Manuale d’uso / di manutenzione del prodotto 30873 del fabbricante Toro
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(Models 30873, 30874, 30881 and 30882) Part No. 14205SL Service Manual Groundsmaster R 4500 - - D/4700 - - D Preface The pur pose of t his public ation is to pr ovide the serv ice technic ian with i n.
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Gr oundsmas ter 4500 - - D/ 4700 - - D T able Of Contents Chapter 1 - - Safety Gener al Safet y I nst ruc tions 1 - - 2 .................. Jackin g Instructions 1 - - 5 ......................... Safet y and I nst ruc tion Dec als 1 - - 6 .............
Gr oundsmas ter 4500 - - D/ 4700 - - D This page is intent ional ly blank ..
Groundsmaster 4500- - D/4700 - -D Page 1 - - 1 Safet y Chapter 1 Safety T able o f Contents GENERAL SAFETY INSTRUCTIONS 2 ............ Before Oper ating 2 ............................ While Operating 3 ............................ Maintenance and Service 4 .
Groundsmaster 4500- - D/4700 - -D Page 1 - - 2 Safety General Safety Instructions The Groun dsmaster 4500 -D and 470 0 - - D have bee n tested and certifi ed by TORO for compliance with exist- ing safety standards and spec ifications.
Groundsmaster 4500- - D/4700 - -D Page 1 - - 3 Safet y While Operating 1. Sit on the seat when st arting an d operating th e ma- chine. 2. Before starting the eng ine: A. Engage the par king brake. B. Make sure traction pedal i s in neutral and the PTO switch is OFF (dise ngaged).
Groundsmaster 4500- - D/4700 - -D Page 1 - - 4 Safety Maintenance and Service 1. The T raction Unit and Cutting Deck Operator ’s Manuals provide information r egarding the operation, general main tenance and maintenanc e intervals for your Groundsmaster machin e .
Groundsmaster 4500- - D/4700 - -D Page 1 - - 5 Safet y Jacking Instructions CAUTION When changing attachments, tires or perform- ing other servic e, use correct jacks and sup- ports. Make sure machine is park ed on a solid, level surface such as a concre te floor .
Groundsmaster 4500- - D/4700 - -D Page 1 - - 6 Safety Safety and Instruction Decals Numerous safe ty and instruction decals are affixed to the Groundsmaster 4500- -D and 4700 - - D. If any decal becomes illegible o r damaged, install a new decal. De- cal part numbers are listed in y our Parts Catalog.
Groundsmaster 4500- - D/4700 - -D Page 2 - - 1 Product Records a nd Maintenance Chapter 2 Product Records and Maintenance T able o f Contents PRODUCT RECORDS 1 ......................... MAINTENANCE 1 .............................. EQUIV ALENTS AND CONVERSIONS 2 .
0.09375 Groundsmaster 4500- - D/4700 - -D Page 2 - - 2 Product Records a nd Maintenance Equivalents and Conversions.
Groundsmaster 4500- - D/4700 - -D Page 2 - - 3 Product Records a nd Maintenance T or que Specifications Recommended fastener torque values are listed in the following tables.
Groundsmaster 4500- - D/4700 - -D Page 2 - - 4 Product Records a nd Maintenance Standard T orque for Dry , Z inc Plate d and Steel Fasteners (Inch Series) Thread Size Grade 1, 5 & 8w i t hT h i n .
Groundsmaster 4500- - D/4700 - - D Page 2 - - 5 Product Records a nd Maintenance Standard T o rque for Dry , Zinc Plated a nd Steel Fasteners (Metric Series) Thre ad Size Class 8.8 Bolts, Screws and Studs with Regular Height Nuts (Class 8 or Stronger Nuts) Class 10.
Groundsmaster 4500- - D/4700 - - D Page 2 - - 6 Product Records a nd Maintenance Other T orque Specifications SAE Grade 8 Steel Set Screws Thread Size Recommended T orque Square Head Hex Socket 1/4 - .
