park machine on a level s urface, lower cu tting decks, stop engine, engage parking brake and remove key from the ignition switch . 2. Gain access to gear p ump from below the machine. 3. Drain the hydra ulic reservoir into a suitable conta iner (see Hydraulic Re[...]

Groundsmaster 4500- - D/4700 - - D Hydraulic System Page 4 - - 80 5. Remove caps and pl ugs from hydraulic lines and fit- tings. 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 reservoi r with new hydraulic oil. 7. [...]

Groundsmaster 4500- - D/4700 - - D Hydraulic System Page 4 - - 81 This page is intentionally blank. Hydraulic System[...]

Groundsmaster 4500- - D/4700 - - D Hydraulic System Page 4 - - 82 Gear Pump Se rvice 1. Dust seal 2. Retaining ring 3. Flange washer 4. Shaft seal 5. Front cover 6. Dowel pin (16 used) 7. Pressure seal 8. Back - - up gasket 9. Thrus t plate (8 use d) 10. Seal (8 used) 1 1. Idler gear 12. Drive shaft 13. Back - - up gasket 14. Pressure seal 15. Fron[...]

Groundsmaster 4500- - D/4700 - - D Hydraulic System Page 4 - - 83 IMPORT ANT : Use caution when clamping gear pump in a vise to avoid distorting any pump compo- nents . 3 . S e c u r et h e f r o n tc o v e ro ft h ep u m pi nav i s ew i t ht h e drive shaft pointing down. 4. Loosen the four (4) cap screws that secu re pump as- sembly . 5. Remove p[...]

Groundsmaster 4500- - D/4700 - - D Hydraulic System Page 4 - - 84 Piston (T raction) Pump Figure 68 FRONT RIGHT 1. Piston pump assembly 2. Flat washer (4 used) 3. Gear pump assembly 4. 90 o hydraulic fitting (2 used) 5. 90 o hydraulic fitting (2 used) 6. 90 o hydraulic fitting 7. O - - ring 8. Hydraulic tee fitting 9. 90 o hydraulic fitting 10. 45 [...]

Groundsmaster 4500- - D/4700 - - D Hydraulic System Page 4 - - 85 5. For assembly purposes, l abel all hydraulic lines con- n e c t e dt og e a rp u m pa n dt r a c t i o np u m pf i t t i n g s . 6. Put a drain pan be low the pump assembly . Remove hydraulic hoses connected to piston and gear pumps. Put plugs or caps on di sconnected hydraulic hos[...]

Groundsmaster 4500- - D/4700 - - D Hydraulic System Page 4 - - 86 IMPORT ANT : A case drain exists in the piston (trac- tion) 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 tha t plugs placed in both of t hese ports are remove d. Failure to remove plugs wi [...]

Groundsmaster 4500- - D/4700 - - D Hydraulic System Page 4 - - 87 This page is intentionally blank. Hydraulic System[...]

Groundsmaster 4500- - D/4700 - - D Hydraulic System Page 4 - - 88 Piston (T raction) Pump Service Figure 72 2 3 6 8 9 10 11 13 1 5 7 12 14 15 16 17 18 19 20 4 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 2 3 10 7 25 10 29 33 34 36 37 38 39 40 41 46 47 42 43 48 49 44 45 41 42 42 55 42 44 45 46 50 51 52 53 10 54[...]

Groundsmaster 4500- - D/4700 - - D Hydraulic System Page 4 - - 89 1. Scre en (2 used ) 2. Plug with O - - ring (2 used) 3. Plug with O - - ring (2 used) 4. Cylinder block assembly 5. V a lve plat e 6. Serv o piston 7. Scre w (4 used ) 8 . O r i f i c e( 2u s e d ) 9. Scre w (4 used ) 10. Plug with O - - ring (4 used) 1 1. Screw (2 used) 12. Plug 13[...]

Groundsmaster 4500- - D/4700 - - D Hydraulic System Page 4 - - 90 Rear T raction Control Manifold 1. Rear traction control manifold 2. Cap screw (2 used) 3. Flange nut (2 used) 4. HI/LOW range control manifo ld 5. Lift circuit junction manifold 6. Hydraulic tube 7. O - - ring 8. Hydraulic straight fitting 9. O - - ring 10. Hydraulic tube 11 . O - -[...]

Groundsmaster 4500- - D/4700 - - D Hydraulic System Page 4 - - 91 Removal (Fig. 73) NOTE: The ports on the rear tra ction 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 eac h port. 1. Read t[...]

Groundsmaster 4500- - D/4700 - - D Hydraulic System Page 4 - - 92 Rear T raction Co ntrol Manifo ld Service 1. Rear traction manifold body 2. Relief valve (port RV) 3. Pressure reducing valve (port PR) 4. #4 ze ro leak p lug wi th O - - ri ng 5. #6 ze ro leak p lug wi th O - - ri ng 6. Check valve (port CV) 7. Orifice (0.050) (port OR1) Figure 74 2[...]

Groundsmaster 4500- - D/4700 - - D Hydraulic System Page 4 - - 93 Control Manifold Cartr idge V alve Service 1. Make sure the contr ol manifold is clean before re- moving the cartridge val ve from the control manifold. 2. If cartr idge valve is solenoid ope rated, remove nut securing solenoid coil to th e cartridge valve. Carefully s l i d ec o i l[...]

Groundsmaster 4500- - D/4700 - - D Hydraulic System Page 4 - - 94 HI/LOW Range Control Manifold 1. HI/LOW range control manifo ld 2. Cap screw (2 used) 3. Flange nut (2 used) 4. Rear traction control manifold 5. Lift circuit junction manifold 6. Hydraulic tube 7. O - - ring 8. Hydraulic tube 9. O - - ring 10. Hydraulic tube 11 . O - - r i n g 12. O[...]

Groundsmaster 4500- - D/4700 - - D Hydraulic System Page 4 - - 95 Removal (Fig. 75) 1. Read the General Pre cautions for Removing an d Installing Hydraulic System Components at the begin- ning of the Service and Repairs section of this chapter . 2. T o prevent contamination of hydraulic system during manifold removal, th oroughly clean exterior of [...]

Groundsmaster 4500- - D/4700 - - D Hydraulic System Page 4 - - 96 Rear Axle Motor 1. Rear axle motor 2. O - - ring 3. Pinion gear 4. External snap ring (2 used) 5. O - - ring 6. Hydraulic fitting 7. O - - ring 8. 90 o hydraulic fitting 9. Cap s crew (2 used ) 10. Flat was her (2 us ed) 11 . O - - r i n g 12. 90 o hydraulic fitt ing 13. O - - rin g [...]

Groundsmaster 4500- - D/4700 - - D Hydraulic System Page 4 - - 97 Removal (Fig. 78) 1. Park machine on a level s urface, lower cu tting decks, stop engine, engage parking brake and remove key from the ignition switch . 2. Read the General Pre cautions for Removing an d Installing Hydraulic System Components at the begin- ning of the Service and Rep[...]

Groundsmaster 4500- - D/4700 - - D Hydraulic System Page 4 - - 98 Front Wheel Motors 1. Flange head screw (6 per planetary) 2. Splined brake shaft 3. Planetary assembly 4. Wheel assembly 5. Lug nut (8 per wheel) 6. Retaining ring 7. Spring plate 8. Compression spring 9. Jam nu t 10. Brake assembly (LH shown) 1 1. Flange head screw (4 per brake) 12.[...]

Groundsmaster 4500- - D/4700 - - D Hydraulic System Page 4 - - 99 7. Remove and discard O - - ring (item 16) from flange of wheel motor . 8. If hydrauli c fittings are to be removed from wheel mo- tor , mark fitting orientation to allow correct assembly (Figs. 80 and 81). Remove fittings from motor and dis- card O - - rings. Installation (Fig. 79) [...]

Groundsmaster 4500- - D/4700 - - D Hydraulic Syst em Page 4 - - 100 Rear Axle and Front Wheel Motor Service Figure 82 2 3 6 8 9 10 11 13 1 5 7 12 14 15 16 17 18 19 20 4 21 22 23 21 25 1. Plu g with O - - ring 2. Minimum angle stop 3. Bias spring 4. Serv o piston 5. O - - ring 6. O - - ring 7. Socket head screw (5 used) 8. Endcap 9. Dowel 10. D owel[...]

Groundsmaster 4500- - D/4700 - - D Hydraulic System Page 4 - - 1 01 NOTE: The fr ont whee l motors a re ident ical (shown in Figure 82). The rear axle motor inclu des a flushing valve for cooling of the closed loop traction ci rcuit and there- fore has some dif ferences from the front motors (Fig. 83). Service of the wheel and axle motors uses the [...]

Groundsmaster 4500- - D/4700 - - D Hydraulic Syst em Page 4 - - 102 Cutting Deck Motor The hydraulic motors used on all cutting decks are the same. Removal 1. Park machine on a level surface, lower cutting decks, stop engine, engage parking brake and remove key from the ignition switch. 2. Read the Gener al Precautions for Remo ving and Installing [...]

Groundsmaster 4500- - D/4700 - - D Hydraulic System Page 4 - - 1 03 This page is intentionally blank. Hydraulic System[...]

Groundsmaster 4500- - D/4700 - - D Hydraulic Syst em Page 4 - - 104 Cutting Deck Motor Service 1. Dust seal (2 used) 2. Retaining ring 3. Flange washer 4. Shaft seal 5. Front flange 6. Pressure seal 7. Backup gasket 8. Front wear plate 9. Drive gear 10. Dowel pin (4 used) 1 1. Idler gear 12. O - - rin g 13. Bod y 14. Rear wear plate 15. Rear c over[...]

Groundsmaster 4500- - D/4700 - - D Hydraulic System Page 4 - - 1 05 5. Remove motor from the vise. T urn motor so that the shaft end is facing down. Rem ove cap screws. 6. Separate rear cove r from body . Lift rear co ver from motor . 7. Carefully remove bo dy . Lift body str aight up to re- move. Make sure the rear wear plate remains on the drive [...]

Groundsmaster 4500- - D/4700 - - D Hydraulic Syst em Page 4 - - 106 Assembly (Fig. 86) NOTE: When assembling t he motor , check the ma rker line on each part to make sure the parts are properly aligned during assembly . 1. Lubricate O- - rings, pressure seals, ba ck - - up gaskets and wear plat e grooves with a thin coat of p etroleum jel- ly . Lub[...]

Groundsmaster 4500- - D/4700 - - D Hydraulic System Page 4 - - 1 07 This page is intentionally blank. Hydraulic System[...]

