Toro Groundsmaster 4500-D Service Manual Download Page 83

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Groundsmaster 4500--D/4700--D

Hydraulic System (Rev. A)

Page 4 -- 45

Procedure for Counterbalance (RV1) Pressure Test

1. Make sure hydraulic oil is at normal operating tem-

perature by operating the machine for approximately 10

minutes. Make sure the hydraulic tank is full.

2. Park machine on a level surface with the cutting units

lowered and off. Make sure engine is off and the parking

brake is engaged.

CAUTION

Prevent personal injury and/or damage to equip-

ment. Read all WARNINGS, CAUTIONS, and Pre-

cautions for Hydraulic Testing at the beginning

of this section.

3. Connect a 1000 PSI gauge to counterbalance test

port on power down and traction assist manifold under

operator’s seat (Fig. 44).

4. Start the engine and put throttle at full engine speed

(2800 + 50 RPM)

with no load on the system.

Do not en-

gage the cutting units

GAUGE READING TO BE

600 to 640 PSI

NOTE:

Counterbalance pressure setting toward the

higher specification (640 PSI) will improve traction on

slopes. Counterbalance pressure setting toward the

lower specification (600 PSI) improves quality of cut.

5. Adjustment of the counterbalance valve can be per-

formed as follows:

NOTE:

Do not remove the valve from the hydraulic

manifold for adjustment.

A. To

increase

pressure setting, turn the adjusting

dial on the counterbalance valve in a clockwise di-

rection. A 1/8 turn on the dial will make a measurable

change in counterbalance pressure (Fig. 45).

B. To

decrease

pressure setting, turn the adjusting

dial on the counterbalance valve in a counterclock-

wise direction. A 1/8 turn on the dial will make a mea-

surable change in counterbalance pressure (Fig.

45).

C. Recheck counterbalance pressure and readjust

as needed.

1. Traction assist manifold (GM 4500--D shown)

2. Counterbalance test port

Figure 44

1. GM 4500--D traction assist manifold

2. GM 4700--D traction assist manifold

3. Counterbalance valve (RV1)

Figure 45

Hydraulic System

Summary of Contents for Groundsmaster 4500-D

Page 1: ...Form No 02104SL Rev E Groundsmaster 4500 D 4700 D Original Instructions EN ...

Page 2: ...ocument or the disclosure of its content This document shall not be reproduced by a third party without the express written consent of The Toro Company and or the appropriate affiliated company Revision History Revision Date Description 2002 Initial Issue A 2003 Updated Engine chapter B 2005 Updated Hydraulic chapter C 2007 Updated Electrical chapter D 2007 Updated Hydraulic chapter E 03 2018 Adde...

Page 3: ...blications To do this effectively we encourage user feedback Please comment on the completeness accuracy organization usability and readability of this manual by an e mail to servicemanuals toro com or Mail to Technical Publication Manager Commercial The Toro Company 8111 Lyndale Avenue South Bloomington MN 55420 1196 Phone 1 952 887 8495 ...

Page 4: ...NOTES _ ...

Page 5: ... Toro com or by sending complete Model and Seri al Number to The Toro Company Attn Technical Publications 8111 Lyndale Avenue South Bloomington MN 55420 1196 The Toro Company reserves the right to change product specifications or this publication without notice This safety symbol means DANGER WARNING or CAUTION PERSONAL SAFETY INSTRUC TION When you see this symbol carefully read the instructions t...

Page 6: ...Groundsmaster 4500 D 4700 D This page is intentionally blank ...

Page 7: ... 22 Testing 4 25 Service and Repairs 4 52 Chapter 5 Electrical System Electrical Schematics and Electrical Harness and Connectors Drawings 5 2 Special Tools 5 2 Troubleshooting 5 3 Electrical System Quick Checks 5 6 Component Testing 5 7 Service and Repairs 5 27 Chapter 6 Axles Planetaries and Brakes Specifications 6 2 Adjustments 6 3 Service and Repairs 6 4 Chapter 7 Chassis General Information 7...

Page 8: ...Groundsmaster 4500 D 4700 D This page is intentionally blank ...

Page 9: ...00 D 4700 D Page 1 1 Safety Chapter 1 Safety Table of Contents GENERAL SAFETY INSTRUCTIONS 2 Before Operating 2 While Operating 2 Maintenance and Service 3 JACKING INSTRUCTIONS 4 SAFETY AND INSTRUCTION DECALS 5 Safety ...

Page 10: ...tches are adjusted correctly so engine cannot be started unless traction pedal is in NEUTRAL and cutting units are DISENGAGED 4 Since diesel fuel is highly flammable handle it care fully A Use an approved fuel container B Do not remove fuel tank cap while engine is hot or running C Do not smoke while handling fuel D Fill fuel tank outdoors and only to within an inch of the top of the tank not the ...

Page 11: ...utting units and other mov ing parts Keep bystanders away 10 Do not overspeed the engine by changing governor setting To assure safety and accuracy check maximum engine speed 11 Shut engine off before checking or adding oil to the crankcase 12 Disconnect battery before servicing the machine Disconnect negative battery cable first and positive cable last If battery voltage is required for troublesh...

Page 12: ...1 Set parking brake and chock both rear tires to pre vent the machine from moving IMPORTANT Do not place jack jack stands or blocks under the wheel motors Wheel motors can be damaged if used for jacking or support points 2 Position jack securely under the frame just to the in side of the front tire 3 Jack front of machine off the ground 4 Position jack stands or hardwood blocks under the frame as ...

Page 13: ...ety Safety and Instruction Decals Numerous safety and instruction decals are affixed to the Groundsmaster 4500 D 4700 D If any decal be comes illegible or damaged install a new decal Decal part numbers are listed in your Parts Catalog Safety ...

Page 14: ...Groundsmaster 4500 D 4700 D Page 1 6 Safety This page is intentionally blank ...

Page 15: ... Fasteners 5 Other Torque Specifications 6 Conversion Factors 6 Product Records Insert Operator s Manual and Parts Catalog for your Groundsmaster 4500 D 4700 D at the end of this chapter Additionally if any optional equipment or ac cessories have been installed to your machine insert the Installation Instructions Operator s Manuals and Parts Catalogs for those options at the end of this chap ter M...

Page 16: ...0 09375 Rev D Groundsmaster 4500 D 4700 D Page 2 2 Product Records and Maintenance Equivalents and Conversions ...

Page 17: ...ailing torque feature hardnessofthesurfaceunderneaththefastener shead or similar condition which affects the installation As noted in the following tables torque values should be reduced by 25 for lubricated fasteners to achieve the similar stress as a dry fastener Torque values may also have to be reduced when the fastener is threaded into aluminum or brass The specific torque value should be det...

Page 18: ... 2 16 2 22 3 30 3 41 4 43 4 58 5 3 8 24 UNF 17 2 18 2 24 3 35 3 47 4 50 4 68 5 7 16 14 UNC 27 3 27 3 37 4 50 5 68 7 70 7 95 9 7 16 20 UNF 29 3 29 3 39 4 55 5 75 7 77 7 104 9 1 2 13 UNC 30 3 48 7 65 9 75 8 102 11 105 10 142 14 1 2 20 UNF 32 3 53 7 72 9 85 8 115 11 120 10 163 14 5 8 11 UNC 65 10 88 12 119 16 150 15 203 20 210 20 285 27 5 8 18 UNF 75 10 95 15 129 20 170 15 230 20 240 20 325 27 3 4 10...

Page 19: ...ft lb 90 10 N m 92 9 ft lb 125 12 N m M16 X 2 0 166 15 ft lb 225 20 N m 229 22 ft lb 310 30 N m M20 X 2 5 325 33 ft lb 440 45 N m 450 37 ft lb 610 50 N m NOTE Reduce torque values listed in the table above by 25 for lubricated fasteners Lubricated fasteners are defined as threads coated with a lubricant such as oil graphite or thread sealant such as Loctite NOTE Torque values may have to be reduce...

Page 20: ... 100 in lb Wheel Bolts and Lug Nuts Thread Size Recommended Torque 7 16 20 UNF Grade 5 65 10 ft lb 88 14 N m 1 2 20 UNF Grade 5 80 10 ft lb 108 14 N m M12 X 1 25 Class 8 8 80 10 ft lb 108 14 N m M12 X 1 5 Class 8 8 80 10 ft lb 108 14 N m For steel wheels and non lubricated fasteners Thread Cutting Screws Zinc Plated Steel Thread Size Threads per Inch Baseline Torque Size Type A Type B Baseline Tor...

Page 21: ...S 4 Engine Run Solenoid 4 SERVICE AND REPAIRS 5 Air Filter System 5 Exhaust System 6 Fuel System 8 Check Fuel Lines and Connections 8 Drain and Clean Fuel Tank 8 Fuel Tank Removal 9 Fuel Tank Installation 9 Radiator 10 Engine 12 Engine Removal 13 Engine Installation 14 Pump Adapter Plate 16 KUBOTA WORKSHOP MANUAL DIESEL ENGINE V2003 T SERIES Kubota Diesel Engine ...

Page 22: ...3 T that is included at the end of this section Most repairs and adjustments require tools which are commonly available in many service shops Special tools are described in the Kubota Workshop Manual Diesel Engine V2003 T The use of some specialized test equipment is explained However the cost of the test equipment and the specialized nature of some re pairs may dictate that the work be done at an...

Page 23: ...S gallons 79 5 21 0 Fuel Injection Pump Bosch Type Mini Pump PFR Governor Centrifugal Mechanical Low Idle no load 1300 50 RPM High Idle no load 2800 50 RPM Direction of Rotation Counterclockwise Viewed from Flywheel Compression Ratio 22 0 1 Injection Nozzle Bosch Throttle Type Engine Oil SAE 10W30 or 10W40 Detergent API CD or higher Oil Pump Trochoid Type Crankcase Oil Capacity liters U S quarts 7...

Page 24: ... and position the fuel stop lever to within 1 16 1 6 mm of stop on the injec tion pump 2 If adjustment is needed loosen lock nut and rotate the threaded end of the swivel until the lever is properly positioned 3 Tighten lock nut Recheck adjustment 1 Run solenoid ON 2 Lever 3 Swivel 4 Lock nut Figure 1 2 3 1 4 Figure 2 1 Run solenoid OFF 2 Solenoid lever 3 Injection pump stop 3 1 2 ...

Page 25: ...RTANT Any leaks in the air filter system will cause serious engine damage Make sure daily that all air cleaner components are in good condition and are properly secured during reassembly 1 Assemble air filter system using Figure 3 as a guide 2 When installing air cleaner hose 8 between air cleaner and turbo charger Fig 4 A Make sure that hose does not contact engine valve cover To modify clearance...

Page 26: ... 3 Exhaust tailpipe 4 Flange head screw 5 Exhaust gasket 6 Lock nut 7 Cap screw 8 Flat washer 9 Spacer 10 Rubber hanger 11 Flange nut 12 Flange head screw 13 Engine mount 14 Muffler clamp 11 2 1 14 3 12 4 11 7 8 6 10 8 7 6 9 13 16 to 22 ft lb 21 to 29 N m 16 to 22 ft lb 21 to 29 N m 16 to 22 ft lb 21 to 29 N m 5 FRONT RIGHT ...

Page 27: ...amage that may prevent a tight seal 1 Install new gasket if original gasket is damaged or torn IMPORTANT Failure to follow the suggested muf fler fastener sequence may result in premature muf fler failure 2 Install muffler and or muffler bracket to the engine using Figure 5 as a guide Hand tighten and then torque the following fasteners from 16 to 22 ft lb 21 to 29 N m in the sequence listed Fig 6...

Page 28: ...l fuel tank outside and wipe up any spilled diesel fuel before start ing the engine Store fuel in a clean safety ap proved container and keep cap in place Use die sel fuel for the engine only not for any other purpose Check Fuel Lines and Connections Check fuel lines and connections periodically as recom mended in the Traction Unit Operator s Manual Check lines for deterioration damage leaking or ...

Page 29: ...l hoses from the suction and return fit tings in top of tank 3 Use draincock to empty fuel tank into a suitable con tainer 4 Remove fuel tank using Figure 7 as a guide Fuel Tank Installation 1 Install fuel tank to frame using Figure 7 as a guide 2 Connect fuel hoses to the suction and return fittings in top of tank 3 Make sure that draincock is closed 4 Fill fuel tank see Traction Unit Operator s ...

Page 30: ...17 Flat washer 18 Flange head screw 19 Coolant reservoir 20 Reservoir cap 21 Flange head screw 22 Flange nut 23 Bulb seal 24 Bottom cover 25 Flange head screw 26 Washer head screw 27 Spacer 28 O ring 29 O ring 30 Oil cooler mount plate 31 Oil cooler clamp 32 Flat washer 33 Cap screw 34 Wire form clamp 35 Cap screw 36 Washer 37 Oil cooler bracket top 38 Bulb seal 39 Foam seal 40 Foam seal FRONT RIG...

Page 31: ... washers Posi tion shroud away from radiator 8 Pivot rear screen and oil cooler away from radiator see Traction Unit Operator s Manual 9 Remove flange head screws and lock nuts securing the radiator to the support frame Pull radiator from the machine 10 Plug any radiator or hose openings to prevent con tamination Installation 1 Remove any plugs used during the removal proce dure 2 Position radiato...

Page 32: ...9 Lock washer 10 Bolt 11 LH engine mount 12 Muffler bracket lift tab 13 Flange nut 14 Cap screw 15 Flat washer 16 Spacer 17 Rubber hanger exhaust 18 Lock nut 19 RH engine mount 20 Cap screw 21 RH engine mount 22 Fusible link 23 Engine wire harness 24 Cap screw 25 Lift tab FRONT RIGHT 13 14 15 17 15 18 19 20 1 2 3 4 5 4 6 7 8 9 10 11 12 23 22 16 21 16 to 22 ft lb 21 to 29 N m 16 to 22 ft lb 21 to 2...