Groundsmaster 4500- - D/4700 - - D Page 3 - - 1 Y anmar Diesel Engine Chapter 3 Y anmar Diesel Engine T able o f Contents SPECIFICA TIONS 2 ............................ Models 3087 3 and 30874 2 .................... Models 3088 1 and 30882 3 .........
Groundsmaster 4500- - D/4700 - - D Page 3 - - 2 Y anmar Diesel Engine Specifications (Models 30873 and 30874) Item Description Make / Designation Y anmar Model 4TNV84T- - ZMTR: 4 - - Cycle, 4 Cylinder , W ater C ooled, T urboc harged, T ier 4i Diesel Engine Bore 3.
Groundsmaster 4500- - D/4700 - - D Page 3 - - 3 Y anmar Diesel Engine Specifications (Models 30881 and 30882) Item Description Make / Designation Y anmar Model 4TNV86CT - - DT R: 4 - - Cycle, 4 Cylinder , W ater Cooled, Turbocharged, T ier 4 Diesel Engine Bore 3.
Groundsmaster 4500- - D/4700 - - D Page 3 - - 4 Y anmar Diesel Engine General Information This Chapter gives information about specifications and repair of the diese l engine used in the Groundsma ster 4500 - - D and 4 700 - - D. General maintenance pro cedures are described in your T raction Unit Operator ’s Manual.
Groundsmaster 4500- - D/4700 - - D Page 3 - - 5 Y anmar Diesel Engine Engine Electronic Control Unit (EC U) The Y anmar engine that powers y our Groundsmaster uses an electronic cont rol unit (ECU) fo r engine man- agement and also to co mmunicate wit h the machine TEC controllers and the operator Info Center display on the mach ine.
Groundsmaster 4500- - D/4700 - - D Page 3 - - 6 Y anmar Diesel Engine Y anmar Engine: Models 3087 3 and 30874 The engine u sed on Groundsmaster mo dels 30873 and 30874 is a Y anm ar TNV Series, tu rbochar ged, diesel engine that complies with EP A interim T ier 4 emission regulations.
Groundsmaster 4500- - D/4700 - - D Page 3 - - 7 Y anmar Diesel Engine Assist regeneration occurs if the engine ECU senses that the DPF b ackpressure has increase d to its max im- um threshold. During assist regener ation, the intake throttle valve limits the air flow into the eng ine while the injectors add additional fuel.
Groundsmaster 4500- - D/4700 - - D Page 3 - - 8 Y anmar Diesel Engine Service and Repairs Air Cleaner Sy stem Figure 6 FRONT RIGHT 1. Air cleaner assembly 2. Air cleaner mount 3. Indicator 4. Adapt er 5. Air cleaner strap 6. Socket head screw (2 used) 7.
Groundsmaster 4500- - D/4700 - - D Page 3 - - 9 Y anmar Diesel Engine Removal (Fig. 6) 1. Park machine on a level s urface, lower cu tting decks, stop engine, apply parking brake and remove key from the ignition switch . 2. Raise and support h ood. 3.
Groundsmaster 4500- - D/4700 - - D Page 3 - - 1 0 Y anmar Diesel Engine Fuel System Figure 9 1. Fuel suction tube 2. Fuel gauge 3. Fuel hose (supply) 4. Return fitting 5. Fuel hose (return) 6. Fuel tank cap 7. Bus hing ( 2 used ) 8. Hose clamp (6 used) 9.
Groundsmaster 4500- - D/4700 - - D Page 3 - - 1 1 Y anmar Diesel Engine DANGER Because diesel fuel is highly flammable, use cau- tion when storing or handling i t. Do not smoke while filling the fuel tank. Do not fill fuel tank while engine is running, hot or when machine is in an enclosed area.
Groundsmaster 4500- - D/4700 - - D Page 3 - - 1 2 Y anmar Diesel Engine Radiator and Oil Cooler Assem bly 1. Radiator/oil cooler assembly 2. Cap screw (4 used) 3. W asher (4 used) 4. Fan 5. Plenum assembly 6. Cap screw (6 used) 7. Flange nut (6 used) 8.