Groundsmaster 4500- - D/4700 - - D Hydraulic Syst em Page 4 - - 108 Deck Control Manifold 1. Deck control manifold 2. Filter mount bracket 3. Flange head screw (2 used) 4. Hydraulic oil filter assembly 5. V alve mount bracket 6. Flange head screw (2 used) 7. Lift control manifold 8. Flange head screw (2 used) 9. Fan dr ive manifo ld Figure 90 FRONT[...]

Groundsmaster 4500- - D/4700 - - D Hydraulic System Page 4 - - 1 09 Removal (Fig. 90) NOTE: The ports on the deck control manifold are marked for easy identification of components. Example: P1 is the gear pump connection port (see Hydraulic Schematics in Chap ter 9 - - Foldout Drawin gs to identify the function of the hydraulic line s and cartridge[...]

Groundsmaster 4500- - D/4700 - - D Hydraulic System Page 4 - - 1 10 Deck Control Man ifold Service (GM 4500 - - D) 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. Zero leak plug (#8) Figure 93 1 3 4 5 6 7 9 8 2 [...]

Groundsmaster 4500- - D/4700 - - D Hydraulic System Page 4 - - 1 1 1 NOTE: The deck control manifol d uses several zer o leak plugs. These plugs have a tapered sealing sur face on the plug head that is designed to resist vibrati on in- duced plug loo sening. The zero leak plu gs also have an O - - ring a s a secondary seal. If zero leak plug remova[...]

Groundsmaster 4500- - D/4700 - - D Hydraulic System Page 4 - - 1 12 Deck Control Man ifold Service (GM 4700 - - D) 1. Manifold body 2. Nut (4 used) 3. Zero leak plug (#6) 4. Zero leak plug (#8) 5. Zero leak plug (#4) 6. Propor tional r elief ( PRV2 & PRV2) 7. Relief valve (R V8, RV9, RV10 & RV1 1) 8. Solenoid valve (SV1 & SV2) 9. Logic [...]

Groundsmaster 4500- - D/4700 - - D Hydraulic System Page 4 - - 1 13 For solenoid and control valve service procedures, se e Control Manifold Cartridge V alve Service in this section. Refer to Figures 95 and 96 for cartridge valve and plug installation torque. IMPORT ANT : A pilot piston (item 6) is placed be- neath e ach of t he relief v alves in d[...]

Groundsmaster 4500- - D/4700 - - D Hydraulic System Page 4 - - 1 14 Steering Contro l V alve 1. Steering wheel cover 2. Lock nut 3. Steering wheel 4. Flat washer 5. Socket head screw (4 used) 6. Flange head screw (4 used) 7. Steering column 8. Steering control valve 9. Socket head screw (4 used) 10. Flange nut (4 used) 1 1. Tinne rman nut (4 used) [...]

Groundsmaster 4500- - D/4700 - - D Hydraulic System Page 4 - - 1 15 CAUTION Before open ing hydraul ic system, operat e all hy - draulic controls to relieve sy stem pressure and avoid injury from pressurized hydraulic oil. See Relieving Hydraulic System Pressure in the Gen- eral Information se ction of this chapter . 8. Disconnect hydraulic lines f[...]

Groundsmaster 4500- - D/4700 - - D Hydraulic System Page 4 - - 1 16 Steering Contro l V alve Service 1. Relief valve assembly 2. Dust seal ring 3. Steering valve housing 4. Shaft seal 5. Thrust washer 6. Bearing race 7. Ring 8. Spring set 9. Cro ss pin 10. Sleeve 1 1. Spool 12. Car dan sh aft 13. O - - rin g 14. Distributor plate 15. Out er gear wh[...]

Groundsmaster 4500- - D/4700 - - D Hydraulic System Page 4 - - 1 17 This page is intentionally blank. Hydraulic System[...]

Groundsmaster 4500- - D/4700 - - D Hydraulic System Page 4 - - 1 18 Steer ing Cylinde r 1. Steering cylinder 2. Ball joint 3. Ball joint 4. Retaining ring 5. Grease fitting 6. Grease fitting 7. 90 o hydraulic fitting 8. O - - ring 9. O - - ring 10. Drive axle assembly 1 1. Ball joint spacer 12. Axle washer 13. Slotted hex nut 14. Cot ter pi n 15. H[...]

Groundsmaster 4500- - D/4700 - - D Hydraulic System Page 4 - - 1 19 Removal (Fig. 101) 1. Park machine on a level s urface, lower cu tting decks, stop engine, engage parking brake and remove key from the ignition switch . 2. Read the General Pre cautions for Removing an d Installing Hydraulic System Components at the begin- ning of the Service and [...]

Groundsmaster 4500- - D/4700 - - D Hydraulic Syst em Page 4 - - 120 Steering Cylinder Service 1. T ube assembly 2. Lock nut 3. Seal 4. O - - r ing 5. O - - r ing 6. Pisto n 7. O - - ring 8. Back - - up seal 9. Seal 10. Head 11 . W i p e r 12. Retaining ring 13. Rod assembly Figure 102 7 10 4 11 8 5 1 6 3 9 2 12 13 7 10 4 11 8 5 1 6 3 9 2 12 13 30 t[...]

Groundsmaster 4500- - D/4700 - - D Hydraulic System Page 4 - - 1 21 Disassembly (Fig. 102) 1. Remove oil from steering cylinder into a drain pan by slowly pumping the cylin der shaft. Plug both ports and clean the outside of the cyl inder . IMPORT ANT : Prevent damage when clamping the cylinder in a vise; clamp on the clevis only . Do not close vis[...]

Groundsmaster 4500- - D/4700 - - D Hydraulic Syst em Page 4 - - 122 Engine Cooling Fan Motor 1. Cap screw (4 used) 2. Fan 3. Flange head screw (4 used) 4. Flange nut (4 used) 5. Fan motor and bracket assembly 6. Flange head screw (8 used) 7. Flat washer (8 used) 8. R - - clamp ( 2 used) 9. Radiator/oil cooler assembly 10. Air intake hose 11 . W a s[...]

Groundsmaster 4500- - D/4700 - - D Hydraulic System Page 4 - - 1 23 Removal (Fig. 103) 1. Park machine on a level s urface, lower cu tting decks, stop engine, apply parking brake and remove key from the ignition switch . 2. Read the General Pre cautions for Removing an d Installing Hydraulic System Components at the begin- ning of the Service and R[...]

Groundsmaster 4500- - D/4700 - - D Hydraulic Syst em Page 4 - - 124 Installation (Fig. 103) 1. If fittings were removed fro m fan motor , lubricate an d place new O- - rings onto fittin gs. Install fittings into port openings. T ighten fittings (see Hydraul ic Fitting Installa- tion in the General Information sectio n of t his chapter). 2. Secure f[...]

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Groundsmaster 4500- - D/4700 - - D Hydraulic Syst em Page 4 - - 126 Engine Cooling Fan Motor S ervice 1. Flange washer 2. O - - ring 3. Front flange 4. Dust seal 5. Retaining ring 6. Front wear plate 7. Shaf t seal 8. Backup gasket 9. Pressure seal 10. Rear wear plate 11 . B o d y 12. Idler gear 13. Cap sc rew ( 4 used) 14. Dowel (2 used) 15. Dri v[...]

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Groundsmaster 4500- - D/4700 - - D Hydraulic Syst em Page 4 - - 128 Fan Control Manifold 1. Fan control manifold 2. Support bracket 3. Flange head screw (2 used) 4. Battery support 5. Air cleaner mount 6. Deck manifold (GM 4500 - - D shown) 7. Hydraulic hose 8. Hydraulic hose 9. Hydraulic tube 10. Hydraulic tube 1 1. Hydraulic tube 12. Hydraulic tu[...]

Groundsmaster 4500- - D/4700 - - D Hydraulic System Page 4 - - 1 29 Removal (Fig. 107) NOTE: The ports on the fan cont rol manifold are marked for easy identification of components. Example: P1 is the gear pump connection port (see Hydraulic Schematics in Chap ter 9 - - Foldout Drawin gs to identify the function of the hydraulic line s and cartridg[...]

Groundsmaster 4500- - D/4700 - - D Hydraulic Syst em Page 4 - - 130 Fan Control M anifold Service 1. Manifold body 2. Zero leak plug (#6) (3 used) 3. Zero leak plug (#4) (2 used) 4. Check valve (port CV) 5. Flow divider cartridge (port FD) 6. Solenoid coil (2 used) 7. Nut 8. Solenoid valve (port S 1) 9. Proportional relief cartridge (port TS) 10. N[...]

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Groundsmaster 4500- - D/4700 - - D Hydraulic Syst em Page 4 - - 132 Lift Control Manifold 1. Deck control manifold 2. Filter mount bracket 3. Flange head screw (2 used) 4. Hydraulic oil filter assembly 5. V alve mount bracket 6. Flange head screw (2 used) 7. Lift control manifold 8. Flange head screw (2 used) 9. Fan dr ive manifo ld Figure 1 10 FRO[...]

Groundsmaster 4500- - D/4700 - - D Hydraulic System Page 4 - - 1 33 Removal (Fig. 1 10) 1. Park machine on a level s urface, lower cu tting decks, stop engine, apply parking brake and remove key from the ignition switch . IMPORT ANT : T o prevent unexpected deck lower- ing, make sure that cutting decks a re fully lowered before loosening hydraulic [...]

Groundsmaster 4500- - D/4700 - - D Hydraulic Syst em Page 4 - - 134 Lift Control Manifold Service (GM 4500 - - D) 1. Manifold body 2. Proportional relief valve (port TS) 3. Solenoid valve (port S6) 4. Solenoid coil (2 used) 5. Check valve (port CV) 6. Orifice (0.080) 7. Zero leak plug (#4) 8. Nut 9. Straigh t fitting 10. O - - rin g 11 . N u t 12. [...]

Groundsmaster 4500- - D/4700 - - D Hydraulic System Page 4 - - 1 35 NOTE: The lift control manifold includes sev eral zero leak plugs. These plugs have a tapered sealing sur face on the plug head that is designed to resist vibrati on in- duced plug loo sening. The zero leak plu gs also have an O - - ring a s a secondary seal. If zero leak plug remo[...]

Groundsmaster 4500- - D/4700 - - D Hydraulic Syst em Page 4 - - 136 Lift Control Manifold Service (GM 4700 - - D) 1. Manifold body 2. Nut 3. Zero leak plug (#4) 4. Relief valve (port R1) 5. Proportional relief valve (port TS) 6. Solenoid valve (ports S2, S3, S7, S8) 7. Solenoid valve (port S1) 8. Solenoid valve (ports S4, S6, S9) 9. Solenoid valve [...]