Page 33: ...ot To avoid possible burns allow the exhaust system to cool before working on or near the muffler 4 Remove exhaust system from engine see Muffler Removal 5 Remove air cleaner system from engine see Air Cleaner Removal 6 Note location of cable ties used to secure wires Dis connect the following electrical components A The temperature sender and alternator Fig 12 Note red wire attached to alternator...

Page 34: ...ft to the front Fig 11 and rear Fig 14 lift tabs on engine 15 Remove flange head nuts rebound washers and cap screws securing the engine mounts to the rubber engine supports CAUTION One person should operate lift or hoist while the other person guides the engine out of the ma chine IMPORTANT Make sure not to damage the engine fuel lines hydraulic lines electrical harness or oth er parts while remo...

Page 35: ... Connect wires and or electrical connections to the following electrical components A The temperature sender and alternator Fig 12 B The engine run solenoid Fig 13 C The high temperature shutdown switch and glow plug connection Fig 14 D Battery frame and wire harness ground to the engine block Fig 15 E The electric starter Fig 15 F Fusible link harness connector and low oil pres sure switch locate...

Page 36: ...Cap screw 4 used 4 Pump adapter plate 5 Plate pin 2 used 6 Dowel 2 used 7 Coupling spacer 8 Shoulder bolt 2 used 9 Spring center coupling 10 Lock washer 11 Cap screw 6 used 12 Cap screw 9 used 5 4 2 12 10 11 10 9 8 7 6 3 2 1 FRONT RIGHT 17 to 21 ft lb 23 to 28 N m 17 to 21 ft lb 23 to 28 N m 35 to 43 ft lb 48 to 58 N m ...

Page 37: ... 2 Install four cap screws and lockwashers to coupling spacer and flywheel Torque cap screws from 17 to 21 ft lb 23 to 28 N m 3 Place dowels in locating holes of coupling spacer Fig 19 4 Position spring center coupling coil springs toward engine Fig 20 over dowels Secure coupling to cou pling spacer with cap screws and lockwashers Torque cap screws from 35 to 43 ft lb 48 to 58 N m 5 Install plate ...

Page 38: ...Groundsmaster 4500 D 4700 D Page 3 18 Kubota Diesel Engine Rev A This page is intentionally blank ...

Page 39: ...ecautions for Removing and Installing Hydraulic System Components 52 Check Hydraulic Lines and Hoses 52 Flush Hydraulic System 53 Charge Hydraulic System 54 Gear Pump 56 Gear Pump Service 58 Piston Traction Pump 62 Piston Traction Pump Service 64 Piston Pump Manual Servo Control Assembly 68 Hydraulic Control Manifolds 2 Wheel 4 Wheel Drive Filtration and Charge Power Down and Traction Assist 70 Hy...

Page 40: ...n positive displacement gear type pump Cutting Deck Relief Pressure 3500 PSI 241 5 bar Steering Relief Pressure 1180 PSI 81 4 bar Lift Lower Relief Pressure 2200 PSI 151 8 bar Front Wheel Motors Fixed displacement piston motors Rear Axle Motor Fixed displacement piston motor Cutting Deck Motors Gear motor Hydraulic Filters 2 Micron nominal spin on cartridge type In line Suction Strainer 100 mesh i...

Page 41: ...s Hydraulic fluid escaping under pressure can have sufficient force to penetrate the skin and cause serious injury If fluid is injected into the skin it must be surgi cally removed within a few hours by a doctor familiar with this type of injury Gangrene may result from such an injury Hydraulic Fitting Installation O Ring Face Seal 1 Make sure both threads and sealing surfaces are free of burrs ni...

Page 42: ...10 ft lb 12 13 N m 6 20 21 ft lb 27 28 N m 8 35 37 ft lb 47 50 N m 10 60 66 ft lb 81 89 N m 12 81 87 ft lb 110 117 N m 16 121 131 ft lb 164 177 N m Figure 4 SAE Straight Thread O Ring Port Adjustable 1 Make sure both threads and sealing surfaces are free of burrs nicks scratches or any foreign material 2 Always replace the O ring seal when this type of fit ting shows signs of leakage 3 Lubricate t...

Page 43: ... equipped with a by pass valve that needs to be turned 90o for tow ing See Traction Unit Operator s Manual for additional tow ing procedures 1 By pass valve location Figure 7 1 Check Hydraulic Fluid The Groundsmaster 4500 D and 4700 D hydraulic systems are designed to operate on anti wear hydraulic fluid The reservoir holds about 7 5 gallons 28 4 liters of hydraulic fluid Check level of hydraulic ...

Page 44: ...Groundsmaster 4500 D 4700 D Hydraulic System Rev A Page 4 6 Hydraulic Schematics Hydraulic Schematic Groundsmaster 4500 D All solenoids are shown as de energized 2200 PSI ...

Page 45: ...Groundsmaster 4500 D 4700 D Hydraulic System Rev A Page 4 7 Hydraulic Schematic Groundsmaster 4700 D All solenoids are shown as de energized 2200 PSI Hydraulic System ...

Page 46: ...r 4500 D 4700 D Hydraulic System Rev A Page 4 8 Hydraulic Flow Diagrams Traction Circuit GM 4500 D Forward 4WD Shown Working Pressure Low Pressure Charge Return or Suction Flow Groundsmaster 4500 D 4700 D 2200 PSI ...

Page 47: ... is directed through the oil filter and to the low pressure side of the closed loop traction circuit A filter bypass valve allows charge oil flow to the closed loop if the filter becomes plugged Charge pressure is limited by a relief valve located in the filtration and charge control manifold Charge pressure can be measured at the charge circuit pressure test port on the filtration and charge cont...

Page 48: ...Groundsmaster 4500 D 4700 D Hydraulic System Rev A Page 4 10 Lower Cutting Units GM 4500 D Shown Working Pressure Low Pressure Charge Return or Suction Flow Groundsmaster 4500 D GM 4700 D 2200 PSI ...

Page 49: ...rom the rod end of the lift cylinders The weight of the cutting decks causes the lift cylinders to extend lowering the cutting units An orifice positioned in the lift lower control valve restricts oil flow from the lift cylinders to control deck drop speed Oil from the rod end of the cylinders is allowed to return to the traction charge cir cuit The piston end of the cylinders are replenished by t...

Page 50: ...Groundsmaster 4500 D 4700 D Hydraulic System Rev A Page 4 12 Raise Cutting Units GM 4500 D Shown Working Pressure Low Pressure Charge Return or Suction Flow Groundsmaster 4500 D 4700 D 2200 PSI ...

Page 51: ... cutting decks the lift lever on the lift lower control valve is pulled to allow valve shift in the lift lower control valve This valve change allows hy draulic pressure to the rod end of the lift cylinder and causes the shaft to retract raising the cutting units Oil from the piston end of the cylinder flows to the traction charge circuit When the lift lever is released the lift cyl inders are hel...

Page 52: ...Groundsmaster 4500 D 4700 D Hydraulic System Rev A Page 4 14 Mow Circuit GM 4500 D Shown Working Pressure Low Pressure Charge Return or Suction Flow Groundsmaster 4500 D 4700 D 2200 PSI ...

Page 53: ...h a solenoid controlled propor tional relief valve PRV1 PRV2 a solenoid valve SV2 two logic cartridges LC1 and LC2 and two brake relief cartridges RV8 and RV9 When the PTO switch is OFF or if decks are raised the deck solenoid valves SV2 and PRV1 PRV2 are not energized allowing hydraulic flow to by pass the deck motors through the manifold When the PTO switch is turned ON with the decks low ered t...

Page 54: ...ting cutting blades increases pres sure of the oil return to the deck control manifold This pressure increase along with the orifice in the manifold and the shifted relief valve RV cause logic cartridge LC1 to shift Fig 16 The oil from the deck motors is finally directed through the orificeand toreliefvalve RV which bleeds the residual pressure in the circuit and al lows the blades to stop in a co...

Page 55: ...Groundsmaster 4500 D 4700 D Hydraulic System Rev A Page 4 17 This page is intentionally blank Hydraulic System ...

Page 56: ...Groundsmaster 4500 D 4700 D Hydraulic System Rev A Page 4 18 Steering Circuit GM 4500 D Right Turn Shown Working Pressure Low Pressure Charge Return or Suction Flow Groundsmaster 4500 D 4700 D 2200 PSI ...

Page 57: ...meter V1 and out the L port Pressure contracts the piston for a left turn The rotary meter ensures that the oil flow to the cylinder is proportional to the amount of the turning on the steering wheel Fluid leaving the cylinder flows back through the spool valve then through the T port and to the hydraulic reservoir The steering wheel and steering control valve return to the neutral position when t...

Page 58: ...O ring Face Seal ORFS adapter fittings for use on this machine 1 INLET HOSE Hose connected from the system cir cuit to the inlet side of the hydraulic tester 2 LOAD VALVE A simulated working load is created in the circuit by turning the valve to restrict flow 3 LOW PRESSUREGAUGE Low range gauge to pro vide accurate reading at low pressure 0 to 1000 PSI A protector valve cuts out when pressure is a...

Page 59: ...igure 21 Measuring Container TOR4077 Use this container for doing hydraulic motor efficiency testing motors with case drain lines only Measure effi ciency of a hydraulic motor by restricting the outlet flow from the motor and measuring leakage from the case drain line while the motor is pressurized by the hydraulic system The table in Figure 23 provides gallons per minute GPM conversion formeasure...

Page 60: ...ed Hydraulic oil in reservoir foams Hydraulic reservoir oil level is low Wrong type of oil is in the hydraulic system Air is leaking in suction line Machine operates in one direction only Traction control linkage is faulty System charge check valve and or system relief valve is defective Pilot direction valve in 4WD manifold is damaged or sticking Traction pedal is sluggish Traction control linkag...

Page 61: ...d lift lower also affected One cutting deck will not operate System pressure to the affected deck is low Spline on affected deck motor or spindle is damaged Deck motor relief valve is stuck or damaged Deck motor is damaged Note If appropriate transfer a suspected damaged motor to another cutting deck If problem follows the motor motor needs repair or replacement Cartridge valve in deck manifold SV...

Page 62: ...manifold is damaged or sticking Proportional valve in gear pump is faulty Gear pump section for lift lower circuit P3 is inefficient Cutting units raise but will not stay up Lift circuit lines or fittings are leaking Detents in lift lower control valve are worn Lift cylinder is damaged Cutting units will not lower Lift arm pivots are binding Lift cylinder is damaged Counterbalance pressure is exce...

Page 63: ... result from such an injury WARNING Before disconnecting or performing any work on the hydraulic system all pressure in the system must be relieved and all rotating ma chine parts must be stopped Stop engine lower or support attachments 1 Clean machine thoroughly before disconnecting or disassembling any hydraulic components Always keep in mind the need for cleanliness when working on hy draulic e...

Page 64: ...rge Pressure Using Pressure Gauge TO TRACTION CONTROL MANIFOLD CHARGE CIRCUIT TO PTO MOW CIRCUIT FROM PTO MOW CIRCUIT FROM PTO MOW CIRCUIT FROM STEERING CONTROL TO LIFT LOWER CIRCUIT TO STEERING CIRCUIT Working Pressure Low Pressure Return or Suction Flow FROM STEERING CONTROL AND LIFT SYSTEM ...

Page 65: ...ssure or pressure is low check for restriction in pump intake line Also inspect charge relief valve located in filter manifold and charge check valve system relief valve in hydrostat If necessary check for internal damage or worn parts in gear pump 6 Also with the pressure gauge still connected to the charge pressure test port monitor the gauge reading while operating the machine in forward and re...

Page 66: ...elief Pressure Using Pressure Gauge TO PTO MOW CIRCUIT FROM PTO MOW CIRCUIT FROM PTO MOW CIRCUIT FROM STEERING CONTROL TO TRACTION CONTROL MANIFOLD TO LIFT LOWER CIRCUIT TO STEERING CIRCUIT CHARGE CIRCUIT Working Pressure Low Pressure Return or Suction Flow NOTE FORWARD DIRECTION TEST SHOWN ...

Page 67: ...se port faces rearward 4 Start the engine and move throttle to full speed 2800 50 RPM Release parking brake 5 Siton seat apply brakesfully andslowly depressthe traction pedal in the appropriate direction While pu shing traction pedal look at pressure reading on gauge GAUGE READING TO BE Forward 5000 PSI Reverse 5000 PSI 6 If traction pressure is too low inspect traction pump relief valves in pisto...

Page 68: ...EST NO 3 Cutting Deck Circuit Pressure Using Pressure Gauge Working Pressure Low Pressure Return or Suction Flow GM 4500 D GM 4700 D TO LIFT LOWER CIRCUIT TO STEERING CIRCUIT TO LIFT LOWER CIRCUIT TO STEERING CIRCUIT FROM LIFT LOWER CIRCUIT FROM LIFT LOWER CIRCUIT ...

Page 69: ...nifold test port for the gear pump section to be tested Fig 28 or 29 CAUTION Keep away from decks during test to prevent per sonal injury from the cutting blades 4 Start engine and move throttle to full speed 2800 50 RPM Engage the cutting units 5 Watch pressure gauge carefully while mowing with the machine 6 Cutting deck circuit pressure should be from 1000 to 3500 PSI and will vary depending on ...

Page 70: ...Cutting Deck Gear Pump Flow Using Tester with Pressure Gauges and Flow Meter Working Pressure Low Pressure Return or Suction Flow TO LIFT LOWER CIRCUIT TO STEERING CIRCUIT FROM LIFT LOWER CIRCUIT FROM DECK MOTORS FROM DECK CONTROL MANIFOLDS NOTE PUMP SECTION P1 TEST SHOWN ...