Groundsmaster 4500- - D/4700 - - D Hydraulic System Page 4 - - 1 37 NOTE: The lift control manifold uses several zero l eak plugs. These plugs have a tapered sealing surface on t h ep l u gh e a dt h a ti sd e s i g n e dt or e s i s tv i b r a t i o ni n d u c e d plug loosening. The z ero leak plugs also have an O - - ring as a secondar y seal. I[...]

Groundsmaster 4500- - D/4700 - - D Hydraulic Syst em Page 4 - - 138 Lift Circuit Junction Manifold 1. Lift circuit junction manifold 2. Flange head screw (2 used) 3. HI/LOW range control manifold 4. Rear traction control manifold Figure 1 16 FRONT RIGHT 2 3 1 4[...]

Groundsmaster 4500- - D/4700 - - D Hydraulic System Page 4 - - 1 39 Removal (Fig. 1 16) 1. Park machine on a level s urface, lower cu tting decks, stop engine, engage parking brake and remove key from the ignition switch . 2. Read the General Pre cautions for Removing an d Installing Hydraulic System Components at the begin- ning of the Service and[...]

Groundsmaster 4500- - D/4700 - - D Hydraulic Syst em Page 4 - - 140 Lift Cylinders: Decks #1, #4 and #5 1. Lift arm (deck #4) 2. Flange nut 3. Lift arm (deck #1) 4. Cylinder pin (3 used) 5. Flange head screw 6. O - - ring 7. 90 o hydraulic fitting (2 per cylinder) 8. O - - ring 9. Lift arm (deck #5) 10. Lift cylinder (decks #4 and #5) 1 1. Lift cyl[...]

Groundsmaster 4500- - D/4700 - - D Hydraulic System Page 4 - - 1 41 Removal (Fig. 1 19) 1. Park machine on a level s urface, lower cu tting decks, stop engine, engage parking brake and remove key from the ignition switch . 2. Read the General Pre cautions for Removing an d Installing Hydraulic System Components at the begin- ning of the Service and[...]

Groundsmaster 4500- - D/4700 - - D Hydraulic Syst em Page 4 - - 142 Lift Cylinders: Decks #2 and #3 1. Flange head screw 2. Flange nut 3. Cylinder pin 4. Lift cylinder 5. Retaining ring 6. Cylinde r pin 7. Lift arm (deck #2) 8. Lift arm (deck #3) 9. O - - ring 10. Hydraulic fitting 11 . O - - r i n g 12. 90 o hydraulic fitting 13. Grease fitting Fi[...]

Groundsmaster 4500- - D/4700 - - D Hydraulic System Page 4 - - 1 43 Removal (Fig. 121) 1. Park machine on a level s urface, lower cu tting decks, stop engine, engage parking brake and remove key from the ignition switch . 2. Read the General Pre cautions for Removing an d Installing Hydraulic System Components at the begin- ning of the Service and [...]

Groundsmaster 4500- - D/4700 - - D Hydraulic Syst em Page 4 - - 144 Lift Cylinders: Decks #6 and #7 (GM 4700 - - D) 1. Lift cylinder 2. Lock nut (2 used per side) 3. Rear link 4. Link assembly 5. Plastic roller 6. Retaining ring 7. Cylinde r pin 8. 90 o hydraulic fitting 9. O - - ring 10. O - - rin g 1 1. Lift arm assembly (deck #6 sho wn) 12. Grea[...]

Groundsmaster 4500- - D/4700 - - D Hydraulic System Page 4 - - 1 45 Removal (Fig. 123) 1. Park machine on a level s urface, lower cu tting decks, stop engine, engage parking brake and remove key from the ignition switch . 2. Read the General Pre cautions for Removing an d Installing Hydraulic System Components at the begin- ning of the Service and [...]

Groundsmaster 4500- - D/4700 - - D Hydraulic Syst em Page 4 - - 146 Lift Cylinder Service 1. T ube assembly 2. Lock nut 3. Wear ring 4. Seal 5. Piston 6. O - - ring 7. O - - ring 8. Back - - up ring 9. Seal 10. Retaining ring 11 . H e a d 12. Wiper 13. Rod assembly 14. Grease fitting (2 used) Figure 125 12 10 9 5 7 4 2 3 11 1 8 6 13 14 10 5 2 11 6 [...]

Groundsmaster 4500- - D/4700 - - D Hydraulic System Page 4 - - 1 47 Disassembly (Fig. 125) 1. Remove oil fro m lift cylinder i nto a drain pan by slowly pumping th e cylinder s haft. Plug both ports and clean the outside of the cy linder . IMPORT ANT : Prevent damage when clamping the cylinder in a vise; clamp on the clevis only . Do not close vise[...]

Groundsmaster 4500- - D/4700 - - D Hydraulic Syst em Page 4 - - 148 Hydraulic Reservoir 1. Plug 2. O - - ring 3. Dipstick 4. Breather 5. Screen filter 6. Hydraulic reservoir 7. Reservoir strainer 8. O - - ring 9. O - - ring 10. Straight hydraulic fitting 11 . O - - r i n g 12. Cap screw (2 used) 13. Flat was her (2 us ed) 14. Clamp ( 2 used) 15. Fl[...]

Groundsmaster 4500- - D/4700 - - D Hydraulic System Page 4 - - 1 49 Removal (Fig. 126) 1. Park machine on a level s urface, lower cu tting decks, stop engine, engage parking brake and remove key from the ignition switch . 2. Read the General Pre cautions for Removing an d Installing Hydraulic System Components at the begin- ning of the Service and [...]

Groundsmaster 4500- - D/4700 - - D Hydraulic Syst em Page 4 - - 150 Radiator and Oil Cooler Assem bly 1. Radiator/oil cooler assembly 2. Cap screw (4 used) 3. W asher (4 used) 4. Fan 5. Plenum assembly 6. Cap screw (6 used) 7. Flange nut (6 used) 8. Air intake hose 9. Hose 10. Hose clamp (4 used) 1 1. Upper radiator shroud 12. Lower radiator shroud[...]

Groundsmaster 4500- - D/4700 - - D Hydraulic System Page 4 - - 1 51 NOTE: The hydra ulic oil cooler on y our Groundsm aster is combined with the radiator . See Radiator and Oil Cooler Assembly in the Service and Repairs section of Chapter 3 - - Diesel Engine for inform ation on removal and installation of th e radiator/oil cooler assembly . 1. Radi[...]

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Groundsmaster 4500- - D/4700 - - D Page 5 - - 1 Elec trical Sys tem Chapter 5 Electrical System T able o f Contents GENERAL INFORMA TION 2 ..................... Operator ’s Manu al 2 .......................... Electrical Drawings 2 .......................... T oro Electronic Co ntrollers (T EC) 2 ............. Y anmar Engine Electronic Control Un[...]

Groundsmaster 4500- - D/4700 - - D Page 5 - - 2 Electrical Syste m General Information Operator ’ s Manual The Operator’s Manual provi des information reg arding the operation, general maintenance and maintenance intervals for your Ground smaster machine. Refer to the Operator ’s Manual for additional infor mation when ser- vicing the machine[...]

Groundsmaster 4500- - D/4700 - - D Page 5 - - 3 Elec trical Sys tem Y anmar Engine Electr onic Control Unit (ECU) The Y anmar engine that powers the Groundsmaster 4500 - - D and 4700 - - D uses an electronic control u nit (ECU) for engine management and a lso t o communi- cate with the TEC controller s and the InfoCenter Display on the machi ne. Al[...]

Groundsmaster 4500- - D/4700 - - D Page 5 - - 4 Electrical Syste m Y anmar Engine Electrical Components When servicing or troublesh ooting the engine electrical components, use the c orrect engine service manu a l and troubleshoo ting manual. Also , the Y anmar SMART- ASSIST - - Direct electronic control diagnostics ser vice system is available to [...]

Groundsmaster 4500- - D/4700 - - D Page 5 - - 5 Elec trical Sys tem This page is intentionally blank. Electrical System[...]

Groundsmaster 4500- - D/4700 - - D Page 5 - - 6 Electrical Syste m Special T ools Order special tools fro m your T oro distribut or . Some tools may also be available from a local supplier . Multimet er The multimeter can test ele ctrical components and cir- cuits for current ( amps), resistance (ohms) or voltage. Obtain this tool locally . NOTE: T[...]

Groundsmaster 4500- - D/4700 - - D Page 5 - - 7 Elec trical Sys tem Battery Hydrometer Use the batter y hydrome ter when meas uring specific gravity of battery electrolyte. Obtain this tool loca lly . Figure 7 Electrical System[...]

Groundsmaster 4500- - D/4700 - - D Page 5 - - 8 Electrical Syste m InfoCenter Display The InfoCenter Display us ed on your Groundsmaster is a LCD device that is located on the consol e. The Info- Center provides information f or the machine operator during machine operation, p rovides elec trical system diagnostic assistance for technicians an d al[...]

Groundsmaster 4500- - D/4700 - - D Page 5 - - 9 Elec trical Sys tem Main Information Scr eens The two (2) InfoCenter main information scre ens (Figs. 10 and 1 1) are displayed after the initial splash screens have been displayed for several seconds. During nor- mal machine operation, the main i nformation screens provide machine informatio n for th[...]

Groundsmaster 4500- - D/4700 - - D Page 5 - - 1 0 Electrical Syste m Main Menu Screen The main menu screen can be accessed from the Info- Center main informatio n or splash screen by pressing and releasing th e menu/back button (left button) on the display . Once to the main menu screen (Fig. 12), naviga- tion to the five (5) differ ent menu items [...]

Groundsmaster 4500- - D/4700 - - D Page 5 - - 1 1 Electri cal System Service Screen The service scree n (Fig. 14 ) contains m achine oper a- tional information including hou rs and counts. V alues listed for these service menu items cannot be change d. If the mac hine PIN has be en entered t o allow access to protected menu item s in the settings s[...]

Groundsmaster 4500- - D/4700 - - D Page 5 - - 1 2 Electrical Syste m Diagnos tics Scr een The diagnostics scr een (Fig. 15) list s the various st ates of machine electrical c omponents. The diagnostics screen should be used to check operation of machi ne controls and to ver ify that switches and cir cuit wir ing are functioning correctly . For each[...]

Groundsmaster 4500- - D/4700 - - D Page 5 - - 13 E lectrical System Settings Screen The settings screen iden tifies the InfoCenter la nguage and decks (English or Metric). The settings screen also allows the operator to customize the backlight (bright- ness) and contrast settings f or the InfoCenter displa y . If either the backligh t (brigh tness)[...]

Groundsmaster 4500- - D/4700 - - D Page 5 - - 1 4 Electrical Syste m About Screen The about scree n (Fig. 18) ide ntifies the ma chine model number , serial number and software revision s for the TEC controllers, InfoCenter and engine electroni c con- trol unit (if available). The about screen also lists the CAN - - bus status . Additional informat[...]

Groundsmaster 4500- - D/4700 - - D Page 5 - - 15 E lectrical System T roubleshooting CAUTION Remove all jewelry , especially rings and watches, before doing any elec t rical trouble- shooting or testing. Disconnect the battery cables unless the tes t requires battery voltage. For effec tive troublesh ooting and repairs, there must be a good underst[...]

Groundsmaster 4500- - D/4700 - - D Page 5 - - 1 6 Electrical Syste m Fault Codes The list below identifies the fault codes that are gener- ated by the TEC controller to identify an electrical sys- tem malfunction (fault) that occurred durin g machine operation. Use the InfoCenter Display f or fault retrieval. NOTE: The following list of fault codes[...]

Groundsmaster 4500- - D/4700 - - D Page 5 - - 17 E lectrical System Fault Code Fault Description 33 Forward piston (traction) pump o utput has open or short to grou nd 34 Reverse piston (traction) pump output has open or short to ground 35 Reverse engine coolin g fan output has open o r short to ground 39 LH PTO outp ut has open or short to ground [...]

Groundsmaster 4500- - D/4700 - - D Page 5 - - 1 8 Electrical Syste m Starting Probl ems NOTE: Check InfoCenter Display for possi ble operator advisories or faults whenever diag nosing machine elec- trical pr oblems. Problem Possible Causes No electrical power to machine (including gauges). Battery is discharged. Battery cab les are loose o r corrod[...]

Groundsmaster 4500- - D/4700 - - D Page 5 - - 19 E lectrical System Starting Problems (c ontinued) Problem Possible Causes Engine cranks, bu t does not start. Fuel tank is empty . Engine is not c ranking fast enoug h. Fuel pump or circuit wir ing is faulty . Engine or fu el system is malfunction ing (see Y anmar Service Manua l). Starter cranks, bu[...]

Groundsmaster 4500- - D/4700 - - D Page 5 - - 2 0 Electrical Syste m Cutting Deck Operatin g Problems NOTE: Check InfoCenter Display for possi ble operator advisories or faults whenever diag nosing machine elec- trical pr oblems. Problem Possible Causes Cutting decks run, but sho uld not, when raised. Decks shut off with PTO switch. The cutting dec[...]

Groundsmaster 4500- - D/4700 - - D Page 5 - - 21 E lectrical System Cutting Deck Lift/Lower Problems NOTE: Check InfoCenter Display for possible operator advisories or faults whenever diagnosing machine elec- trical p roblems . NOTE: T ol o w e ra c u t t i n gd e c k ,t h eo p e r a t o rm u s tb ei n the operator seat and the t raction speed must[...]

Groundsmaster 4500- - D/4700 - - D Page 5 - - 2 2 Electrical Syste m Cutting Deck Lift/Lower Problems (Continued) Problem Possible Causes On Groundsmaster 4700- - D, center cutting decks will not raise or lower , but bo th wing cutting decks w ill raise and lower . The center deck lift switch or circuit wiring is faulty . Fuse(s) for TEC con trolle[...]

Groundsmaster 4500- - D/4700 - - D Page 5 - - 23 E lectrical System Electrical System Quick Checks Battery T est (Open Circuit T est) Use a multimeter to measure the voltage between th e battery terminals. Set multimeter to t he DC volts settin g. The batter y should be at a tempera ture of 60 o to 100 o F( 1 6 o to 38 o C). The ignition key sho ul[...]

Groundsmaster 4500- - D/4700 - - D Page 5 - - 2 4 Electrical Syste m Adjustments T raction Pedal Adjustment The traction pedal includes a neutra l assembly that is used to adjust the traction neutral position (Fig. 19). T rac tion pedal adjus tment may be ne cessary to make sure that traction pe dal movement provides the correct full reverse and fu[...]

Groundsmaster 4500- - D/4700 - - D Page 5 - - 25 E lectrical System 6. After any adju stment of the spring shaft and rod en d bearing, use the InfoCenter Displa y Diagnostics menu to obtain and se lect the Traction Pedal menu item (see InfoCenter Display in this ch apter). Ch oose Outp uts and the InfoCenter display will identify the traction pedal[...]

Groundsmaster 4500- - D/4700 - - D Page 5 - - 2 6 Electrical Syste m T raction Pedal Position Sensor Calibration IMPORT ANT : A properly installed and calibrated traction pedal position sensor i s critical to accurate traction system respons e and for reliable sensor life. Use care when rem oving, installing and cali- brating the traction pedal pos[...]

Groundsmaster 4500- - D/4700 - - D Page 5 - - 27 E lectrical System Component T esting For accurate resistance and/or continuity checks, elec- trically disconnect the c omponent being tested from the circuit (e.g. unplug the ig nition switch connector before checking continuity of the switch t erminals). NOTE: For engine component testing informati[...]

Groundsmaster 4500- - D/4700 - - D Page 5 - - 2 8 Electrical Syste m 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 sta rt[...]

Groundsmaster 4500- - D/4700 - - D Page 5 - - 29 E lectrical System Fusible Link Harnes s Y our Groundsmaster uses two (2) fusible links for circuit protection . These fusible links ar e located in a har ness that connects the starter B+ terminal to the wire harness (Fig. 28). If either of these links should fail, current to the protected circuits [...]

Groundsmaster 4500- - D/4700 - - D Page 5 - - 3 0 Electrical Syste m PTO Switch The two position P TO switch is located on the console arm (Fig. 30). The PT O switch is pulled up to engage the PT O and pushed in to d isengage the PTO. NOTE: T o engage the PT O, the seat has to be occu- pied, traction s peed has to be in low range (mow) and t h ec u[...]

Groundsmaster 4500- - D/4700 - - D Page 5 - - 31 E lectrical System Hi/Low Speed, Engine Speed Request and Cutting Deck Lift Switches The Hi/Low speed, engine spee d 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[...]

Groundsmaster 4500- - D/4700 - - D Page 5 - - 3 2 Electrical Syste m Headlight Switch The headlight switch is locate d on the operator side of the console arm (Fig. 34). This two (2) position rocker switch allows the headl ights to be turned on and off. T esting 1. Park machine on a level surface, lower cutting decks, engage parking brake and stop [...]

Groundsmaster 4500- - D/4700 - - D Page 5 - - 33 E lectrical System Seat Switch The seat switch is normally open and closes wh en the operator is on the se at. The seat switch and its electrica l connector are located i n the seat assembly . If the trac- tion system or PT O switch is engaged whe n the operator raises out of the seat , an opera tor [...]

Groundsmaster 4500- - D/4700 - - D Page 5 - - 3 4 Electrical Syste m Parking Brake Switch The parking brake switch is a normally open pr oximity switch. The parking brake sw itch is attached to the bot - tom of the RH brake pedal (Fig. 37) . When the par king brake is not ap plied, the parking br ake detent is positioned near the target end of the [...]

Groundsmaster 4500- - D/4700 - - D Page 5 - - 35 E lectrical System Cutting Deck Position Switches The cutting deck positi on switches are normally o pen proximity switches that are located on the tra ction unit frame (Fig. 39). The sensing pl ate is located on the cut- ting deck lift ar m. The Groundsmaster 4500 - - D uses two (2) cutting de ck po[...]

Groundsmaster 4500- - D/4700 - - D Page 5 - - 3 6 Electrical Syste m Relays with Four (4) T erminals Y our Groundsmaster uses a number of el ectrical relays that have four (4) terminals. A tag near the wire harn ess relay connector can be used t o identify each relay . The main power relay is used to provide curr ent to most of the fuse protected c[...]

Groundsmaster 4500- - D/4700 - - D Page 5 - - 37 E lectrical System 6. Connect multimeter (ohms setting ) leads to relay ter- minals 30 and 87. Ground terminal 86 an d apply +12 VDC to terminal 8 5 . The relay shoul d make and break continuity betwe en terminals 30 an d 87 as +12 VDC is applied and remove d from terminal 85. 7. Disconnect voltage a[...]

Groundsmaster 4500- - D/4700 - - D Page 5 - - 3 8 Electrical Syste m Relays with Five (5) T erminals Y our Groundsmaster uses a number of el ectrical relays that have five (5 ) termin als. A tag near the wire ha rness relay connector can be used t o identify each relay . The main relay is used on models 30873 and 30874 to provide current for severa[...]

Groundsmaster 4500- - D/4700 - - D Page 5 - - 39 E lectrical System T raction Pedal Positi on Sensor The traction pedal position sensor is connected to the traction peda l assembly (Fig. 46). This position s ensor determines the neutra l band for the tra ction pedal, the direction of travel des ired by the operator and the trac- tion speed. The pos[...]

Groundsmaster 4500- - D/4700 - - D Page 5 - - 4 0 Electrical Syste m T oro Electronic Controllers (TEC) Groundsmaster 4500 - - D and 4700 - - D machines use a T oro Electronic Contro ller ( TEC - - 5002) to control electri- cal system operation. Groundsmaster 4700 - - D ma- chines use an additional TEC - - 5001 controller for electrical control of [...]

Groundsmaster 4500- - D/4700 - - D Page 5 - - 41 E lectrical System The connection termin al functions for the TEC control- lers are shown in F igures 48 (T EC - - 5002) an d 49 (TEC - - 5001). Note that electrical po wer for controller outputs is provided through three (3) connector termin- als (PWR 2, PWR 3 and PWR 4) each protected with a 7.5 am[...]

Groundsmaster 4500- - D/4700 - - D Page 5 - - 4 2 Electrical Syste m Hydraulic Solenoid V alve Coils Figure 51 1. Deck c ontr ol manif old 2. Lift control manifold 3. Fan control manifo ld 4. HI/LOW range control manifold 1 4 3 2 FRONT RIGHT GROUNDSMASTER 4500 - - D SHOWN Numerous hydraulic solenoid valve coils are used on the hydraulic control ma [...]

Groundsmaster 4500- - D/4700 - - D Page 5 - - 43 E lectrical System Solenoid Coil T esting 1. Park machine on a level s urface, lower cu tting decks, stop engine, engage parking brake and remove key from the ignition switch . 2. Locate hydraulic solenoid valve coil to be tested (Fig. 51). 3. Disconnect wire har ness conn ector from solen oid valve [...]

Groundsmaster 4500- - D/4700 - - D Page 5 - - 4 4 Electrical Syste m Piston (T raction) Pump Contr ol Solenoid Coils The piston (tract ion) pump us es an electronic contr ol as- sembly for swash plate rotation. Electrical outputs from the machine TEC controlle r are provided to two (2) solenoid coils for pump control. The piston pump control assemb[...]