Page 71: ...2 Disconnect appropriate hydraulic hose from 90o hy draulic fitting in gear pump Fig 31 4 Install hydraulic flow meter in series with the discon nected hose and fitting in gear pump section 5 Make sure the flow control valve on the tester is fully open 6 Start engine and move throttle to full speed 2800 50 RPM Do not engage the cutting units IMPORTANT Do not fully restrict oil flow through tester ...

Page 72: ...Meter Working Pressure Low Pressure Return or Suction Flow GM 4500 D GM 4700 D TO LIFT LOWER CIRCUIT TO STEERING CIRCUIT TO LIFT LOWER CIRCUIT TO STEERING CIRCUIT FROM LIFT LOWER CIRCUIT FROM LIFT LOWER CIRCUIT TESTER PUMP SECTION P1 LOCATION FOR TESTER PUMP SECTION P2 LOCATION FOR TESTER PUMP SECTION P1 LOCATION FOR TESTER PUMP SECTION P2 LOCATION FOR ...

Page 73: ... meter in series with the the dis connected hose and deck motor inlet 5 Make sure the flow control valve on the tester is fully open CAUTION Keep away from decks during test to prevent per sonal injury from the cutting blades 6 Start engine and move throttle to full speed 2800 50 RPM Engage the cutting units 7 Watch pressure gauge carefully while slowly closing the flow control valve to fully clos...

Page 74: ...g Deck Motor Case Drain Leakage Using Tester with Pressure Gauges and Flow Meter GM 4500 D DECK 2 TEST SHOWN TESTER DECK 2 LOCATION FOR TO LIFT LOWER CIRCUIT TO STEERING CIRCUIT FROM STEERING CONTROL VALVE MEASURING CONTAINER Working Pressure Low Pressure Return or Suction Flow ...

Page 75: ...ing with the first motor in the circuit see Hydraulic Schematic 3 Disconnect pressure return hose from the motor to be tested Fig 35 Install flow tester in series with the motor and the disconnected return hose Make sure the flow control valve on tester is fully open Fig 36 4 Disconnect the motor case drain hose small diame ter hose where it connects to bulkhead fitting at the frame rail not at th...

Page 76: ...Pressure Gauge G P2 P1 PB P3 P4 STEERING CYLINDER STEERING CONTROL T P TO LIFT LOWER CIRCUIT TRACTION CIRCUIT RESERVOIR FROM TO PTO MOW CIRCUIT CHARGE CIRCUIT FROM OIL FILTER TO RESERVOIR NOTE LEFT TURN SHOWN VALVE 1180 PSI L R Working Pressure Low Pressure Return or Suction Flow 50 50 PROPORTIONAL FLOW DIVIDER ...

Page 77: ...rt the engine and move throttle to full engine speed 2800 50 RPM IMPORTANT Hold steering wheel at full lock only long enough to get a system pressure reading Holding the steering wheel against the stop for an extended period will damage the steering motor 5 Turn steering all the way in one direction and mo mentarily hold the steering wheel against resistance GAUGE READING TO BE 1150 TO 1500 PSI 6 ...

Page 78: ...T NO 8 Lift Lower Circuit Relief Pressure Using Pressure Gauge Working Pressure Low Pressure Return or Suction Flow FROM PTO MOW CIRCUIT TO STEERING CIRCUIT TO PTO MOW FROM STEERING CIRCUIT CIRCUIT FROM PTO MOW FROM STEERING CIRCUIT GM 4500 D SHOWN CIRCUIT 2200 PSI ...

Page 79: ...rily hold the lever with the lift cylinder at full extension while looking at the gauge GAUGE READING TO BE 2000 to 2600 PSI 6 Stop the engine 7 If specification is not met adjust or clean relief valve located on the side of power down and traction assist control manifold under operator seat Fig 40 A If pressure is too high remove cap on relief valve Fig 41 Adjust relief valve by rotating adjustme...

Page 80: ...Pressure Gauges and Flow Meter P2 P1 P3 P4 RESERVOIR FROM FROM OIL FILTER TRACTION CIRCUIT TO PTO MOW CIRCUIT TO STEERING CIRCUIT TO PTO MOW CIRCUIT TO LIFT LOWER CIRCUIT NOTE LIFT LOWER GEAR PUMP FLOW TEST SHOWN Working Pressure Low Pressure Return or Suction Flow TOW VALVE CHARGE CIRCUIT FORWARD 50 50 PROPORTIONAL FLOW DIVIDER ...

Page 81: ... section and one of the circuit hoses Fig 42 Make sure the tester flow control valve is OPEN IMPORTANT The pump is a positive displacement type If pump flow is completely restricted or stopped damage to the pump tester or other com ponents could occur 4 Start the engine and move throttle to full speed 2800 50 RPM DO NOT engage the cutting units 5 While watching pressure gauges slowly close flow co...

Page 82: ...Page 4 44 TEST NO 10 Counterbalance RV1 Pressure Using Pressure Gauge Working Pressure Low Pressure Return or Suction Flow GM 4500 D SHOWN FROM PTO MOW CIRCUIT TO STEERING CIRCUIT FROM PTO MOW CIRCUIT FROM STEERING CIRCUIT FROM STEERING CIRCUIT 2200 PSI ...

Page 83: ...o 640 PSI NOTE Counterbalance pressure setting toward the higher specification 640 PSI will improve traction on slopes Counterbalance pressure setting toward the lower specification 600 PSI improves quality of cut 5 Adjustment of the counterbalance valve can be per formed as follows NOTE Do not remove the valve from the hydraulic manifold for adjustment A To increase pressure setting turn the adju...

Page 84: ...Traction Circuit RV5 Relief Pressure Using Pressure Gauge TO PTO MOW CIRCUIT FROM PTO MOW CIRCUIT FROM PTO MOW CIRCUIT FROM STEERING CONTROL TO TRACTION CONTROL MANIFOLD TO LIFT LOWER CIRCUIT TO STEERING CIRCUIT CHARGE CIRCUIT Working Pressure Low Pressure Return or Suction Flow ...

Page 85: ...traction pedal and monitor the pressure gauge Pressure should increase until the re lief valve lifts GAUGE READING TO BE 520 to 570 PSI 6 Relief valve RV5 is located on the lower rear side of the 2WD 4WD control manifold Fig 47 Adjustment of the relief valve can be performed as follows NOTE Do not remove the valve from the hydraulic manifold for adjustment A To increase relief pressure setting rem...

Page 86: ...n Circuit Reducing Valve PR1 Pressure Using Pressure Gauge TO PTO MOW CIRCUIT FROM PTO MOW CIRCUIT FROM PTO MOW CIRCUIT FROM STEERING CONTROL TO TRACTION CONTROL MANIFOLD TO LIFT LOWER CIRCUIT TO STEERING CIRCUIT CHARGE CIRCUIT Working Pressure Low Pressure Return or Suction Flow ...

Page 87: ...ion pedal in the reverse direction While pushing traction pedal look at pressure reading on gauge GAUGE READING TO BE 420 to 470 PSI 6 Pressure reducing valve PR1 is located on the low er rear side of the 2WD 4WD control manifold Fig 50 Adjustment of this valve can be performed as follows NOTE Do not remove the valve from the hydraulic manifold for adjustment A To increase pressure setting remove ...

Page 88: ...age 4 50 TEST NO 13 Traction Assist RV2 Pressure Using Pressure Gauges Working Pressure Low Pressure Return or Suction Flow GM 4500 D SHOWN FROM PTO MOW CIRCUIT TO STEERING CIRCUIT FROM PTO MOW CIRCUIT FROM STEERING CIRCUIT FROM STEERING CIRCUIT 2200 PSI ...

Page 89: ...r both pressure gauges 6 As traction circuit pressure reaches approximately 1800 PSI directional valve PD3 should shift This shift will allow counterbalance hydraulic flow to be directed to the traction assist valve RV2 While maintaining trac tion circuit pressure look at pressure reading on gauge connected to the counterbalance test port GAUGE READING TO BE 650 to 750 PSI 7 Adjustment of the trac...

Page 90: ...ir or Replacement of Components 1 Check oil level in the hydraulic reservoir and add cor rect oil if necessary Drain and refill hydraulic system reservoir and change oil filter if component failure was severe or system is contaminated see Flush Hydraulic System 2 Lubricate O rings and seals with clean hydraulic oil before installing hydraulic components 3 Make sure caps or plugs are removed from t...

Page 91: ...draulic reservoir see Hydraulic Reservoir Inspection 6 Reconnect all hydraulic hoses lines and compo nents that were disconnected while draining system NOTE Use only hydraulic fluids specified in the Trac tion Unit Operator s Manual Other fluids may cause system damage 7 Fill hydraulic reservoir with new hydraulic fluid see Traction Unit Operator s Manual 8 Disconnect electrical connector from eng...

Page 92: ...nt of the machine 10 Make sure traction pedal and lift control lever are in neutral Start engine and run it at low idle 1300 rpm The charge pump should pick up oil and fill the hydraulic system If there is no indication of fill in 30 seconds stop the engine and determine the cause 11 After the hydraulic system starts to show signs of fill actuate lift control lever until the lift cylinder rod move...

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Page 94: ... O ring 13 90o hydraulic fitting 14 Suction hose 15 Suction hose 16 O ring 17 Hydraulic hose 18 Hydraulic hose 19 Hydraulic hose 20 Hydraulic hose 21 O ring 22 Hydraulic fitting 23 O ring 24 O ring 25 O ring 26 Gear pump assembly 27 Piston pump assembly 28 Coupler 29 Cap screw 30 Washer 31 O ring 32 Spacer Figure 54 85 to 95 ft lb 115 to 128 N m FRONT RIGHT 1 2 25 3 24 4 23 23 16 6 12 8 9 10 13 5 ...

Page 95: ...rs securing gear pump to piston pump Remove gear pump cou pler spacer and o rings from machine Installation 1 Lubricate new o rings with clean hydraulic oil and position on gear pump 2 Slide coupler onto the piston pump output shaft 3 Position o rings and spacer to gear pump Align gear teeth and slide gear pump input shaft into coupler Secure gear pump to piston pump with two 2 cap screws and wash...

Page 96: ...3 N m 26 25 12 9 24 22 7 20 28 21 29 6 4 27 13 4 1 15 5 10 8 2 4 23 11 14 3 12 4 18 17 13 12 19 14 16 Disassembly Work in a clean area as cleanliness is extremely impor tant when repairing hydraulic pumps Thoroughly clean the outside of pump After cleaning remove port plugs and drain oil from pump 1 Scribe a line at an angle across front plate 15 bo dies 10 19 26 adapter plates 23 24 and backplate...

Page 97: ...15 Remove plug 7 and o ring 9 from rear adapter plate 24 16 Remove proportional valve 6 from backplate as sembly 27 Inspection 1 Clean and dry all pump components Remove nicks and burrs from all parts with emery cloth 2 Check spline drive shaft for twisted or broken teeth Also check for damaged keyway on drive shaft that drives the slip fit gears of the pump 3 Inspect both the drive gear and idler...

Page 98: ... gear pocket of front body 10 and into front plate bushings 8 Install front adapter plate 23 in place on front body 10 Check positioning marks for correct orientation 9 Install middle body 19 onto front adapter plate 23 Place wear plate 12 into the gear pocket with the pres sure seal and backup gasket against the front adapter plate 10 Install key 17 in slot of drive gear shaft Dip slip fit gear 1...

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Page 100: ...lic fitting 14 Suction hose 15 Suction hose 16 Wire harness 17 Hydraulic hose 18 Hydraulic hose 19 Hydraulic hose 20 Hydraulic hose 21 O ring 22 Hydraulic fitting 23 O ring 24 O ring 25 O ring 26 Gear pump assembly 27 Piston pump assembly 28 Coupler 29 Cap screw 30 Washer 31 O ring 32 Spacer 33 O ring 34 O ring 35 O ring 36 O ring 37 O ring Figure 56 85 to 95 ft lb 115 to 128 N m FRONT RIGHT 1 2 2...

Page 101: ... pull pump assembly from adapter plate and raise it out of the machine Installation 1 Carefully lower piston pump into the machine and position it to the engine adapter plate Support pump to prevent it from falling while installing two 2 cap screws and washers securing piston pump to engine adapter plate Torque screws from 85 to 95 ft lb 115 to 128 N m 2 Install gear pump to piston pump see Gear P...

Page 102: ...27 Control arm 28 Servo control assembly 29 Washer 30 Orifice plate 3 used 31 Flat washer 32 Housing gasket 33 Cover plate gasket 34 Control assembly gasket 35 Plug 36 O ring 37 Seal sub assembly 38 Roll pin 39 Bearing 40 Dowel bushing 41 Cradle sub assembly 42 Cap screw 43 Button head cap screw 44 Bushing 45 Bearing Figure 57 20 8 32 6 7 31 5 18 11 9 33 19 33 10 1 29 4 3 12 13 24 3 21 31 25 2 34 ...

Page 103: ...e the housing 19 and drive shaft 21 from rotat ing kit assembly 6 and camplate assembly 11 7 Remove camplate 11 from rotating kit assembly 6 and servo piston follower 8 from camplate 11 8 Remove the four socket head screws 5 and wash ers 31 retaining each cover plate 9 10 9 Remove jam nut 1 washer 29 and seal washer 4 Hold the servo piston bolt with hex key and unscrew cover plate 10 from bolt 10 ...

Page 104: ...place on pump housing Install servo piston assembly 7 and cover plate 10 into servo piston bore in right side of housing Fig 61 Retain cover plate with four washers 31 and socket head screws 5 Torque screws from 40 to 48 in lb 4 5 to 5 4 N m To obtain neutral centering the servo piston assembly is required Measure in from the left side and set servo piston 500 12 7 mm from surface of housing servo...

Page 105: ... o ring on relief valves 16 26 Install reliefvalve in thecavity inbackplate andtorque from100 to 110 ft lb 136 to 149 N m 15 Install new o ring on bypass valve 14 Install by pass valve 14 into backplate 20 Note Make sure paddle of bypass valve is perpendicular to relief valve axis prior to installing or damage could result 16 Apply a small amount of petroleum jelly to the steel side of valve plate...