Groundsmaster 4500- - D/4700 - - D Page 5 - - 45 E lectrical System Hydraulic Oil T emperature Sender A temperature sender is used as an input for the TEC controller to identify if the hyd r aulic oil temp erature has reached an excessive level. Th e hydraulic oil tempera- ture sender is attached to the rear axle motor at the rear of the machine (F[...]

Groundsmaster 4500- - D/4700 - - D Page 5 - - 4 6 Electrical Syste m Fuel Pump (Models 30873 and 30874) The fuel pump i s attached to th e air cleaner m ount below the fuel water separator (Fig. 5 7). Operational T est 1. Park machine on a level surface, lower cutting decks, stop engine and apply parking brake. Raise hood to access fuel pump. 2. Di[...]

Groundsmaster 4500- - D/4700 - - D Page 5 - - 47 E lectrical System Fuel Pump (Models 30881 and 30882) The fuel pump is attached to the air clean er mount below the fuel water se parator (Fig. 58). Operatio nal T es t 1. Park machine on a level s urface, lower cu tting decks, stop engine and apply parking brake. Raise hood to access fu el pump. 2. [...]

Groundsmaster 4500- - D/4700 - - D Page 5 - - 4 8 Electrical Syste m CAN - - bus T e rmination Resistor System communication between electri cal components on Groundsmaster 4500 - - D and 4700 - - D machines is accomplished on a CAN - - bus communication system. T wo (2) specially designed, twisted cables form the bus for the network used on the ma[...]

Groundsmaster 4500- - D/4700 - - D Page 5 - - 49 E lectrical System Diode Assemblies The Groundsmaster engi ne wire harness contains a diode assembly that is u sed for circuit protection fro m voltage spikes whe n the engine starter solenoid is de - - energized. This di ode assembly plugs into the en gine wire harness near the eng ine starter motor[...]

Groundsmaster 4500- - D/4700 - - D Page 5 - - 5 0 Electrical Syste m Service and Repairs NOTE: For engine compone nt repair informati on (e.g. starter mo tor), re fer to the Y anmar Se rvice M anual that is correct for your G r oundsmaster model. Battery Care 1. The top of the b attery mus t be kept clean. lf the ma- chine is stored in a location w[...]

Groundsmaster 4500- - D/4700 - - D Page 5 - - 51 E lectrical System Battery Service The battery is the heart of the electrical system. With regular and proper service, batter y life can be extended. Additionally , battery and electrical component failure c a nb ep r e v e n t e d . CAUTION When working with batt eries, use extreme cau- tion to avoi[...]

Groundsmaster 4500- - D/4700 - - D Page 5 - - 5 2 Electrical Syste m Battery T esting 1. Conduct a hydr ometer tes t of the battery elect rolyte. IMPORT ANT : Make sure the area around the cells is clean before opening the batter y caps. A. Measure the specific gravity of each cell with a hydrometer . Draw electrolyte in and out of the hydrometer b[...]

Groundsmaster 4500- - D/4700 - - D Page 5 - - 53 E lectrical System Battery Charging T o minimize possible damage to the battery and allow the battery to be fully charged, the slow ch arging meth- od is presented here. This charging me thod can be ac- complishe d with a constan t current bat tery charg er which is available in most loca tions. CAUT[...]

Groundsmaster 4500- - D/4700 - - D Page 5 - - 5 4 Electrical Syste m This page is intentionally blank.[...]

Groundsmaster 4500- - D/4700 - - D Page 6 - - 1 Ax les, Planetarie s and Brakes Chapter 6 Axles, Planetaries and Brakes T able o f Contents SPECIFICA TIONS 2 ............................ GENERAL INFORMA TION 3 ..................... Operator ’s Manu al 3 .......................... ADJUSTMENTS 4 .............................. Planetary Wheel D rive[...]

Groundsmaster 4500- - D/4700 - - D Page 6 - - 2 Axles, Planetaries and Brakes Specifications Item Specification T ire pressure (front and rear) 20 psi (138 kPa) Rear wheel toe - - in 0 . 1 2 5i n( 3m m ) Wheel lug nut torqu e (front and rear) 85 to 100 ft- -lb (1 16 to 135 N - -m) Steering cylinder bolt torque 100 to 125 ft - -lb (136 to 169 N - - [...]

Groundsmaster 4500- - D/4700 - - D Page 6 - - 3 Ax les, Planetarie s and Brakes General Information Operator ’ s Manual The T raction Unit Operator ’s Manual provides informa- tion regarding th e operation, gen eral maintenan ce and maintenance intervals for your Groundsmaster ma- chine. Refer t o this publicat ion for additio nal informa tion [...]

Groundsmaster 4500- - D/4700 - - D Page 6 - - 4 Axles, Planetaries and Brakes Adjustments Planetary Wheel Drive End Play A front planetary wheel drive assembly that is properly operating should have no en dplay . Any endplay in a planetary assembly indicates tha t t here are potential problems with the planetary . Check planetary endplay at interva[...]

Groundsmaster 4500- - D/4700 - - D Page 6 - - 5 Ax les, Planetarie s and Brakes This page is intentionally blank. Axles, Planetaries and Brakes[...]

Groundsmaster 4500- - D/4700 - - D Page 6 - - 6 Axles, Planetaries and Brakes Service and Repairs Brake Assembly 1. Flange head screw (6 per planetary) 2. Splined brake shaft 3. Planetary assembly (2 used) 4. Front wheel assembly (2 used) 5. Lug nut (8 per wheel) 6. Retaining ring 7. Spring plate 8. Compression spring 9. Jam nu t 10. Brake assembly[...]

Groundsmaster 4500- - D/4700 - - D Page 6 - - 7 Ax les, Planetarie s and Brakes Brake Assembly Rem oval (Fig. 1) 1. Park machine on a level surface and raise cut ting decks to allow easier access to front brake assembly . Stop engine, engage parking brake and remove key from the ignition s witch. 2. Drain oil from planetary wheel drive/bra k e asse[...]

Groundsmaster 4500- - D/4700 - - D Page 6 - - 8 Axles, Planetaries and Brakes 4. Install flange he ad screws (item 1 1) to secure brake assembly to frame. Tighte n screws in a crossing pattern to a torque from 75 to 85 ft - - lb (102 to 1 16 N - - m) . 5. Install brake cabl e to pull rod on brake assembly . Brake cable end should be compl etely thr[...]

Groundsmaster 4500- - D/4700 - - D Page 6 - - 9 Ax les, Planetarie s and Brakes This page is intentionally blank. Axles, Planetaries and Brakes[...]

Groundsmaster 4500- - D/4700 - - D Page 6 - - 1 0 Axles, Planetaries and Brakes Brake Inspection and Repair 1. Brake housing (LH shown) 2. Seal 3. Pull ro d 4. Clevis pin (2 used) 5. Link (2 used) 6. Hit ch pin ( 2 used) 7. Stationary disc (4 used) 8. Rotating disc (3 us ed) 9. Retaining ring 10. Gask et 1 1. Rotati ng actu ator 12. Extension sprin[...]

Groundsmaster 4500- - D/4700 - - D Page 6 - - 1 1 Axles, Planetaries and Brakes This page is intentionally blank. Axles, Planetaries and Brakes[...]

Groundsmaster 4500- - D/4700 - - D Page 6 - - 1 2 Axles, Planetaries and Brakes Planetary Wheel Drive Assembly Figure 7 FRON T RIGHT 1. Flange head screw (6 per planetary) 2. Splined brake shaft 3. Planetary assembly (2 used) 4. Front wheel assembly (2 used) 5. Lug nut (8 per wheel) 6. R etaining ring 7. Spring plate 8. Compression spring 9. Jam nu[...]

Groundsmaster 4500- - D/4700 - - D Page 6 - - 13 Axles, Planetaries a nd Brakes 4. Remove front wheel assembly . 5. Remove hydraulic whe el motor (see Front Wheel Motors in the Service and Repairs section of Chapte r 4 - - Hydraulic System). 6. Remove brak e assembly (see Brake Assembl y in this section). 7. Support planetary assemb ly to prevent i[...]

Groundsmaster 4500- - D/4700 - - D Page 6 - - 1 4 Axles, Planetaries and Brakes Planetary Wheel Drive Service 1. Spindle 2. Boot seal 3. Oil seal 4. Inner bearing cone 5. Inner bearing cup 6. Whee l stud (8 u sed) 7. Socket head screw (16 used) 8. Lock washer (16 used) 9. Housing 10. Dowel pin (2 used) 1 1. Outer bearing cup 12. Outer bearing cone [...]

Groundsmaster 4500- - D/4700 - - D Page 6 - - 15 Axles, Planetaries a nd Brakes NOTE: The planetary wheel drive assem b ly can be ser- viced with the p lanetary installed to machine. If th e spindle (item 1) needs t o be removed fr om machine, see Planetary Wheel Drive A ssembly in this section. Disassembly (Figs . 1 1 and 12) 1. If plane tary whee[...]

Groundsmaster 4500- - D/4700 - - D Page 6 - - 1 6 Axles, Planetaries and Brakes F . Lightly oil bearing journals on spindle shaft. Slide housing assembly onto spindle (item 1) taking care to not damage seal or spindle. Make sure that inner bearing in housing fully seats against spin dle shaft shoulder . G. Install outer bearing cone (item 12) onto [...]

Groundsmaster 4500- - D/4700 - - D Page 6 - - 17 Axles, Planetaries a nd Brakes This page is intentionally blank. Axles, Planetaries and Brakes[...]

Groundsmaster 4500- - D/4700 - - D Page 6 - - 1 8 Axles, Planetaries and Brakes Rear Axle Assembly Figure 13 70 ft - - lb (94 N - - m) m aximum FRON T RIGHT 85 to 100 ft - - lb (1 16 to 135 N - - m) 1. Rear a xle mot or 2. O - - ring 3. Pinion gea r 4. External snap ring (2 used) 5. O - - ring 6. Hydraulic fitting 7. O - - ring 8. 90 o hydraulic fi[...]

Groundsmaster 4500- - D/4700 - - D Page 6 - - 19 Axles, Planetaries a nd Brakes Remove Rear Axle (Fig. 13) 1. Park machine on a level s urface, lower cu tting decks, stop engine, engage parking brake and remove key from the ignition switch . 2. Drain oil from rear axle an d rear axle gearbox (Figs. 14 and 15). CAUTION When changing attachments, tir[...]

Groundsmaster 4500- - D/4700 - - D Page 6 - - 2 0 Axles, Planetaries and Brakes 2. If removed, install the tie r od to rear axle (Fig. 1 6). T ighten b all joint castle nuts a nd install new cott er pins. 3. Support axle under machine with a jack. Position axle assembly to rear fra me mount. 4. Install rear axle p ivot pin to secure axle to frame. [...]

Groundsmaster 4500- - D/4700 - - D Page 6 - - 21 Axles, Planetaries a nd Brakes This page is intentionally blank. Axles, Planetaries and Brakes[...]

Groundsmaster 4500- - D/4700 - - D Page 6 - - 2 2 Axles, Planetaries and Brakes Rear Axle Service Figure 19 3 2 4 5 6 7 8 9 10 14 13 12 11 15 1 10 11 8 9 8 13 16 17 18 19 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 20 41 42 43 50 44 45 46 47 48 49 51 54 55 56 57 58 59 52 53 60 61 62 63 64 22[...]

Groundsmaster 4500- - D/4700 - - D Page 6 - - 23 Axles, Planetaries a nd Brakes 1. LH axle support 2. Flange bushing (2 used) 3. Axle vent 4. Filter 5. V ent extension 6. Cap screw (4 used per gear case) 7. Shi m set 8. Seal washer 9. Plug 10. Lock nut 1 1. Lock washer 12. Grease fitting 13. Bal l bear ing 14. Screw (2 used per steering arm) 15. Ax[...]

Groundsmaster 4500- - D/4700 - - D Page 6 - - 2 4 Axles, Planetaries and Brakes Bevel Gear Case and Axle Case The following proce dures assume the rear axle assem- bly has been re moved from the machine. Removal 1. Remove the moun ting screws, nuts and lock wash- ers. Remove th e bevel ge ar case/axle case assembly and O-ring from the ax le support[...]

Groundsmaster 4500- - D/4700 - - D Page 6 - - 25 Axles, Planetaries a nd Brakes 5. Remove the knuckl e pin mounting screws and th e knuckle pin. Remove the g asket and any remaining gas- ket mater ial from either m ating surface (Fig. 23). 6. While hol ding the bevel gear case, tap the upper en d of the bevel gear shaft o ut of the upper bearin g a[...]

Groundsmaster 4500- - D/4700 - - D Page 6 - - 2 6 Axles, Planetaries and Brakes Installation 1. Coat new shaft seal with grease and install in axle case as shown (Fig. 25). 1. Axle case 2. Bevel gear case 3. Sh aft sea l Figure 25 1 2 3 2. Install the lower beve l gear and bevel gear shaft in the axle case cover . Coat a new O -ring with grease and[...]

Groundsmaster 4500- - D/4700 - - D Page 6 - - 27 Axles, Planetaries a nd Brakes 5. Determine necessary qu antity of support shims. A . L u b r i c a t et h ea x l ec a s es u p p o r tb u s h i n gw i t ha thin coat of grease and slide axle case suppo rt onto knuckle pin. B. Position support shims that were r e moved during disassembly between axle[...]

Groundsmaster 4500- - D/4700 - - D Page 6 - - 2 8 Axles, Planetaries and Brakes 9. Remove th e bevel gear c ase/axle case assembly from the axle suppo rt. Coat a new O- ring with grease and temporar ily install the ax le cover assembly . Position a dial indica tor at the tooths center . Prevent the axle from turning and measure the lower bevel ge a[...]

Groundsmaster 4500- - D/4700 - - D Page 6 - - 29 Axles, Planetaries a nd Brakes Axle Shafts The following p rocedure s assume t he rear a xle assem- bly has been removed fr om the machine. Removal 1. Remove the axle cover mounting screws. Remove t h ea x l ec o v e rf r o mt h ea x l ec a s ea sa na s s e m b l y (Fig. 32). 2. Use a bea ring puller[...]

Groundsmaster 4500- - D/4700 - - D Page 6 - - 3 0 Axles, Planetaries and Brakes Input Shaft/Pinion Gea r Figure 35 1 1. Nut (2 used) 2. Lock washer (2 used) 3. Stud (2 used) 4. Lock nut 5. Stake washer 6. Oil seal 7. O-ring 8. Seal collar 9. Beari ng 10. O -ring 1 1. Input shaft/pinion g ear 12. Bearing case 13. Shim 14. Screw (2 used) 15. Gear cas[...]

Groundsmaster 4500- - D/4700 - - D Page 6 - - 31 Axles, Planetaries a nd Brakes 5. Instal l a new stake washer . Install the lock nut finge r tight. 6. Set the beari ng 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 un til 4 to[...]

Groundsmaster 4500- - D/4700 - - D Page 6 - - 3 2 Axles, Planetaries and Brakes Differentia l Gear The following proce dures assume the rear axle assem- bly has been re moved from the machine. Removal 1. Remove bevel gear case/axle case assemblies (see Bevel Gear Case/Axle Case Assembly in this section of this manual). IMPORT ANT : Do not interchan[...]

Groundsmaster 4500- - D/4700 - - D Page 6 - - 33 Axles, Planetaries a nd Brakes Inspection 1. Measure the dif ferential side gear O.D. and the dif- ferential case I.D. to determine the side gear to ca se clearance (Fig. 42) . Replace components as ne cessary . SIDE GEAR TO CASE CLEARANCE: 0.002 to 0 .012 in. (0. 05 to 0.30 mm) SIDE GEAR O.D. (Facto[...]

Groundsmaster 4500- - D/4700 - - D Page 6 - - 3 4 Axles, Planetaries and Brakes Installation 1. If the r ing gear was removed from th e differ ential case, use medium strength Loctite thread locker and tighten the mountin g screws from 22 to 25 ft -lb (30 to 34 N - - m) . 2. Apply molybdenum disul fide lubricant (Three Bond 1901 or equivalent ) to [...]

Groundsmaster 4500- - D/4700 - - D Page 6 - - 35 Axles, Planetaries a nd Brakes Pinion Gear to Ring Gear Engagement The final position o f the pinion gear is verified b y using the gear contact pattern method as de scribed in the fol- lowing procedure. GEAR TOOTH DEFINITIONS (Fig. 46): To e - - the portion of the too th surface at the end to- wards[...]

Groundsmaster 4500- - D/4700 - - D Page 6 - - 3 6 Axles, Planetaries and Brakes Gear Patter n Movement Sum mary Every gear has a characteristic pattern. The il lustrations show typical patte rns only and exp lain how patt erns shift as gear location is chan ged. 1. If contact is toward th e heel or base of the g ear (Fig. 49): A. Install thick er o[...]

Groundsmaster 4500- - D/4700 - - D Page 7 - - 1 Chassis Chapter 7 Chassis T able o f Contents GENERAL INFORMA TION 2 ..................... Operator ’s Manu al 2 .......................... Cutting Deck Identification 2 .................... SERVICE AND REP AIRS 4 ...................... Steering Co lumn 4 ...................... ...... T raction Peda[...]

Groundsmaster 4500- - D/4700 - - D Page 7 - - 2 Chassis General Information Operator ’ s Manual The T raction Unit and Cutting Deck Operator ’s Manuals provide information regard ing the operation, general maintenance and mainten ance intervals for your Groundsmaster machine. Refer to these publications for additional infor mation when servicin[...]

Groundsmaster 4500- - D/4700 - - D Page 7 - - 3 Chassis This page is intentionally blank. Chassis[...]

Groundsmaster 4500- - D/4700 - - D Page 7 - - 4 Chassis Service and Repairs Steering Column 1. Steering wheel cover 2. Lock nut 3. Steering wheel 4. Flat washer 5. Socket head screw (4 used) 6. Flange head screw (4 used) 7. Steering column 8. Steering control valve 9. Socket head screw (4 used) 10. Flange nut (4 used) 1 1. Tinne rman nut (4 used) 1[...]

Groundsmaster 4500- - D/4700 - - D Page 7 - - 5 Chassis 9. Loosen and remove fou r (4) socket head screws (item 5) that secure steering control valve to steering column. 10. Loosen and remove four (4) socket head screws (item 9) and flange nuts (item 10) that secure steering column to machine. 1 1. Carefully raise steer i n gc o l u m na s s e m b [...]

Groundsmaster 4500- - D/4700 - - D Page 7 - - 6 Chassis Tr a c t i o n P e d a l 1. Washer head screw (2 used) 2. Reverse pedal pad 3. Pedal assembly 4. Spring pin 5. Forward pedal pad 6. Accelerator pedal 7. Cap screw 8. Flat washer 9. Jam nut 10. Rod end bearing 1 1. Slo tted ro ll pin 12. Cap screw (4 used) 13. Flange bearing mount 14. Flange nu[...]

Groundsmaster 4500- - D/4700 - - D Page 7 - - 7 Chassis IMPORT ANT : A properly assembled and calibr ated traction pedal position sensor is critical to accur ate traction system response a nd for reliable sensor life. Use care when rem oving, assembling and cali - brating the traction pedal position s ensor . Disassembly (Fig. 5) 1. Park machine on[...]

Groundsmaster 4500- - D/4700 - - D Page 7 - - 8 Chassis Console Arm 1. Console arm frame 2. LH cover 3. RH cover 4. W asher head screw (10 used) 5. Phillips head screw 6. Lock nut 7. Cover plate 8. Flange head screw (2 used) 9. Mount 10. U - - nut (5 used) 1 1. Flange head screw (5 used) 12. S witch panel 13. Riv et (2 used ) 14. Arm rest 15. Flang[...]

Groundsmaster 4500- - D/4700 - - D Page 7 - - 9 Chassis Disassembly (Fig. 8) 1. Park machine on a level s urface, lower cu tting decks, stop engine and engage parking brake. Remove key from igni tion switch. 2. Remove two (2) flange head screws (item 8) and then cover plate (item 7) from outside of console arm. Locate and retrieve two (2) flang e s[...]

Groundsmaster 4500- - D/4700 - - D Page 7 - - 10 Chassis Lift Arms for Cutting Decks #1, #4 and #5 1. Flat washer 2. Flange nut 3. Lift arm (#1 deck) 4. Lift cylinder pin 5. Flange head screw 6. Flange nut 7. Cap screw 8. Lift cylinder (#4 and #5 decks) 9. Lift cylinder (#1 deck) 10. Thrust washer (2 used per arm) 1 1. Lock nut 12. Pivot pin 13. Sl[...]

Groundsmaster 4500- - D/4700 - - D Page 7 - - 1 1 Chassis 5. Loosen and remo ve lock nut (item 1 1) from lift arm pivot pin. 6. Support lift arm and pull lift arm pivot pin from lift arm and frame. Locate and remove thr ust washers from bot h sides of lift arm during p ivot pin removal. 7. Remove lift arm from machin e. 8. Disassemble lift arm as n[...]