Page 106: ...nd o ring from plug 3 Remove retaining ring 20 from pin that retains feed back link and spool valve Remove pin feedback link spool valve and bell crank from control housing 4 Compress spring and remove retaining ring 3 Re move spring retainer spring and second spring retainer from spool valve 5 Clean all parts and lubricate in clean hydraulic oil for reassembly Reassembly 1 Install spring retainer...

Page 107: ...all switch into adapter The adjustment procedure for the switch are as follows A Install switch while moving link back and forth until detent action is detected Back out the switch until the detent action is very slight B Attach the leads from a test light to the switch ter minals Note A multimeter could be used instead of a test light C Move the link out of the detent position The test light will...

Page 108: ... 2 Wheel 4 Wheel Drive Filtration and Charge Power Down and Traction Assist 1 Power down traction assist manifold 2 Flange head screw 3 used 3 Filtration charge manifold 4 Flange head screw 4 used 5 2WD 4WD manifold 6 Cap screw 2 used 7 Flange nut 2 used Figure 64 FRONT RIGHT 4 2 6 5 7 3 1 ...

Page 109: ...connect electrical connector from the solenoid valve 3 Disconnect hydraulic lines from manifold being re moved and put caps or plugs on open hydraulic lines and fittings Label disconnected hydraulic lines for prop er reassembly 4 Remove hydraulic manifold from the frame using Figure 64 as guide Installation 1 Install hydraulic manifold to the frame using Figure 64 as guide 2 Remove caps and plugs ...

Page 110: ...UG TORQUE SAE 2 41 TO 49 in lb 4 6 to 5 6 N m SAE 4 6 to 10 ft lb 8 to 13 N m SAE 5 10 to 15 ft lb 13 to 20 N m SAE 6 15 to 20 ft lb 20 to 27 N m SAE 10 35 to 40 ft lb 48 to 54 N m NOTE The ports on the manifold are marked for easy identification of components Example P1 is a piston pump connection port and 2 is the location for the sole noid valve See Hydraulic Schematics to identify the function...

Page 111: ...nd out 20 to 30 times to flush out contamination Be extremely careful not to damage car tridge Use compressed air for cleaning 7 Reinstall the cartridge valve A Lubricate new seal kit components with clean hy draulic oil and install on valve The o rings sealing rings and backup rings must be arranged properly on the cartridge valve for proper operation and seal ing IMPORTANT Use care when handling...

Page 112: ...m 4 2 6 10 12 8 10 8 12 5 3 7 9 15 1 13 11 16 11 14 PLUG TORQUE SAE 4 6 to 10 ft lb 8 to 13 N m SAE 5 10 to 15 ft lb 13 to 20 N m SAE 6 15 to 20 ft lb 20 to 27 N m SAE 10 35 to 40 ft lb 48 to 54 N m NOTE The ports on the manifold are marked for easy identification of components Example P2 is the gear pump connection port and P1 is the connection from the oil cooler See Hydraulic Schematics to iden...

Page 113: ... lb 27 1 N m 20 ft lb 27 1 N m 2 3 4 5 1 25 ft lb 33 9 N m 6 6 NOTE The ports on the manifold are marked for easy identification of components Example CB is the con nection port from the lift lower control valve and CHG is the charge circuit connection See Hydraulic Schemat ics to identify the function of the hydraulic lines and car tridge valves at each port For cartridge valve service procedures...

Page 114: ... 2 3 25 ft lb 33 9 N m 20 ft lb 27 1 N m 1 7 7 7 25 ft lb 33 9 N m 20 ft lb 27 1 N m 20 ft lb 27 1 N m 20 ft lb 27 1 N m NOTE The ports on the manifold are marked for easy identification of components Example C1 is the con nection port from the LH deck lift cylinder and CHG is the charge circuit connection See Hydraulic Schematics to identify the function of the hydraulic lines and cartridge valve...

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Page 116: ... is the gear pump connection port See Hydraulic Schematics to identify the function of the hydraulic lines and cartridge valves at each port 1 Read the General Precautions for Removing and Installing Hydraulic System Components at the begin ning of the Service and Repairs section of this chapter 2 Disconnect electrical connector from the solenoid valve 3 Disconnect hydraulic lines from manifold an...

Page 117: ... Hydraulic Schematics to identify the function of the hydraulic lines and cartridge valves at each port location For solenoid and control valve service procedures see Hydraulic Control Manifold Service 2 Wheel 4 Wheel Drive Control in this section Refer to Figure 70 for car tridge valve installation torque NOTE The Groundsmaster 4500 D deck drive man ifold uses several zero leak plugs These plugs ...

Page 118: ... P1 is the gear pump connection port See Hydraulic Schematics to identify the function of the hydraulic lines and cartridge valves at each port 1 Read the General Precautions for Removing and Installing Hydraulic System Components at the begin ning of the Service and Repairs section of this chapter 2 Disconnect electrical connector from the solenoid valve 3 Disconnect hydraulic lines from manifold...

Page 119: ...entification of components Example P1 is the gear pump connection port See Hydraulic Schematics to identify the function of the hydraulic lines and cartridge valves at each port location For solenoid and control valve service procedures see Hydraulic Control Manifold Service 2 Wheel 4 Wheel Drive Control in this section Refer to Figure 72 for car tridge valve installation torque NOTE The Groundsma...

Page 120: ...xle Motor 1 Axle motor 2 O ring 3 Pinion gear 4 External snap ring 5 O ring 6 Hydraulic fitting 7 O ring 8 90o hydraulic fitting 9 Cap screw 10 Flat washer Figure 73 FRONT RIGHT Arrows on side of motor case point up 59 to 73 ft lb 80 to 99 N m 3 4 2 5 6 7 7 8 5 9 10 1 ...

Page 121: ...aps or plugs on ports to prevent contamination IMPORTANT Support axle motor to prevent motor from falling during removal 4 Remove motor using Figure 73 as a guide Installation 1 If removed install pinion gear to axle motor 2 Install o ring onto motor Position motor to rear axle assembly making sure that arrows on the side of motor case point upward Align gear teeth and slide motor into place 3 Sec...

Page 122: ...O ring 11 Piston wheel motor 12 Flat washer 13 Cap screw 14 O ring 15 90o hydraulic fitting 16 O ring 17 90o hydraulic elbow 18 O ring 19 O ring 20 RH brake assembly 21 Hydraulic tee fitting 22 45o hydraulic fitting 23 O ring 24 Hydraulic fitting 25 O ring Figure 74 FRONT RIGHT Arrows on side of motor case point up 1 2 3 4 5 6 7 8 9 11 12 13 14 15 10 16 17 18 19 21 10 14 18 22 16 2324 25 14 15 10 ...

Page 123: ...onnect hydraulic hoses and tubes from wheel motor Put caps or plugs on motor ports to prevent con tamination IMPORTANT Support wheel motor to prevent mo tor from falling during removal 4 Remove wheel motor using Figure 74 as a guide Installation 1 Position wheelmotor to brakeassembly makingsure that arrows on the side of motor case point upward 2 Align splines on motor shaft and splined brake shaf...

Page 124: ... Service of the front and rear motors requires the same procedure NOTE The rear axle motor does not have a shaft seal The case drain from the rear axle motor provides lu brication for the input gear case of the rear axle Cleanliness is extremely important when repairing hy draulic motors Work in a clean area Before disconnect ing the lines clean port area of motor Thoroughly clean the outside of t...

Page 125: ...t thrust bearing 13 and races 10 for wear 11 Check the condition of the needle bearing 17 in housing and replace if necessary Reassembly 1 Clean all parts in suitable solvent and lubricate all in ternal parts with clean hydraulic oil before reassembly 2 If necessary install new needle bearing 17 in hous ing 3 with numbered end of the bearing outward 3 Install retaining ring 9 on shaft Install thru...

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Page 127: ...onnect hydraulic lines from deck motor Put caps or plugs on fittings and hoses to prevent contami nation Tag hydraulic lines for proper reassembly 4 Remove two socket head screws that secure hy draulic motor to cutting deck Fig 77 5 Lift hydraulic motor from cutting deck Installation 1 Align splines on motor shaft and spindle shaft Posi tion hydraulic motor to the cutting unit 2 Secure motor to cu...

Page 128: ... Disassembly Fig 78 1 Plug motor ports and clean the outside of the motor thoroughly After cleaning remove plugs and drain any oil out of the motor 2 Use a marker or scribe to make a diagonal mark across the front flange housing and rear cover for reas sembly purposes Fig 79 IMPORTANT Avoid using excessive clamping pressure on the motor housing to prevent distorting the housing 3 Clamp front flang...

Page 129: ...oring and wear Any broken or nicked gear teeth must be replaced D Inspect gear face edge for sharpness Sharp edges of gears will mill into bearing blocks and thus must be replaced 4 Inspect bearing blocks for the following A Bearing areas should not have excessive wear or scoring B Face of bearing blocks that are in contact with gears should be free of wear roughness or scoring C Thickness of bear...

Page 130: ...embly Firm hand pressure should be sufficient to engage the dowel pins 14 Check to make sure that the surface of the rear bear ing block is slightly below the face of the housing If the bearing block is not below the housing check assembly for a shifted pressure seal backup seal or o ring Cor rect before proceeding 15 Apply a light coating ofpetroleum jelly to the exposed side of the rear cover 16...

Page 131: ...ly and remove itonly if damage or wear is identified 2 Remove plug with o ring spring and relief valve from the rear cover 3 Clean and inspect removed parts Visually inspect relief valve seat and plug threads in the rear cover 4 If relief valve seat was removed apply medium strength thread locking compound e g Loctite 242 to seatand installin rear cover Torque seatfrom 4 to 6 ft lb 5 4 to 8 1 N m ...

Page 132: ... Orifice port B 7 Cap screw 8 Spacer 9 Spacer tube 10 Lift lever 11 Control knob 12 Curved washer 13 Cotter pin 14 Thread forming screw 15 Proximity switch 16 Flange head screw 17 Switch plate 18 Insert nut 19 Flange nut 20 Extension spring 21 Cap screw 22 Valve support 23 Link 24 Lock nut 25 O ring Figure 84 FRONT RIGHT 3 4 2 1 5 6 7 11 10 22 21 20 14 15 16 9 17 19 8 23 12 9 18 13 24 25 ...

Page 133: ...Components at the begin ning of the Service and Repairs section of this chapter NOTE Before disconnecting the hydraulic lines clean the port area of the lift lower control valve assembly 3 Tag hydraulic lines for proper reassembly 4 Remove lift lower control valve using Figure 86 as a guide Installation 1 Install control valve using Figure 86 as a guide 2 Make sure hydraulic tank is full Add corre...

Page 134: ...ntrol valve body 13 Detent plug 14 Spool spring 15 O ring 16 Retaining ring 17 Detent spring 18 Disc 19 Plug 20 Washer 21 Wiper seal 22 Backup washer 23 O ring 24 O ring 25 O ring 26 O ring 27 Backup washer 28 O ring Figure 85 20 to 25 ft lb 27 to 33 N m 3 4 6 8 10 14 18 19 13 2 11 17 12 15 16 20 7 5 1 27 26 25 24 23 22 15 9 28 21 30 to 35 ft lb 41 to 48 N m 30 to 35 ft lb 41 to 48 N m 4 to 5 ft l...

Page 135: ...ched Damaged spools cannot be replaced Assembly 1 Thoroughly clean and dry all parts Apply a light coat ing of clean hydraulic oil to parts prior to assembly NOTE All O rings back up washers wiper seals and nylon poppet should be replaced as new items 2 Install new O ring 15 in proper groove in spool bore 3 Installplug 6 with new back up washer 22 and O ring 23 Torque plug from 30 to 45 ft lb 41 t...

Page 136: ...fitting 10 Spacer 11 Left lift lever 12 Control knob 3 used 13 Center lift lever 14 Right lift lever 15 Curved washer if equipped 16 Cotter pin 17 Thread forming screw 18 Proximity switch 3 used 19 Lock nut 20 Flange head screw 21 Switch plate 22 Nut insert 23 Flange nut 24 Extension spring 3 used 25 Cap screw 26 Valve support 27 Link 3 used Figure 86 FRONT RIGHT 1 5 4 3 20 6 7 8 9 10 12 15 17 18 ...

Page 137: ...Components at the begin ning of the Service and Repairs section of this chapter NOTE Before disconnecting the hydraulic lines clean the port area of the lift lower control valve assembly 3 Tag hydraulic lines for proper reassembly 4 Remove lift lower control valve using Figure 86 as a guide Installation 1 Install control valve using Figure 86 as a guide 2 Make sure hydraulic tank is full Add corre...

Page 138: ...g 13 Retaining ring 14 Washer 15 Spool spring 16 Plunger 17 Detent plunger 18 Detent plug 19 Disc 20 Detent spring 21 Plug 22 Wiper seals 23 Backup washer 24 O ring 25 O ring 26 O ring 27 O ring 28 O ring 29 Backup washer Figure 87 20 to 25 ft lb 27 to 33 N m 16 7 9 1 5 25 2 18 19 20 17 26 21 27 28 29 4 8 14 15 3 13 10 6 12 12 23 24 22 11 30 to 35 ft lb 41 to 48 N m 30 to 35 ft lb 41 to 48 N m 4 t...

Page 139: ...e spools and spool bores are matched Damaged spools cannot be re placed Assembly 1 Thoroughly clean and dry all parts Apply a light coat ing of clean hydraulic oil to parts prior to assembly NOTE All O rings back up washers wiper seals and nylon poppets should be replaced as new items 2 Install new O rings 12 in proper grooves in spool bores 3 Install plugs 6 with new back up washers 29 and O ring...