Groundsmaster 4500- - D/4700 - - D Page 7 - - 12 Chassis Lift Arms for Cutting Decks #2 and #3 1. Grease fitting 2. Set screw (2 used per stop) 3. Rotation stop 4. Flange head screw 5. Lock nut 6. Slotted roll pin 7. Pivo t pin 8. Bumper 9. Thrust washer 10. Lift cylinder pin 1 1. Deck pivot shaft 12. Lift arm (#2 deck shown) 13. Flange nut 14. Thr[...]

Groundsmaster 4500- - D/4700 - - D Page 7 - - 13 Chassis Removal (Fig. 13) 1. Park machine on a level s urface, lower cu tting decks, stop engine, engage parking brake and remove key from the ignition switch . 2. Remove cutti ng deck from lift arm (see Cutting Deck Operat or ’s Manu al). 3. Remove lift cylinder pin (item 10) that secures lift cyl[...]

Groundsmaster 4500- - D/4700 - - D Page 7 - - 14 Chassis Lift Arms for Cutting Decks #6 and #7 (Groundsmaster 4700 - - D) 1. Retaining ring 2. Flat washer (4 used per support arm) 3. Cap screw (4 used per support arm) 4. Flange bushing 5. Lift cylinder 6. Plastic roller 7. Lock nut 8. Grease fitting 9. Rear link 10. Lift link 1 1. Carriage screw 12[...]

Groundsmaster 4500- - D/4700 - - D Page 7 - - 15 Chassis Removal (Fig. 15) 1. Park machine on a level s urface, lower cu tting decks, stop engine, engage parking brake and remove key from the ignition switch . 2. Remove cutti ng deck from lift arm (see Cutting Deck Operat or ’s Manu al). 3. Remove pin (item 27) that secures lift links (ite m 10) [...]

Groundsmaster 4500- - D/4700 - - D Page 7 - - 16 Chassis Operator Seat 1. Seat frame 2. Seat plate 3. T orsion spring 4. Seat plate latch 5. Clevis pin 6. Flat washer 7. Cotter pin 8. Hair pin (4 used) 9. Seat frame rod (2 used) 10. R - - clamp (2 used) 1 1. Flat washer ( 3 used) 12. Hair pin 13. Seat pivot shaft 14. Screw (2 used) 15. Flat washer [...]

Groundsmaster 4500- - D/4700 - - D Page 7 - - 17 Chassis Removal (Fig. 17) 1. Park machine on a level s urface, lower cu tting 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 ar m assembly t o prevent it fr om shifting. 4. Remove [...]

Groundsmaster 4500- - D/4700 - - D Page 7 - - 18 Chassis Operator Seat Service 1. Backrest cushion 2. Seat cushion 3. LH armrest cover 4. LH armrest 5. Bushing (2 used) 6. Backrest 7. Plug (2 used) 8. Cable tie (3 used) 9. LH adjustment rail 10. Bumper (2 used) 11 . W a s h e r 12. Cap screw (2 used) 13. Seat 14. Nut 15. Spring (2 used) 16. Magnet [...]

Groundsmaster 4500- - D/4700 - - D Page 7 - - 19 Chassis Disassembly (Fig. 19) 1. Remove seat from ma chine for service (see Opera- tor Seat Removal in this section). 2. Disassemble operator sea t a s necessary using Fig- u r e1 9a sag u i d e . Assembly (Fig. 19) 1. Asse mble operator seat using Figure 19 as a guide. 2. Install seat to machine (se[...]

Groundsmaster 4500- - D/4700 - - D Page 7 - - 20 Chassis Operator Seat Suspension 1. Cover 2. Cover 3. Level control 4. Air control valve 5. Shock absorber 6. Air spring 7. Air tube assembly 8. Wire harness 9. Compressor 10. Bellows 11 . S t o p 12. Bumper set (2 used) 13. Roller (4 used) 14. W asher (2 used) 15. T ether 16. Rivet (2 used) 17. W as[...]

Groundsmaster 4500- - D/4700 - - D Page 7 - - 21 Chassis NOTE: Most of the seat suspension com ponents can be serviced with the seat suspension base mounte d to the seat plate. If the air spring assembly (item 6) requires removal, the seat suspension base will have to be re- moved from t he seat plat e. Disassembly (Fig. 20) 1. Park machine on a le[...]

Groundsmaster 4500- - D/4700 - - D Page 7 - - 22 Chassis Hood 1. Screen 2. Latch keeper 3. Pop rivet (2 used) 4. Hood 5. Plastic plug (20 used) 6. Hood screen 7. Radiator mount 8. Flange head screw 9. Hair pin (2 used) 10. Rear bumper 1 1. Washer (2 used) 12. Rubber bumper (2 used) 13. Flange nut (2 used) 14. Pop rivet (4 used) 15. Flex draw latch [...]

Groundsmaster 4500- - D/4700 - - D Page 7 - - 23 Chassis Removal (Fig. 22) 1. Park machine on a level s urface, lower cu tting decks, stop engine, engage parking brake and remove key from the ignition switch . 2. Release hood la tches and raise hood. 3. Remove hair pins and washers from pivot pins on ra- diator frame. 4. Remove hood fr om pivot pin[...]

Groundsmaster 4500- - D/4700 - - D Page 7 - - 24 Chassis This page is intentionally blank.[...]

Groundsmaster 4500- - D/4700 - - D Cutting D ecks Page 8 - - 1 Chapter 8 Cutting Decks T able o f Contents SPECIFICA TIONS 2 ............................ GENERAL INFORMA TION 3 ..................... Operator ’s Manu al 3 .......................... TROUBLESHOOTING 4 ......................... Factors That Can Affect Quality of Cut 4 ......... SPECI[...]

Groundsmaster 4500- - D/4700 - - D Cutting Decks Page 8 - - 2 Specifications Groundsmaste r 4700 - - D Groundsmaster 4500 - - D MOUNTING: All cutting decks are supporte d by inde- pendent lift arms and are interch angeable to any cutting deck positions. The Groundsmaster 4500 - - D uses five (5) cutting decks. The Gro undsmaster 4700 - - D uses sev[...]

Groundsmaster 4500- - D/4700 - - D Cutting D ecks Page 8 - - 3 General Information CAUTION Never install or work on the cuttin g decks or lift arms with the engine running. Always stop en- gine and remove key fr om ignition switch first. Operator ’ s Manual The Cutting Deck Operator ’s Manual provides in forma- tion regarding th e operation, ge[...]

Groundsmaster 4500- - D/4700 - - D Cutting Decks Page 8 - - 4 T roubleshooting There are a number of factors th at can contribute to un- satisfactory quali ty of cut, some of which may be tu rf conditions. T urf conditions such as excessive thatch, “sponginess”, uneven ground con ditions or attempting to cut off too much grass height may not al[...]

Groundsmaster 4500- - D/4700 - - D Cutting D ecks Page 8 - - 5 Special T ools Order special tools f rom your T oro Distributor . Rear Roller Bearing and Seal Installation T ools These tools are used to assemble the c utting deck rear roller . T oro Part Numbers: Inner Seal T ool 1 15 - - 0852 Bearing/Outer Seal T ool 1 15 - - 0853 Bearing Installat[...]

Groundsmaster 4500- - D/4700 - - D Cutting Decks Page 8 - - 6 Adjustments CAUTION Never install or work on the cutting decks or lift arms with the engine running. Always stop en- gine and remove key from ignition switch first. See the Cutting Deck Operator ’s Manual for adjustment procedures for cutti ng decks on the Groundsmaster 4500 - - D and [...]

Groundsmaster 4500- - D/4700 - - D Cutting D ecks Page 8 - - 7 This page is intentionally blank. Cutting Decks[...]

Groundsmaster 4500- - D/4700 - - D Cutting Decks Page 8 - - 8 Service and Repairs CAUTION Never install or work on the cutting decks or lift arms with the engine running. Always stop en- gine and remove key from ignition switch first. Blade Spindle A ssembly 1. Flange nut (6 used) 2. Hydraulic deck motor 3. Spindle plate 4. Cutting deck 5. O - - ri[...]

Groundsmaster 4500- - D/4700 - - D Cutting D ecks Page 8 - - 9 Removal (Fig. 4) 1. Park machine on a level s urface, lower cu tting decks, stop engine, engage parking brake and remove key from the ignition switch . 2. Remove two (2) socket hea d screws and flat wash- ers that secure hydraulic motor to the cutti ng deck (Fig. 5). Remove hydraulic mo[...]

Groundsmaster 4500- - D/4700 - - D Cutting Decks Page 8 - - 10 Blade Spindle Ser vice Disassembly (Fig. 6) 1. Remove blade spin d le from cutting deck (see Blade Spindle Removal in this section). 2. Loosen and remo ve spindle nut from t op of spindle shaft. 3. Remove the spin d le shaft from the spi ndle housing which may require the use of an arbo[...]

Groundsmaster 4500- - D/4700 - - D Cutting D ecks Page 8 - - 1 1 3. Using an arbor press, push the bearing cups into th e top and bottom of the spindle housin g. The t op bearing cup must contact the outer bearing s pacer previously installed, and the bottom bearing cup must contact the large snap ring. Make sure that the assembly is correct by sup[...]

Groundsmaster 4500- - D/4700 - - D Cutting Decks Page 8 - - 12 Rear Roller 1. Deck frame 2. Rear roller assembly 3. Grease fitting 4. Roller shaft screw 5. Roller mount 6. Flange head screw 7. Skid bracket 8. Cap screw Figure 10 8 5 4 1 7 6 3 2 FRONT RIGHT 29 to 35 ft - - lb (40 to 47 N - - m) 29 to 35 ft - - lb ( 4 0t o4 7N - - m )[...]

Groundsmaster 4500- - D/4700 - - D Cutting D ecks Page 8 - - 13 Removal (Fig. 10) 1. Park machine on a level s urface, lower cu tting decks, stop engine, engage parking brake and remove key from the ignition switch . 2. If cutting deck is eq u ipped with a roller scraper (Fig. 1 1), remove fasteners securing left and right scraper ro d brackets to [...]

Groundsmaster 4500- - D/4700 - - D Cutting Decks Page 8 - - 14 Rear Roller Service Disassembly (Fig. 12) 1. Remove bearing lock nut from ea ch end of roller shaft. 2. Loosely secure roll er assembly in bench vise and lightly ta p one end of roller shaft until outer seals and bearing are remove d from opposite end of roller tube. Remove second set o[...]

Groundsmaster 4500- - D/4700 - - D Cutting D ecks Page 8 - - 15 3. From the r oller tube end with o nly the inner seal installed, carefully install th e roller shaft into the roller tube. Make sure that seals are not damaged as sh aft is installed. 4. Instal l new bearing and outer seal s into second end of roller tube: A. Position a second new bea[...]