Page 140: ... Steering wheel cover 8 Steering column bracket 9 Flange head screw 10 Flange head screw 1 used 11 Lock washer 12 Flat washer 13 Steering tower cover 14 O ring 15 Hydraulic adapter 16 O ring 17 In port P 18 Right turn port R 19 Load sensing port PB 20 Left turn port L 21 Out port T Figure 88 17 18 19 20 21 FRONT RIGHT 6 5 4 10 11 12 3 1 2 15 9 13 9 8 16 14 7 20 to 26 ft lb 28 to 35 N m ...

Page 141: ...tem Components at the begin ning of the Service and Repairs section of this chapter NOTE Before disconnecting the hydraulic lines clean the port area of the steering valve assembly 3 Tag hydraulic lines for proper reassembly 4 Remove steering valve from machine using Figure 88 as a guide Installation 1 Install steering valve using Figure 88 as a guide 2 Make sure hydraulic tank is full Add correct...

Page 142: ...ts Work in a clean area Before disassembly drain the oil then plug the ports and thoroughly clean the exterior During repairs always protect machined surfaces 1 Remove the seven cap screws from the steering valve assembly 2 Remove end cap geroter spacer geroter drive wear plate sealring and o rings fromhousing Fig 89 3 Remove the plug and relief valve 4 Slide the spool and sleeve assembly from the...

Page 143: ...g springs 5 Apply a light coating of clean hydraulic fluid to the spool and slide it into the sleeve Be sure the centering springs fit into the notches in the sleeve 6 Install the pin 7 Apply a light coating of petroleum jelly to the inner edge of the dust and quad seals 8 Put the thrust bearing and races into the housing The thrust bearing goes between the two races Fig 90 IMPORTANT Do not damage...

Page 144: ... arm deck 4 2 Flange nut 3 Lift arm deck 1 4 Cylinder pin 3 used 5 Flange head screw 6 O ring 7 90o hydraulic fitting 8 O ring 9 Lift arm deck 5 10 Lift cylinder deck 4 11 Lift cylinder deck 1 12 Lift cylinder deck 5 13 Cylinder pin 3 used Figure 91 2 7 8 6 3 4 5 10 9 2 13 4 13 5 1 11 FRONT RIGHT 12 ...

Page 145: ... and cylinder shaft clevis which will free lift cylin der from lift arm 5 Remove flange nut and flange head screw that se cure the cylinder pin 13 to the frame Pull pin from frame and cylinder barrel clevis 6 Remove lift cylinder from machine Installation Fig 91 1 Position cylinder barrel clevis to frame and insert cyl inder pin 13 into frame and clevis Secure pin with flange nut and flange head s...

Page 146: ...1 Lift arm deck 2 shown 2 Cylinder pin 3 Flange head screw 4 O ring 5 90o hydraulic fitting 6 O ring 7 Retaining ring 8 Cylinder pin 9 Hydraulic fitting 10 Grease fitting 11 Lift cylinder 12 Flange nut 13 Rotation stop 14 Set screw Figure 93 1 12 7 11 10 9 8 7 3 2 4 6 5 4 6 FRONT RIGHT 13 14 ...

Page 147: ...e the cylinder pin 2 to the lift arm Remove pin from lift arm and cylinder shaft clevis 5 Remove one retaining ring from the cylinder pin 8 Remove cylinder pin from the frame and cylinder barrel clevis 6 Remove lift cylinder from machine Installation Fig 93 1 Position cylinder barrel clevis to frame and insert cyl inder pin 8 with one retaining ring installed through the frame and cylinder clevis ...

Page 148: ... ring 2 Cylinder pin 3 Thrust washer 4 Lift link 5 Link assembly 6 Bushing 7 Plastic roller 8 Rear link 9 Lock nut 10 90o hydraulic fitting 11 Lift cylinder 12 O ring 13 Grease fitting 14 O ring 15 Support frame 16 Lift arm deck 6 shown Figure 95 10 11 10 8 9 7 4 3 1 1 2 4 3 1 5 6 7 2 1 14 12 13 FRONT RIGHT 15 16 ...

Page 149: ... Locate and remove plastic rollers 7 positioned on both sides of cyl inder clevis 5 Remove one retaining ring that secures the cylinder pin 2 to the support frame Pull pin from frame and cyl inder barrel clevis 6 Remove lift cylinder from machine Installation Fig 95 1 Position cylinder barrel clevis to support frame and insert cylinder pin 2 into frame and clevis Secure pin with retaining ring 2 P...

Page 150: ...lic System Rev A Page 4 112 Lift Cylinder Service 1 Barrel with clevis 2 Collar 3 Shaft with clevis 4 Dust seal 5 Rod seal 6 O ring 7 Back up ring 8 Head 9 O ring 10 Uni ring 11 Piston 12 Locking nut Figure 97 12 10 9 5 11 7 4 1 2 3 8 6 ...

Page 151: ... piston Re move O ring back up ring rod seal and dust seal from the head Assembly 1 Make sure all parts are clean before reassembly 2 Coat new O rings Uni ring rod seal back up ring and dust seal with clean hydraulic oil A Install Uni ring and O ring to the piston B Install dust seal O ring back up ring and dust seal to the head IMPORTANT Do not clamp vise jaws against the shaft surface Protect sh...

Page 152: ...Retaining ring 5 Grease fitting 6 Grease fitting 7 90o hydraulic fitting 8 O ring 9 O ring 10 Ball joint spacer 11 Ball joint spacer 12 Axle washer 13 Hex slotted nut 14 Cotter pin 15 Drive axle assembly Figure 98 6 4 1 2 10 5 4 3 12 14 11 13 7 8 9 9 15 100 to 125 ft lb 135 to 169 N m 100 to 125 ft lb 135 to 169 N m FRONT RIGHT ...

Page 153: ... washer and ball joint spacer from the threaded ends of ball joints Fig 98 Remove steering cylinder with ball joints from machine Locate and retrieve ball joint spacers from top of axle assembly Installation 1 Place a washer onto each ball joint Slide ram end ball joint through hole on steering arm Secure with axle washer and hex slotted nut Slide fixed end of cylinder through hole on axle Install...

Page 154: ...700 D Hydraulic System Rev A Page 4 116 Steering Cylinder Service 1 Butt and tube assembly 2 Shaft 3 Piston rod assembly 4 Gland 5 Lock nut 6 O ring 7 PTFE seal 8 O ring 9 O ring 10 U cup 11 Wiper Figure 99 1 6 7 3 9 10 4 11 2 8 5 ...

Page 155: ...nd remove lock nut Remove piston and gland from rod 5 Remove all seals and O rings 6 Wash parts in clean solvent Dry parts with com pressed air Do not wipe parts dry with paper towels or cloth Lint in a hydraulic system will cause damage 7 Carefully inspect internal surface of barrel for dam age deep scratches out of round etc Replace en tire cylinder if barrel is damaged Inspect piston rod and pi...

Page 156: ...and remove key from the ignition switch 2 Read the General Precautions for Removing and Installing Hydraulic System Components at the begin ning of the Service and Repairs section of this chapter 3 Drain reservoir into a suitable container see Trac tion Unit Operator s Manual 4 Disconnect hydraulic hoses from reservoir 5 Remove hydraulic reservoir using Figure 100 as a guide Inspection 1 Clean hyd...

Page 157: ... all solvent is drained from the cooler CAUTION Use eye protection such as goggles when using compressed air 2 Dry inside of oil cooler using compressed air in the opposite direction of the oil flow 3 Plug both ends of oil cooler Clean exterior of cooler Make sure fins are clear of dirt and debris 4 The oil cooler should be free of corrosion cracked tubes and excessive pitting of tubes Installatio...

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Page 159: ... 8 Indicator Lights 9 PTO and Hi Lo Speed Control Switches 10 Seat Switch 11 Parking Brake Switch 11 Cutting Deck Position Switch 12 Cutting Deck Lift Lower Switch 13 Ramp up Module 14 Hour Meter 15 Glow Relay 15 Start Neutral Seat Cutting Deck Parking Brake and High Temperature Relays 16 Hydraulic Valve Solenoids 17 Engine Run Solenoid 18 Fuel Pump 19 Glow Controller 20 Temperature Sender 21 Temp...

Page 160: ...plier Multimeter The multimeter can test electrical components and cir cuits for current resistance or voltage NOTE Toro recommends the use of a DIGITAL Volt Ohm Amp multimeter when testing electrical circuits The high impedance internalresistance ofa digitalme ter in the voltage mode will make sure that excess cur rent is not allowed through the meter This excess current can cause damage to circu...

Page 161: ...n switch or circuit wiring is faulty The fusible link from the battery is faulty Starter solenoid clicks but starter will not crank NOTE If the solenoid clicks the problem is not in the in terlock circuit Low battery charge Loose or corroded battery cables Loose or corroded ground Faulty wiring at the starter Faulty starter solenoid Faulty starter Nothing happens when start attempt is made Control...

Page 162: ...ontinues to run but should not when the traction pedal is engaged with no operator in the seat The seat switch or circuit wiring is faulty Traction neutral switch or circuit wiring is faulty The engine stops during operation but is able to restart The operator is lifting off the seat The seat switch or circuit wiring is faulty The engine shutdown delay is faulty The ignition switch or circuit wiri...

Page 163: ...e cutting deck position switch or circuit wiring to the affected decks is faulty The cutting deck lift lower switch or circuit wiring to the affected decks is faulty The PTO relay or circuit wiring to the affected decks is faulty The Ramp up module or circuit wiring is faulty Hydraulic valve solenoid s or circuit wiring to the affected decks is faulty A hydraulic problem exists see Troubleshooting...

Page 164: ...s a relative condition of the bat tery Load testing of the battery will provide additional and more accurate information Voltage Measured Battery Charge Level 12 68 V or higher Fully charged 100 12 45 V 75 charged 12 24 V 50 charged 12 06 V 25 charged 11 89 V 0 charged Check Operation of Interlock Switches CAUTION Do not disconnect safety switches They are for the operator s protection Check the o...

Page 165: ...nu ity with a multimeter ohms setting make sure that power to the circuit has been disconnected Ignition Switch The ignition key switch has three positions OFF ON PREHEAT and START The terminals are marked as shown The circuit wiring of the ignition switch is shown in the chart With the use of a multimeter ohms setting the switch functions may be tested to determine whether continuity exists betwe...

Page 166: ...pplies power to ignition switch terminal B Fuse 2 10 Amp A Supplies power to the PTO circuit Fuse 3 10 Amp A Supplies power to the power point outlet Fuse 4 10 Amp A Supplies power from ignition switch terminal I Fuse 5 2 Amp Only on machines with Serial Number above 230000000 A Supplies power from ignition switch terminal I to Standard Control Module Fuse 6 10 Amp Only on machines with SerialNumb...

Page 167: ...on as the high temperature shutdown switch stops the engine To test the high temperature shutdown light and circuit wiring start the engine and ground the blue white wire attached to high temperature shutdown switch on fly wheel end of engine see High Temperature Shutdown Switch in this Chapter Warning light should illuminate and engine should stop running Glow Plug Indicator Light The glow plug l...

Page 168: ...marked as shown in Figure 11 The circuitry of these switches is shown in the chart be low With the use of a multimeter ohms setting the switch functions may be tested to determine whether continuity exists between the various terminals for each switch position Verify continuity between switch termi nals SWITCH POSITION NORMAL CIRCUITS OTHER CIRCUITS ON 2 3 5 6 OFF 1 2 4 5 1 PTO switch 2 Hi Lo spee...

Page 169: ... 6 Replace switch as needed Reconnect switch con nector 1 Electrical connector 2 Seat switch Figure 12 2 1 Parking Brake Switch The switch used for the parking brake is a normally open proximity switch The parking brake switchis locatedun der the steering tower cover Fig 13 and closes when the parking brake is released The sensing plate for the switch is an integralcomponentof the parking brake ro...

Page 170: ...perating Switch Testing 1 Park machine on a level surface lower cutting units stop engine engage parking brake and remove key from the ignition switch 2 Disconnect deck position switch that requires testing from machine wiring harness 3 Check the continuity of the switch by connecting a multimeter ohms setting across the switch connector terminals 4 With the cutting unit in the lowered position th...

Page 171: ...tch 2 Remove console cover from machine 3 Locate cutting deck lift lower switch that requires testing Disconnect switch connector from machine wir ing harness 4 Check the continuity of the switch by connecting a multimeter ohms setting across the switch connector terminals 5 With the lift lever in the neutral position there should be continuity across the switch terminals 6 Pull back on the lift l...

Page 172: ...decks 6 and 7 on the GM 4700 D The ramp up module can be monitored by the three LED slocatedonthemodulebelowtheharnessconnec tion 1 All module LED s will be off when the PTO switch is OFF 2 When the PTO switch is turned ON and interlock switches allow cutting deck operation seat occupied decks lowered etc the Power LED will illuminate im mediately The S1 and S2 LED s will gradually illumi nate dur...

Page 173: ...ve 260000600 the relay is attachedto thewire harnesswith afour wireconnector Fig 22 NOTE Prior to taking small resistance readings with a digital multi meter short the meter test leads together The meter will display a small resistance value usually 0 5 ohms or less This resistance is due to the internal resistance of the meter and test leads Subtract this val ue from from the measured value of th...

Page 174: ...nt you are testing 1 Verify coil resistance between terminals 85 and 86 with a multimeter ohms setting A For the Tyco Electronics relay VF4 65F11 re sistance should be from 71 to 88 ohms B For the Hella Electronics relay 66211 resist ance should be from 70 to 80 ohms 2 Connect multimeter ohms setting leads to relay ter minals 30 and 87 Ground terminal 86 and apply 12 VDC to terminal 85 The relay s...

Page 175: ...t you are testing 1 Make sure engine is off Disconnect hydraulic valve solenoid electrical connector Fig 25 2 Apply 12VDC source directly to the solenoid Listen for solenoid to switch on 3 Remove 12VDC source from the solenoid Listen for solenoid to switch off 4 Measure resistance between the two connector ter minals The resistance for the solenoid coil should be about 7 2 ohms 5 Install new solen...