Groundsmaster 4500- - D/4700 - - D Cutting Decks Page 8 - - 16 Front Roller Service Disassembly (Fig. 18) 1. Remove roller moun ting bolt. 2. Remove roller assembly from carrier frame. 3. T o remove bearin gs and bearing spa cer: A. Insert pu nch throug h end of rolle r and drive opp o- site bearing out by alternating ta ps to opposite side of inne[...]

Groundsmaster 4500- - D/4700 - - D Cutting D ecks Page 8 - - 17 This page is intentionally blank. Cutting Decks[...]

Groundsmaster 4500- - D/4700 - - D Cutting Decks Page 8 - - 18 Cutting Deck Carrier Frame 1. Carr ier fr ame 2. L ynch pin 3. Thrust washer 4. Pivot shaft 5. Lift arm (#4 shown) 6. Flange nut (2 used p er deck) 7. Hardened washer (2 used per deck) 8. Cap screw (2 used per deck) 9. Cap s crew 10. Reb ound w asher 11 . P i v o t s h a f t 12. Lif t a[...]

Groundsmaster 4500- - D/4700 - - D Cutting D ecks Page 8 - - 19 Removal an d Insta llation ( Fig. 19) Each cutting deck is suspended from a carrier frame. The cutt ing deck car rier frame is attached to the lif t arm and allows the cutting de ck to pivot on the lift arm pivot shaft. Cutting deck positions are identifi ed in Figure 20. Cutting deck [...]

Groundsmaster 4500- - D/4700 - - D Cutting Decks Page 8 - - 20 This page is intentionally blank.[...]

Groundsmaster 4500- - D/4700 - - D Foldout Drawings Page 9 - 1 Chapter 9 Foldout Drawings T able o f Contents ELECTRICAL DRA WING DESIGNA TIONS 2 ....... HYDRAULIC SCHEMA TICS Groundsmaster 45 00 - - D 3 ..................... Groundsmaster 4500- - D with Optional Flow Divider Kit 4 ........................... Groundsmaster 47 00 - - D 5 ...........[...]

Groundsmaster 4500- - D/4700 - - D Foldout Drawings Page 9 - 2 Electrical Drawing Designations The following a bbreviations are us ed for wire harness colors on the electrical sch ematics and wire harness drawings in this chapter . ABBREVIA TION COLOR BK BLACK BR or BN BROWN BU BLUE GN GREEN GY GRA Y OR ORANGE PK PINK Ro rR D R E D TT A N VIO VIOL [...]

Page 9 - 3 Hydr aulic S chem atic Groundsmaster 4500 - - D 1. FLOWS SHOWN ARE CALCUL A TED A T HI GH IDLE AND 95% PUMP EFFICIENCY UNLE SS OTHERWISE NOTED 0.630” ROD 0.630” ROD 1050 PSI 1600 PSI 6.2 GPM 11 . 4 G P M 3500 PSI 3500 PSI 1500 PSI 1500 PSI P1 P2 T1 G1 PRV1 PRV2 LC1 LC2 M1 M2 M3 M4 T RV09 PRV S1 CV FD P2 P1 ST L M1 M2 PE T R P CHG G1 [...]

Page 9 - 4 Hydr aulic S chem atic With Optional Flow Di vider Kit 1. FLOWS SHOWN ARE CALCUL A TED A T HI GH IDLE AND 95% PUMP EFFICIENCY UNLE SS OTHERWISE NOTED 0.630” ROD 0.630” ROD 1050 PSI 1600 PSI 6.2 GPM 11 . 4 G P M 3500 PSI 3500 PSI 1500 PSI 1500 PSI P1 P2 T1 G1 PRV1 PRV2 LC1 LC2 M1 M2 M3 M4 T RV09 PRV S1 CV FD P2 P1 ST L M1 M2 PE T R P [...]

Page 9 - 5 Hydr aulic S chem atic Groundsmaster 4700 - - D 1. FLOWS SHOWN ARE CALCUL A TED A T HI GH IDLE AND 95% PUMP EFFICIENCY UNLE SS OTHERWISE NOTED 0.630” ROD 0.630” ROD 1050 PSI 6.2 GPM 11 . 4 G P M T PRV S1 CV FD P2 P1 ST L M1 M2 PE T R 50/50 FLOW DIVIDER FAN CONTR OL MANIFO LD MANIFO LD 4350 PSI 30.5 GPM 1.83 CID / 0.89 CID PR 450 PSI [...]

Page 9 - 6 1. FLOWS SHOWN ARE CALCUL A TED A T HI GH IDLE AND 95% PUMP EFFICIENCY UNLE SS OTHERWISE NOTED 0.630” ROD 0.630” ROD 1050 PSI 6.2 GPM 11 . 4 G P M T PRV S1 CV FD P2 P1 ST L M1 M2 PE T R 50/50 FLOW DIVIDER FAN CONTR OL MANIFO LD MANIFO LD 4350 PSI 30.5 GPM 1.83 CID / 0.89 CID PR 450 PSI RV PSI .050 CV T P2 M8 CH OR1 250 PSI 5000 PSI E[...]

Page 9 - 7 Electr ical Schematic Groundsmaster 4500 - - D/4700 - - D Models 30881 and 30882 GM4700- D TRACTION PEDAL POSITI ON SENSOR TRACTION PEDAL POSITI ON SENSOR LH (#4) DECK RH (#5) DECK All r elays and so lenoids are shown as de - - energiz ed. All gr ound wir es are black. WIRE COLOR ABBREVIA TIONS. NOTE: REFER TO ELE CTRICAL DRA WING DESIGN[...]

Page 9 - 8 Electr ical Schematic Groundsmaster 4500 - - D/4700 - - D Models 30873 and 30874 All r elays and so lenoids are shown as de - - energiz ed. All gr ound wir es are black. GM4700- D TRACTION PEDAL POSITI ON SENSOR TRACTION PEDAL POSITI ON SENSOR LH (#4) DECK RH (#5) DECK LH (#7) DEC K POSIT ION SWI TCH RH (#6) DECK POSI TIO N SWIT CH WIRE [...]

Page 9 - 9 Electr ical Schematic Groundsmaster 4500 - - D/4700 - - D Optional Operator Cab All r elays and so lenoids are shown as de - - energiz ed. All gr ound wir es are black. WIRE COLOR ABBREVIA TIONS. NOTE: REFER TO ELE CTRICAL DRA WING DESIGNA TIONS IN THIS CHAPTER FOR[...]

Page 9 - 10 Groundsmaster 4500 - - D/4700 - - D Ma in Wi re Ha rn es s P26 DECK PTO 1 P24 DECK PTO 2 P19 S5 P20 S6 P89 INTERCONNECT T O SEA T/ CONSOLE P04 HEADLIGHT RH P79 HEADLIGHT LH P07 RH (#5 ) DECK POSITION SWITCH P13 P87 GM 4700 INTERCONNECT GROUND P88 GM 4700 INTERCONNECT P93 ENGIN E GROUND P21 FAN D I RE C T I ON P22 FAN SPEED P69 TEC- -500[...]

Page 9 - 1 1 Groundsmaster 4500 - - D/4700 - - D Ma in Wi re Ha rn es s DRAWING DESIGNA TIONS IN THIS CHAPTER NOTE: T HIS DRAWING IDENTIFIES WIRE GAUGE SIZE AND WIRE COLOR. REFER TO ELECTRICAL FOR ADDITIO NAL INFORMA TION. TRACTION PEDAL POSITI ON SENSOR RH (#5) DECK POSITI ON SWI TCH LH (#4) DECK POSITI ON SWI TCH[...]

Page 9 - 12 Groundsmaster 4500 - - D/4700 - - D Seat and Console Wire Har n ess[...]

Page 9 - 13 Groundsmaster 4500 - - D/4700 - - D Seat and Console Wire Har n ess DRAWING DESIGNA TIONS IN THIS CHAPTER NOTE: T HIS DRAWING IDENTIFIES WIRE GAUGE SIZE AND WIRE COLOR. REFER TO ELECTRICAL FOR ADDITIO NAL INFORMA TION.[...]

Page 9 - 14 Groundsmaster 4500 - - D/4700 - - D Power Center Wir e Harness[...]

Page 9 - 15 Groundsmaster 4500 - - D/4700 - - D Power Center Wir e Harness DRAWING DESIGNA TIONS IN THIS CHAPTER NOTE: T HIS DRAWING IDENTIFIES WIRE GAUGE SIZE AND WIRE COLOR. REFER TO ELECTRICAL FOR ADDITIO NAL INFORMA TION.[...]

Page 9 - 16 D e c k6a n d7W i r eH a r n e s s Groundsmaster 4700 - - D LH (#7) DECK RH (#6) DECK POSI TIO N SWITCH POSI TIO N SWITCH 1 11 21 31 41 30 20 10 40 50 NO TE T AB POS ITION PIN AND BACKSHELL ORIEN T A TION (TEC- -5001)[...]

Page 9 - 17 D e c k6a n d7W i r eH a r n e s s Groundsmaster 4700 - - D DRAWING DESIGNA TIONS IN THIS CHAPTER NOTE: T HIS DRAWING IDENTIFIES WIRE GAUGE SIZE AND WIRE COLOR. REFER TO ELECTRICAL FOR ADDITIO NAL INFORMA TION. LH (#7) DEC K RH (#6 ) DECK POSITION SWITCH POSITION SWITCH[...]

Page 9 - 18 (Models 30881 and 30882) Engi ne Wire H arnes s Dr awing Groundsmaster 4500 - - D/4700 - - D PIN AND BACKSHELL ORIEN T A TION FOR P01 & P02[...]

Page 9 - 19 (Models 30881 and 30882) Engi ne Wire H arnes s Dia gram DRAWING DESIGNA TIONS IN THIS CHAPTER NOTE: T HIS DRAWING IDENTIFIES WIRE GAUGE SIZE AND WIRE COLOR. REFER TO ELECTRICAL FOR ADDITIO NAL INFORMA TION. Groundsmaster 4500 - - D/4700 - - D[...]

Page 9 - 20 (Models 30873 and 30874) Engi ne Wire H arnes s Dr awing Groundsmaster 4500 - - D/4700 - - D PIN AND BACKSHELL ORIEN T A TION FOR P23[...]

Page 9 - 21 DRAWING DESIGNA TIONS IN THIS CHAPTER NOTE: T HIS DRAWING IDENTIFIES WIRE GAUGE SIZE AND WIRE COLOR. REFER TO ELECTRICAL FOR ADDITIO NAL INFORMA TION. (Models 30873 and 30874) Eng i n e Wire H arn e ss D ia g ram Groundsmaster 4500 - - D/4700 - - D[...]