Page 176: ...nd the other lead to the pin of the red wire The resistance of the hold coil should be about 10 9 ohms 4 Connect solenoid to the wiring harness Live Testing 1 Disconnect connector from the engine run solenoid NOTE The solenoid may be removed from the engine or tested in place 2 If the solenoid is removed from the engine make sure that the solenoid linkage moves freely and is free of dirt debris an...

Page 177: ...s 5 Place disconnected pump discharge hose into a large graduated cylinder sufficient enough to collect 1 quart 0 95 liter 6 Collect fuel in the graduated cylinder by turning igni tion switch ON Allow pump to run for 30 seconds then release ignition switch to OFF 7 The amount of fuel collected in the graduated cylin der should be approximately 11 75 fl oz 350 ml after 30 seconds 8 Replace fuel pum...

Page 178: ...re energized D Glow indicator lamp goes out and glow plugs deenergize after 10 seconds 4 Place ignition switch in the START position Verify the following while in the START position A Glow indicator lamp is out B Glow relay is energized C Glow plugs are energized D Power to terminal 1 of the glow controller NOTE If there is no power to terminal 1 of the glow con troller verify continuity of the ci...

Page 179: ...e to the internal re sistance of the meter and test leads Subtract this value from from the measured value of the component you are testing 3 Check resistance of the sender with a multimeter ohms setting as the temperature increases A The meter should indicate more than 600 ohms at 70oF 21oC B The meter should indicate approximately 460 ohms at 100oF 38oC C The meter should indicate from 54 to 78 ...

Page 180: ...st 5 minutes before taking test readings A Set variable resistance to 71 ohms Apply a 14 0 01 VDC to the circuit The needle should point to the middle of the green area 80oC B Set variable resistance to 38 ohms The needle should point between the green and red area 105oC 3 Turn off the voltage source Disconnect voltage source gauge and variable resistance Temperature Gauge Check The following proc...

Page 181: ...hutdown Switch Test CAUTION Make sure engine is cool before removing the temperature switch 1 Lower coolant level in the engine and remove the temperature shutdown switch 2 Put switch in a container of oil with a thermometer and slowly heat the oil Fig 37 CAUTION Handle the hot oil with extreme care to prevent personal injury or fire 3 Check continuity of the switch with a multimeter ohms setting ...

Page 182: ...ontinuity across the switch terminals when the traction pedal is in the neutral position See Piston Pump Control Assembly in Chapter 4 Hy draulicSystemsfordisassemblyandreassemblyproce dures for the neutral switch 1 Piston traction pump 2 Neutral switch Figure 38 2 1 Diode Assemblies Diode D8 provide logic for theinterlock switches Diodes D2 D3 D4 GM 4700 D only and D5 GM 4700 D only are used for ...

Page 183: ...or circuit protection from voltage spikes when PTO relays are de energized Diode Circuit Board Test The diodes can be individually tested using a digital multimeter ohms setting and the table to the right If any of the diodes are damaged the diode circuit board must be replaced Figure 40 H A B C D E F G D1 A D1 B D1 C D1 D DIODE DIAGRAM CIRCUIT BOARD D1 D D1 C D1 B D1 A Red Lead on Terminal Black ...

Page 184: ...uter or hand held device can not be re programmed and does not record intermittent fault data The Standard Control Module can be used to check op eration of machine switches by monitoring the LED s of the module Ifa Module LED does notilluminate e g the in seat input LED does not illuminate with the seat occu pied and the ignition switch in the run position testing of the switch and circuit wiring...

Page 185: ...p open flames and electrical sparks away from the battery do not smoke Nausea may result if the gases are inhaled Un plug charger from electrical outlet before con necting or disconnecting charger leads to or from battery posts IMPORTANT Do not remove fill caps while clean ing 2 Check battery condition weekly or after every 50 hours of operation Keep terminals and entire battery case clean because...

Page 186: ...posts IMPORTANT Before cleaning the battery tape or block vent holes to the filler caps and make sure the caps are on tightly C Check for signs of wetness or leakage on the top of the battery which might indicate a loose or missing filler cap overcharging loose terminal post or over filling Also check battery case for dirt and oil Clean the battery with a solution of baking soda and water then rin...

Page 187: ... load tester to the battery termi nals following the manufacturer s instructions Connect a digital multimeter to the battery terminals F Apply a test load of one half the Cranking Perfor mance see Battery Specifications rating of the bat tery for 15 seconds G Take a voltage reading at 15 seconds then re move the load H Using the table below determine the minimum voltage for the cell temperature re...

Page 188: ...l ventilated place to dissipate gases produced from charging These gases are explosive keep open flame and elec trical spark away from the battery Do not smoke Nausea may result if the gases are inhaled Un plug the charger from the electrical outlet before connecting or disconnecting the charger leads from the battery posts 3 Following the manufacturer s instructions con nect the charger cables to...

Page 189: ...TMENTS 3 SERVICE AND REPAIRS 4 Brake Assembly 4 Brake Inspection and Repair 6 Planetary Wheel Drive Assembly 8 Planetary Wheel Drive Service 10 Rear Axle Assembly 12 Bevel Gear Case and Axle Case 14 Differential Shafts 18 Axle Shafts 19 Input Shaft Pinion Gear 20 Differential Gear 22 Pinion Gear to Ring Gear Engagement 25 Axles Planetaries and Brakes ...

Page 190: ...ue 100 to 125 ft lb 135 to 169 N m Planetary brake housing and wheel motor 75 to 85 ft lb 101 to 115 N m mounting screw torque Rear wheel toe in 125 in 3 2 mm Tire pressure front and rear 20 psi 1 4 bar Planetary gear drive lubricant SAE 85W 140 wt gear lube Planetary gear lube capacity each wheel 16 fl oz 47 l Rear axle lubricant SAE 85W 140 wt gear lube Rear axle gear lube capacity 80 fl oz 2 37...

Page 191: ...D Page 6 3 Axles Planetaries and Brakes Rev B Adjustments See Traction Unit Operator s Manual for adjustment procedures for Groundsmaster 4500 D and Ground smaster 4700 D axles planetaries and brakes Axles Planetaries and Brakes ...

Page 192: ...and wheel assembly 5 Lug nut 6 Retaining ring 7 Spring plate 8 Compression spring 9 Jam nut 10 LH Brake assembly 11 Flange head screw 12 Hex plug 13 Piston motor 14 Flat washer 15 Cap screw 16 O ring 17 O ring 18 RH brake assembly 19 Brake cable Figure 1 FRONT RIGHT 75 to 85 ft lb 101 to 115 N m 85 to 100 ft lb 115 to 135 N m 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 17 18 16 17 19 ...

Page 193: ...t brake assembly and remove flange head capscrews 11 securing brake assembly to frame Re move brake assembly 8 Remove splined brake shaft 9 Complete brake inspection and repair Install Brake Assembly Fig 1 NOTE The stepped end of the splined brake shaft must be aligned toward the hydraulic wheel motor Fig 2 1 Install splined brake shaft into brake assembly 2 Install brake assembly onto frame align...

Page 194: ...Brake Inspection and Repair Fig 4 1 Scrape gasket material 10 from brake housing and planetary wheel drive mounting surfaces 2 Remove retaining ring 9 3 Remove stationary discs 7 and rotating discs 8 4 Remove extension springs 12 5 Remove actuator assembly 3 4 5 6 and 11 and balls 13 6 Remove seal 2 from brake housing 7 Wash parts in cleaning solvent Inspect components for wear or damage 8 Reverse...

Page 195: ...Groundsmaster 4500 D 4700 D Page 6 7 Axles Planetaries and Brakes Rev B This page is intentionally blank Axles Planetaries and Brakes ...

Page 196: ...etary Wheel Drive Removal 1 Park machine on a level surface lower cutting units stop engine engage parking brake and remove key from the ignition switch 2 Drain oil from planetary wheel drive brake assembly see Traction Unit Operator s Manual CAUTION When changing attachments tires or perform ing other service use correct blocks hoists and jacks Make sure machine is parked on a solid level surface...

Page 197: ...l flange head screws that secure planetary assembly Torque screws from 75 to 85 ft lb 101 to 115 N m 2 Install brake assembly to planetary see Brake As sembly WARNING Failure to maintain proper wheel lug nut torque could result in failure or loss of wheel and may result in personal injury 3 Install wheel assembly Torque lug nuts from 85 to 100 ft lb 115 to 135 N m 4 Lower machine from jack stands ...

Page 198: ...7 18 19 20 21 22 23 24 25 26 27 28 29 118 to 144 in lb 13 3 to 16 3 N m Planetary Wheel Drive Disassembly Figure 7 1 Remove retaining ring 17 2 Remove end cap 19 and o ring 20 3 Remove thrust plug 21 and thrust washer 22 4 Remove retaining ring 23 primary gear 24 and drive shaft 25 5 Remove primary carrier 26 secondary gear 27 and secondary carrier 28 NOTE Steps 6 10 are necessary only if inspecti...

Page 199: ...hen secure ring gear 16 to housing 9 with socket head screws 7 and lock wash ers 8 Torque screws from 118 to 144 in lb 13 3 to 16 3 N m 8 Install secondary carrier 28 secondary gear 27 and primary carrier 26 9 Install drive shaft 25 and primary gear 24 Secure gear with retaining ring 23 10 Install thrust washer 22 and thrust plug 21 11 Install o ring 20 and end cap 19 Secure end cap with retaining...

Page 200: ...erator s Manual CAUTION When servicing rear axle use correct blocks hoists and jacks Make sure machine is parked on a solid level surface such as a concrete floor Always chock or block wheels Use jack stands or solid wood blocks to support the raised machine If the machine is not properly supported by blocks or jack stands the ma chine may move or fall which may result in per sonal injury 3 Chock ...

Page 201: ...ere should be from 002 to 020 inch 05 to 51 mm clearance between rear frame mount and axle mounting boss Add thrust washers if needed to adjust clearance 5 Install flat washer and lock nut onto pivot pin Lock nut should be tightened enough to allow pivot pin to ro tate 70 ft lb 94 N m maximum 6 Install hydraulic motor to axle assembly see Rear Axle Motor in Service and Repairs section of Chapter 4...

Page 202: ...vel gear case axle case assemblies 1 2 3 4 5 6 1 Cap screw 2 Lock nut 3 Lock washer 4 Axle support 5 Bevel gear case axle case assembly 6 O ring Figure 11 35 to 41 ft lb 47 to 56 N m 35 to 41 ft lb 47 to 56 N m 3 Remove the axle cover mounting screws Remove the axle cover from the axle case as an assembly Fig 12 1 Axle case 2 Axle cover assembly 3 Mounting screw 4 O ring Figure 12 1 2 3 4 17 to 20...

Page 203: ...d discard bevel gear shaft seal from axle case Fig 14 1 Knuckle pin 2 Mounting screw 3 O ring 4 Bevel gear case 5 Upper bearing 6 Bevel gear shaft 7 Collar 8 Upper bevel gear 9 Lower bevel gear 10 Lower bearing 11 Axle case 12 Axle case cover 13 O ring 14 Shaft seal 15 Bushing Figure 14 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 17 to 20 ft lb 23 to 27 N m 17 to 20 ft lb 23 to 27 N m Thread locking Compo...

Page 204: ...se cover Fig 17 Tighten cover screws from 17 to 20 ft lb 23 to 27 N m 3 Slide the bevel gear case over the bevel gear shaft and installthe bevelgear andcollar Makesure thebevel gear shaft is completely seated in the upper and lower bearings Fig 17 4 Install the knuckle pin Use medium strength thread locking compound and tighten the knuckle pin mounting screws from 17 to 20 ft lb 23 to 27 N m 1 Axl...

Page 205: ...rmined remove mounting screws apply heavy strength thread locking compound to screw threads reinstall screws and torque from 57 to 67 ft lb 77 to 91 N m IMPORTANT Correct engagement between bevel gears is critical to axle performance and durability 7 Temporarily install the bevel gear case axle case as sembly on the axle support Position a dial indicator at the tooths center Prevent the axle from ...

Page 206: ... ferential shaft assemblies 1 Remove the mounting screws nuts and lock wash ers Remove the bevel gear case axle case assembly and O ring from the axle support Fig 21 2 Mark and pull the differential shaft assembly from the axle support 3 Remove the retaining ring and bevel gear Fig 22 4 Drive the differential shaft out of the bearings Re move the bearings and bearing shims 5 Inspect all gears shaf...

Page 207: ... wear Replace components as necessary Installation 1 Coat new axle shaft seal with grease and install in axle cover as shown Fig 25 2 Press the axle cover and bearing assembly onto the axle shaft Press only on the inner race of the cover bearing Fig 25 3 Install retaining ring spacer and correct combina tion of bearing shims Install bevel gear and bearing 4 Coat a new O ring with grease and instal...

Page 208: ...Remove and discard the stake washer 5 Drive the input shaft pinion gear out from the outer bearing cone and bearing case Remove and discard the oil seal and O ring 6 Inspect all gears shafts bearings spacers and cases for damage and wear Replace components as necessary NOTE Replacementinputshaft pinion gear 11 is only available in matched set with differential ring gear Installation NOTE When inst...

Page 209: ...temporarily install gear case assembly into axle case Tighten mounting nuts and screws from 35 to 41 ft lb 47 to 56 N m 10 Insert a screwdriver through the drain plug hole to hold ring gear and measure the pinion gear to ring gear backlash Fig 29 PINION GEAR TO RING GEAR BACKLASH 0 004 to 0 016 in 0 10 to 0 40 mm 11 Adjust backlash by increasing or reducing gear case shim thickness 12 Check pinion...

Page 210: ...the axle case 6 Drive the spring pin from the differential case with a punch and hammer Discard the spring pin Fig 31 NOTE Mark and arrange all components so they can be reassembled in their original position 7 Remove the differential pinion shaft pinion gears and pinion washers Remove the differential side gears and side gear shims Remove the ring gear only if it will be replaced Fig 32 NOTE Repl...

Page 211: ...41 in 34 00 to 34 06 mm 2 Measure the differential pinion shaft O D and the pinion gear I D to determine the pinion shaft to pinion gear clearance Fig 34 Replace components as nec essary PINION SHAFT TO PINION GEAR CLEARANCE 0 001 to 0 010 in 0 03 to 0 25 mm PINION SHAFT O D Factory Spec 0 550 to 0 551 in 13 97 to 13 10 mm PINION GEAR I D Factory Spec 0 551 to 0 552 in 13 10 to 14 02 mm 3 Inspect ...

Page 212: ...htly over several gear teeth 8 While applying a light load to either side gear rotate either pinion gear until the side gears have made one complete revolution 9 Ideal tooth contact should cover more than 35 of each tooth surface The contact area should be in the center of each tooth and extend 1 3 to 1 2 way across each tooth from the toe small end Fig 36 10 Adjust side gear shims if necessary to...

Page 213: ...ig 38 Adjustments to the gear contact position are made by moving the input shaft pinion gear bearing case shims or by moving the differential gear case differential bear ing shims Fig 39 NOTE Bearing case shims are available in 0 004 in 0 10 mm and 0 008 in 0 20 mm thickness NOTE Differential bearing shims are available in 0 004 in 0 10 mm 0 008 in 0 20 mm and 0 016 in 0 40 mm thickness Study the...

Page 214: ...ft toward ring gear B Install thinner or remove differential bearing shim s to move ring gear backward C Repeat until proper tooth contact and pinion gear to ring gear backlash are correct 2 If contact is toward the toe or tip of the gear Fig 41 A Install thinner or remove bearing case shim s to move pinion shaft away from ring gear B Install thicker or additional differential bearing shim s to mo...

Page 215: ...s For Cutting Decks 1 4 and 5 4 Lift Arms For Cutting Decks 2 and 3 6 Lift Arms For Cutting Decks 6 and 7 Groundsmaster 4700 D only 8 Hood 10 General Information Cutting Deck Identification Cutting decks on the Groundsmaster 4500 D and 4700 D are identified as shown in Figure 1 Figure 1 4 Deck 1 Deck 5 Deck 7 Deck GM4700 6 Deck GM4700 3 Deck 2 Deck CUTTING DECK LOCATIONS Chassis ...

Page 216: ...ver 22 Instrument plate 23 Steering column bracket 24 Flange head screw 25 Compression spring 26 Flange head screw 27 Lock washer 28 Flat washer 29 Cotter pin 30 Parking brake rod 31 Ignition switch 32 Tower cover 33 Cotter pin 34 Flat washer 35 Parking brake rack 36 Hydraulic fitting 37 O ring 38 O ring 39 Switch plate 40 Carriage bolt 41 Flat washer 42 Lock nut 43 Parking brake proximity switch ...

Page 217: ... Park machine on a level surface lower cutting units stop engine engage parking brake and remove key from the ignition switch 2 Disassemble steering tower as needed using Figure 2 as a guide Assembly 1 Assemble steering tower using Figure 2 as a guide Chassis ...

Page 218: ... Lift arm 5 deck 31 Lock nut 32 Flange bushing 33 Front carrier frame 34 Grease fitting 35 Deck carrier frame 36 Grease fitting 37 O ring 38 O ring Figure 3 FRONT RIGHT 2 37 38 6 3 4 5 1 7 8 9 10 32 2 15 14 13 12 11 34 32 10 4 16 17 18 19 21 20 22 16 23 24 25 26 27 32 28 29 19 31 14 5 33 36 35 30 Removal 1 Park machine on a level surface lower cutting units stop engine engage parking brake and rem...

Page 219: ...ange head screw and flange nut NOTE Install thrust washer on deck pivot shaft before installing cutting deck on pivot shaft 4 Position and install cutting deck to lift arm see Cut ting Unit Operator s Manual 5 If lift arm for either deck 4 or 5 was removed slide hydraulic hoses through the hose retaining loop on the lift arm and install hoses to the deck motor Fig 5 Make sure that deck is lowered ...

Page 220: ...deck shown 13 Flange bushing 14 Flange nut 15 Retaining ring 16 Lift cylinder 17 Grease fitting 18 Lock nut 19 Hydraulic fitting 20 Lift cylinder pin 21 Thrust washer 22 Flange head screw 23 Lift cylinder pin 24 Cap screw 25 Hydraulic fitting 26 Cap screw 27 Lift arm rotation stop 28 Set screw 29 O ring 30 O ring 31 Grease fitting Figure 6 FRONT RIGHT 1 2 3 4 5 6 7 8 12 9 10 11 14 15 16 17 19 18 2...

Page 221: ...pivot pin 3 Install lift cylinder to lift arm with cylinder pin Secure cylinder pin to lift arm with flange head screw and flange nut NOTE Install thrust washer on deck pivot shaft before installing cutting deck on pivot shaft 4 Position and install cutting deck to lift arm see Cut ting Unit Operator s Manual NOTE The lift arms for cutting decks 2 and 3 are fitted with a lift arm rotation stop blo...

Page 222: ...ut 18 Proximity switch 19 Lock nut 20 Thrust washer 21 Lift arm deck 6 shown 22 Carrier pivot pin 23 Compression spring 24 Thrust washer 25 Flat washer 26 Lock nut 27 Pin 28 Pivot pin 29 Slotted roll pin 30 Support arm deck 6 shown 31 Flange nut 32 Bushing 33 Link 34 Grease fitting 35 Self tapping screw 36 R clamp 37 Wire harness 38 Switch actuator 39 Flange bushing 40 O ring 41 O ring 42 Deck car...

Page 223: ...t thrust washer between rear of lift arm and support arm Slide pivot pin into support arm and lift arm Align roll pin in piv ot pin with slot in support arm flange 2 Install and tighten lock nut to secure lift arm pivot pin 3 Install lift cylinder to lift arm with cylinder pin Secure cylinder pin to lift arm with flange head screw and flange nut NOTE Install compression spring and thrust washer on...

Page 224: ...r 25 Cap screw 26 Bumper weight 27 Rear bumper 28 Rubber bumper 29 Flange head screw 30 Bumper weight clamp 31 Back washer 32 Foam seal 33 Lock nut 34 Cap screw 35 Hood receiver retainer 36 Spring washer 37 Hood receiver spacer 38 Axle stop 39 Flat washer 40 Hood latch 41 Pop rivet 42 Cap screw 43 Cap screw 44 Draw latch 45 Hood lock pin 46 Pop rivet 47 Latch plate 48 Foam seal 49 Foam seal 50 Foa...

Page 225: ...g 11 and raise hood 3 Unhook lanyard from hood lock pin remove pin and slide hood tubes rearward off guides Fig 12 Installation 1 Slide hood tubes onto guides install hood lock pin and hook lanyard to hood pin Fig 12 2 Secure hood to frame with latches Fig 11 3 Check hood alignment for correct operation of hood latches and dust seals 1 Hood latch Figure 11 1 1 Hood lock pin 2 Lanyard Figure 12 2 1...

Page 226: ...Groundsmaster 4500 D 4700 D Page 7 12 Chassis This page is intentionally blank ...

Page 227: ... ADJUSTMENTS 5 Blade Stopping Time 5 Blade Plane Inspection and Adjustment 6 SERVICE AND REPAIRS 8 Blade Spindle Assembly 8 Blade Spindle Service 10 Rear Roller 12 Rear Roller Service Non Greasable Bearings 13 Rear Roller Service Greasable Bearings with Retaining Ring 14 Rear Roller Service Greasable Bearings with Bearing Nut 16 Front Roller Service 18 Cutting Deck Carrier Frame 20 Cutting Units ...

Page 228: ...Each cutting unit equipped with 27 inch 68 6 cm length 250 inch 6 mm thick heat treated steel blade Anti scalp cup installed on cutting blade The standard blade is optimized for most cutting applications Optional high lift angle sail and Atomic blades are available for those situations where the stan dard blade is not ideal DISCHARGE Clippings are discharged from the rear of the mowing decks Pre d...

Page 229: ...s should rotate at the same speed See items in Troubleshooting Section of Chapter 4 Hydraulic System 3 Tire pressure Check air pressure of each tire Adjust to pressures specified in Cutting Unit Operator s Manual 4 Blade condition Sharpen blades if their cutting edges are dull or nicked Inspect blade sail for wear or damage Replace blade if needed 5 Mower housing condition Make sure that cutting c...

Page 230: ...taller TOR4869 Outer Seal Installer TOR4071 Outer Oil Seal Installer TOR4072 Shaft Seal Protector TOR4073 Handle TOR4074 Spline Insert Tool Figure 1 Rear Roller Grease Nozzle 107 1998 This tool is used to grease the cutting unit rear roller bearings when equipped with greasable bearings Figure 2 Rear Roller Bearing and Seal Installation Tools These tools are used to assemble the cutting unit rear ...

Page 231: ...me to a complete stop in approximately 5 seconds after the cutting deck engagement switch is shut down NOTE Make sure the decks are lowered onto a clean section of turf or hard surface to avoid dust and debris To verify this stopping time have a second person stand back from the deck at least 20 feet and watch the blades on one of the cutting decks Have the machine operator shut the cutting decks ...

Page 232: ...one height of cut bracket at a time 1 Remove height of cut bracket front left or right from deck frame 2 Position 060 inch 1 5 mm and or 030 inch 8 mm shims between the deck frame and bracket to achieve the desired blade height setting 3 Install height of cut bracket to deck frame with re maining shims assembled below the height of cut bracket NOTE Socket head bolt and spacer for front bracket are...

Page 233: ...Groundsmaster 4500 D 4700 D Cutting Units Rev B Page 8 7 This page is intentionally blank Cutting Units ...

Page 234: ... gine and remove key first Blade Spindle Assembly 1 Flange nut 2 Socket head screw motor mounting 3 Spindle plate 4 Cutting deck 5 O ring 6 Spindle assembly 7 Cap screw 8 Cutting blade 9 Anti scalp cup 10 Blade bolt 11 Rubber flap if equipped 12 Flap plate if equipped 13 Pop rivet steel if equipped Figure 3 1 2 3 4 6 7 8 9 10 11 12 13 5 FRONT RIGHT 85 to 110 ft lb 115 to 149 N m ...

Page 235: ...vice remove cutting unit see Cutting Unit Operator s Manual 5 Remove blade bolt anti scalp cup and cutting blade see Cutting Unit Operator s Manual 6 Remove cap screws and flange nuts securing spindle assembly to cutting deck Slide spindle assem bly out the bottom of the deck Remove spindle plate from top of deck Installation 1 Install spindle assembly and spindle plate to cutting deck with cap sc...

Page 236: ...alled Replacement bearings are sold only with a matched spacer set and snap ring These parts cannot be purchased separately 1 If large snap ring was removed or if replacing the spindle housing install snap ring into spindle housing groove Make sure snap ring is seated in groove IMPORTANT If bearings are being replaced make sure to use the large spacer inside spacer and spacer ring that are include...

Page 237: ...ith grease 8 Install spindle spacer onto shaft Carefully slide spindle shaft through spindle housing The bottom seal and spindle spacer fit together when the spindle is installed fully 9 Thread spindle nut onto shaft and tighten nut from 130 to 160 ft lb 177 to 216 N m 10 Install spindle plug to top of spindle housing Attach a hand pump grease gun to either grease fitting and fill housing cavity w...

Page 238: ... rear of deck frame Remove roller mounts and rear roller assembly from deck frame 4 Loosen fasteners securing each end of roller to roller mounts Remove mounts from roller Installation Fig 8 1 Place roller assembly into roller mounts 2 Install roller and roller mount assembly into rear of deck frame Secure assembly to deck frame with flange head screws IMPORTANT If roller design includes grease fi...

Page 239: ...ch with pick and pull ring from shaft 2 Loosely secure roller assembly in bench vise and lightly tap one end of roller shaft until free from bearing and housing 3 Remove second bearing from shaft by supporting bearing on inner race and tapping on roller shaft 4 Discard removed bearings Inspect shaft retaining rings and roller for damage Replace components as needed Roller Assembly Fig 9 1 Press ne...

Page 240: ... 14 Rear Roller Service Greasable Bearings with Retaining Ring 1 Roller shaft 2 Outer seal 3 Retaining ring 4 Outer oil seal 5 Grease fitting 6 Washer 7 Inner seal 8 Ball bearing 9 Inner oil seal 10 Roller tube Figure 11 6 3 5 4 2 1 7 8 9 10 6 3 5 4 2 1 7 8 9 10 ...

Page 241: ...he roller shaft IMPORTANT If ball bearing has a seal on one side install bearing with seal orientated toward the out side of the roller A Use tool TOR4066 and handle TOR4073 to install ball bearing into one end of roller tube B Install roller shaft from opposite end of roller Be careful not to damage the inner oil seals C Put roller in a vertical position and support shaft and bearing with tool TO...

Page 242: ... installation IMPORTANT During assembly process frequently check that bearings rotate freely and do not bind If any binding is detected consider component re moval and reinstallation 2 Install new bearing and outer seals into one end of roller tube A Position a new bearing into one end of roller tube Use bearing outer seal tool see Special Tools with a soft face hammer to fully seat bearing agains...

Page 243: ...t shaft and bearings still freely rotate IMPORTANT Make sure that all grease is removed from shaft threads to prevent bearing lock nut loos ening 5 Thoroughly clean threads on both ends of roller shaft NOTE If original bearing lock nut s are being used apply Loctite 242 or equivalent to threads of lock nut s 6 Install bearing lock nut onto each end of the roller shaft Make sure that outer seals ar...

Page 244: ... into roller A Press first bearing into housing Press on outer race only or equally on inner and outer races B Insert bearing spacer C Press second bearing into roller housing press ing equally on inner and outer races until the inner race comes in contact with the spacer 2 Install roller assembly into deck frame 1 Mounting bolt 2 Bearing 3 Spacer 4 Front roller Figure 18 80 ft lb 108 N m 2 2 3 4 ...

Page 245: ...Rev D Groundsmaster 4500 D 4700 D Cutting Units Rev B Page 8 19 This page is intentionally blank Cutting Units ...

Page 246: ...Lynch pin 3 Thrust washer 4 Pivot shaft 5 Lift arm 4 shown 6 Cap screw 7 Rebound washer 8 Pivot shaft 9 Lift arm 2 shown 10 Lock nut 11 Flat washer 12 Compression spring 13 Pivot shaft 14 Lift arm 6 shown Figure 19 2 4 3 1 5 FRONT RIGHT 14 12 13 3 1 11 10 3 7 8 6 1 9 Decks 2 and 3 Decks 6 and 7 Decks 1 4 and 5 ...

Page 247: ... liftarm The frame is secured to the liftarm pivot shaft with a lynch pin Fig 19 2 Carrier frames for the center two cutting decks 2 and 3 have a thrust washer between the carrier frame and the lift arm The frame is secured to the lift arm pivot shaft with a rebound washer and cap screw Fig 19 3 Carrier frames for the rear two cutting decks 6 and 7 on the GM4700 D have a compression spring and thr...

Page 248: ...Rev D Groundsmaster 4500 D 4700 D Cutting Units Rev B Page 8 22 This page is intentionally blank ...

Page 249: ...CUIT DIAGRAMS Glow Plug Circuit Diagram 9 Crank Circuit Diagram 10 Run Transport Circuit Diagram 11 Run Mow Circuit Diagram 12 WIRE HARNESS DRAWINGS Main Wire Harness Drawing Serial Number Below 220999999 14 Serial Number From 230000001 to 26000060016 Serial Number Above 260000600 18 Console Wire Harness Drawing Serial Number Below 220999999 20 Serial Number From 230000001 to 26000060022 Serial Nu...

Page 250: ...Groundsmaster 4500 D 4700 D Electrical Diagrams Rev A Page 9 2 This page is intentionally blank ...

Page 251: ...ck GN BU W OR W GLOW OVER TEMP LOW OIL PRESSURE ALTERNATOR CLUSTER GAUGE CONTROLLER GLOW PLUG KUBOTA START RELAY K5 GLOW RELAY DECKS 2 3 5 DECKS 1 4 FRONT PTO FRONT PTO DECK RAISED NOT IN NEUTRAL SEAT VACANT OFF IN 4WD DECK UP IN CENTER POSITION FRONT DECK POSITION DECK RAISED FRONT DECK POSITION Serial Number Below 220999999 ...

Page 252: ...Rev D Page 9 4 Electrical Schematic Groundsmaster 4500 D All relays and solenoids are shown as de energized All ground wires are black GLOW RELAY Serial Number From 230000001 to 260000600 ...

Page 253: ...Rev D Page 9 5 Electrical Schematic Groundsmaster 4500 D All relays and solenoids are shown as de energized All ground wires are black Serial Number Above 260000600 ...

Page 254: ...UGE GN CONTROLLER GLOW PLUG KUBOTA START RELAY K5 DECKS 2 3 5 FRONT PTO DECKS 1 4 FRONT PTO DECK 6 LEFT PTO DECK 7 RIGHT PTO NOT IN NEUTRAL SEAT VACANT IN 4WD OFF DECK UP IN CENTER POSITION DECK RAISED FRONT DECK POSITION DECK RAISED FRONT DECK POSITION DECK RAISED LEFT DECK POSITION DECK RAISED RIGHT DECK POSITION DECK UP IN CENTER POSITION DECK UP IN CENTER POSITION Serial Number Below 220999999...

Page 255: ...Rev D Page 9 7 Electrical Schematic Groundsmaster 4700 D All relays and solenoids are shown as de energized All ground wires are black GLOW RELAY Serial Number From 230000001 to 260000600 ...

Page 256: ...Rev D Page 9 8 Electrical Schematic Groundsmaster 4700 D All relays and solenoids are shown as de energized All ground wires are black Serial Number Above 260000600 ...

Page 257: ...VACANT OFF IN 4WD DECK RAISED FRONT DECK POSITION DECK UP IN CENTER POSITION DECK RAISED FRONT DECK POSITION NOTE The wire harness and relays of the GM 4500 D and GM 4700 D Glow Plug Circuit Power Current Control Current Indicator Gauge Current Groundsmaster 4500 D 4700 D Serial Number Below 220999999 to show the operational circuits are the same The drawing on this page uses the GM 4500 D Schemat...

Page 258: ...OCCUPIED OFF IN 4WD Crank Circuit Power Current Control Current Indicator Gauge Current Groundsmaster 4500 D 4700 D DECK RAISED FRONT DECK POSITION DECK UP IN CENTER POSITION DECK RAISED FRONT DECK POSITION NOTE The wire harness and relays of the GM 4500 D and GM 4700 D Serial Number Below 220999999 to show the operational circuits are the same The drawing on this page uses the GM 4500 D Schematic...

Page 259: ...AL SEAT OCCUPIED OFF IN 2WD DECK UP IN CENTER POSITION FRONT DECK POSITION DECK RAISED FRONT DECK POSITION Run Transport Circuit Power Current Control Current Indicator Gauge Current Groundsmaster 4500 D 4700 D OFF NOTE The wire harness and relays of the GM 4500 D and GM 4700 D Serial Number Below 220999999 to show the operational circuits are the same The drawing on this page uses the GM 4500 D S...

Page 260: ...K LOWERED NOT IN NEUTRAL SEAT OCCUPIED ON IN 4WD DECK UP IN CENTER POSITION FRONT DECK POSITION DECK LOWERED FRONT DECK POSITION OFF NOTE Refer to Cutting Deck Position Switch and Cutting Deck Lift Lower Switch in Chapter 5 Electrical System for information on cutting deck switch operation NOTE The wire harness and relays of the GM 4500 D and GM 4700 D Serial Number Below 220999999 to show the ope...

Page 261: ...Rev D Page 9 13 This page is intentionally blank ...

Page 262: ...ERCONNECT TO GM 4700 CENTER DECK PTO 2 3 5 P14 CENTER DECK PTO 1 4 YELLOW YELLOW YELLOW YELLOW YELLOW WHITE YELLOW BLUE WHITE YELLOW ORANGE RED BLACK BLACK BLACK BLACK GREEN GRAY RED BLACK BLUE WHITE ORANGE BLACK GREEN YELLOW VIOLET GREEN YELLOW BLACK ORANGE GREEN TAN BROWN GREEN BLACK BLACK BLACK ORANGE BLACK BLUE PINK RED BLACK BLUE WHITE RED BLACK GREEN BLACK PINK GRAY PINK ORANGE VIOLET BLUE P...

Page 263: ...NTER DECK 1 4 P14 FUEL PUMP P20 INTERCONNECT TO ENGINE P23 INTERCONNECT P4 NEUTRAL SWITCH P6 CENTER DECK P9 CENTER DECK P8 PARKING BRAKE P17 WARNING LIGHTS P1 IGNITION J4 WARNING LIGHTS P2 1 2 3 4 5 SP5 SP1 SP2 SP7 SP6 1 2 PTO 2 3 5 RELAY RELAY GLOW RELAY B 1 2 SP3 OVER TEMP SWITCH OIL PRESSURE ALT L TO ENGINE SWITCH 2 SWITCH 1 Groundsmaster 4500 D 4700 D Main Wire Harness Serial Number Below 2209...

Page 264: ...K PINK BLACK PINK WHITE PINK BLUE WHITE RED ORANGE RED RED BROWN BLUE BLUE ORANGE WHITE BLACK GREEN BROWN BLACK BLACK BLACK BLACK BLACK CABLE SHIELD YELLOW VIOLET GREEN ORANGE YELLOW GREEN GREEN RED BLACK BLUE WHITE ORANGE GRAY BLUE BLACK BROWN WHITE BROWN GREEN GRAY BLUE WHITE BLACK BLACK BLACK Serial Number From 230000001 to 260000600 ...

Page 265: ...Rev D Page 9 17 Groundsmaster 4500 D 4700 D Main Wire Harness Serial Number From 230000001 to 260000600 ...

Page 266: ...NK PINK PINK BLACK PINK WHITE PINK BLUE WHITE RED ORANGE RED RED BROWN BLUE BLUE ORANGE WHITE BLACK GREEN BROWN BLACK BLACK BLACK BLACK BLACK CABLE SHIELD YELLOW VIOLET GREEN ORANGE YELLOW GREEN GREEN RED BLACK BLUE WHITE ORANGE GRAY BLUE BLACK BROWN WHITE BROWN GREEN GRAY BLUE WHITE BLACK BLACK BLACK Serial Number Above 260000600 ...

Page 267: ...Rev D Page 9 19 Groundsmaster 4500 D 4700 D Main Wire Harness Serial Number Above 260000600 AND UP SN 280000001 ...

Page 268: ...TRAL CAPACITOR YELLOW GREEN WHITE GREEN GREEN GRAY WHITE YELLOW RED BLACK DIODE 8 LEFT DECK CENTER DECKS RIGHT DECK GREEN BROWN ORANGE PINK ORANGE GREEN YELLOW ORANGE VIOLET YELLOW DIODE PACK INTERCONNECT TO MAIN RAMP UP MODULE VIOLET ORANGE VIOLET BLACK ORANGE GREEN GREEN YELLOW BLUE TAN BLUE WHITE GREEN YELLOW BLACK PINK PTO SWITCH K7 PARKING BRAKE K6 HIGH TEMP 2WD 4WD SWITCH GLOW CONTROLLER TEM...

Page 269: ...P13 P12 P8 P7 P9 P11 P16 P15 P17 J2 J3 P28 LEFT DECK P19 DIODE 8 P18 DIODE PACK P6 TEMPERATURE GAUGE P2 TEMPERATURE GAUGE J1 GLOW CONTROLLER P3 PTO SWITCH P5 2WD 4WD SWITCH P4 3 2 1 2 1 3 4 5 1 2 3 4 5 6 1 2 POWER POINT P22 1 2 3 B A MAIN HARNESS SP6 SP4 SP3 SP5 SP1 SP8 SP9 SP7 SP2 P1 Groundsmaster 4500 D 4700 D Console Wire Harness CENTER PTO LEFT PTO RIGHT PTO START K6 HIGH TEMP P14 Serial Numbe...

Page 270: ...T BROWN ORANGE VIOLET RED BLACK PINK BLACK BLACK BLACK BLUE BLACK BLUE BLACK PINK BLACK PINK PINK ORANGE PINK BLACK ORANGE TAN YELLOW BLUE GRAY GREEN GREEN GREEN BLUE WHITE ORANGE ORANGE PINK SHIELDED CABLE YELLOW YELLOW ORANGE GRAY PINK YELLOW BLUE GREEN YELLOW PINK GREEN WHITE YELLOW BLACK VIOLET WHITE PINK PINK PINK BLACK PINK BLACK RED RED RED WHITE BLACK BLACK RED WHITE GREEN GND ...

Page 271: ...Rev D Page 9 23 Groundsmaster 4500 D 4700 D Console Wire Harness Serial Number From 230000001 to 260000600 ...

Page 272: ...HIELDED CABLE ORANGE GREEN WHITE GREEN WHITE YELLOW TAN GRAY PINK YELLOW BLUE YELLOW BLUE WHITE ORANGE ORANGE GREEN GREEN GREEN BLUE GRAY BROWN TAN ORANGE BLACK BROWN PINK BLACK PINK BROWN PINK BLACK BLACK GREEN ORANGE VIOLET PINK VIOLET RED BLACK PINK ORANGE BLACK PINK VIOLET BLACK PINK PINK RED WHITE BLACK RED RED BLACK PINK BLACK RED WHITE BLACK BLACK BROWN BLACK BROWN BROWN ...

Page 273: ...Rev D Page 9 25 Groundsmaster 4500 D 4700 D Console Wire Harness Serial Number Above 260000600 ...

Page 274: ...CK BLUE BLUE WHITE WHITE GRAY GREEN YELLOW BLACK RED BLACK RUN SOLENOID HOLD OVER TEMPERATURE OIL PRESSURE P1 J5 J4 PULL GROUND BLUE WHITE STARTER G P2 GROUND J3 FUSIBLE LINK ALTERNATOR R L Groundsmaster 4500 D 4700 D Engine Wire Harness TO MAIN HARNESS INTERCONNECT TO MAIN HARNESS Serial Number Below 220999999 ...

Page 275: ...TCH P1 FUEL SOLENOID P5 TO MAIN HARNESS A B SP2 SP1 P4 TO MAIN HARNESS P2 STARTER G J4 OIL PRESSURE J6 STARTER S J3 GROUND P7 DIODE P6 ALTERNATOR 1 2 J1 TEMPERATURE SENDER Serial Number Below 220999999 Engine Wire Harness Groundsmaster 4500 D 4700 D ...

Page 276: ...Rev D Page 9 28 Serial Number Above 230000000 Engine Wire Harness Groundsmaster 4500 D 4700 D BLACK BLUE WHITE GREEN WHITE WHITE BLUE PINK GRAY RED BLACK BLACK FUSIBLE LINK ORANGE BLACK ...

Page 277: ...Rev D Page 9 29 Serial Number Above 230000000 Engine Wire Harness Groundsmaster 4500 D 4700 D ...

Page 278: ...Rev D Page 9 30 Deck 6 and 7 Wire Harness Groundsmaster 4700 D GREEN BLACK YELLOW PINK PINK PINK BLACK ORANGE VIOLET BLACK BLACK YELLOW VIOLET BLACK ...

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Toro Groundsmaster 4500-D, Service Manual

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