Groundsmaster 4500- - D/4700 - - D P age 3 - - 13 Y anmar Diesel Engine Removal (Fig. 1 1) 1. Park machine on a level s urface, lower cu tting decks, stop engine, engage parking brake and remove key from the ignition switch . 2. Remove hood fro m the machin e (see Hood Rem oval in the Service and Repairs section of Chapter 7 - - Chas- sis).
Groundsmaster 4500- - D/4700 - - D Page 3 - - 1 4 Y anmar Diesel Engine 13. Plug all radiator/oil cooler and hose op enings to pre- vent contamination. 14. If necessary , remove draincock (item 7 in Fig. 13), plug (item 6 in Fig. 13) and hydraulic pl ug (item 8 in Fig.
Groundsmaster 4500- - D/4700 - - D P age 3 - - 15 Y anmar Diesel Engine This page is intentionally blank. Ya n m a r Diesel Engine.
Groundsmaster 4500- - D/4700 - - D Page 3 - - 1 6 Y anmar Diesel Engine Engine Figure 14 1. LH front engine mount br acket 2. RH front engine mount bracket 3. LH rear engine mount b racket 4. RH rear engine mount bracket 5. Lock washer (16 used) 6. Cap scre w (16 u sed) 7.
Groundsmaster 4500- - D/4700 - - D P age 3 - - 17 Y anmar Diesel Engine Engine Removal (Fig. 14) 1. Park machine on a level s urface, lower cu tting decks, stop engine, engage parking brake and remove key from the ignition switch . 2. Remove hood fro m the machin e (see Hood Rem oval in the Service and Repairs section of Chapter 7 - - Chas- sis).
Groundsmaster 4500- - D/4700 - - D Page 3 - - 1 8 Y anmar Diesel Engine 10. Support hydraulic pump assembly to prevent it from shifting or falling. Remove fastener s that secure piston (traction) pump to engi ne (see Piston (T raction) Pump in the Service and Repairs section of Chapter 4 - - Hy- draulic System).
Groundsmaster 4500- - D/4700 - - D P age 3 - - 19 Y anmar Diesel Engine 13. Check position of wires, fuel lines and hyd raulic hoses for proper clearance with rotating, high temp era- ture and moving compone nts. 14. Connect positive battery cable to battery first and then negati ve battery cable.
Groundsmaster 4500- - D/4700 - - D Page 3 - - 2 0 Y anmar Diesel Engine Pump Ada pter Plate Figure 17 1. Flyw heel p late 2. Hardened washer (8 used) 3. Spring coupler 4. Cap screw (8 used) 5. Cap screw with patchlock (8 used) 6. Hardened washer (8 used) 7.
Groundsmaster 4500- - D/4700 - - D P age 3 - - 21 Y anmar Diesel Engine Coupler Removal (Fig. 17) NOTE: The hydraulic pump assembly ne eds to be re- moved from engine befor e coupler can be removed .
Groundsmaster 4500- - D/4700 - - D Page 3 - - 2 2 Y anmar Diesel Engine Exhaust System (Mod els 30881 and 30882) Figure 19 1. Gasket 2. Exhaust assembly stay 3. Exhaust assembly stay 4. Exhaust assembly stay 5. Exhaust assembly stay 6. Nut 7. DOC t emp senso r (inle t) 8.
Groundsmaster 4500- - D/4700 - - D P age 3 - - 23 Y anmar Diesel Engine Groundsmaster models that are powered by a diesel en- gine that complies with EP A T ier 4 emission regulations are equipped with an exhau st system that includes a diesel oxidation catalyst (DOC) and a diesel particulate filter (DPF).
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Groundsmaster 4500- - D/4700 - - D Hydraulic System Pa ge 4 - - 1 Chapter 4 Hydraulic System T able o f Contents SPECIFICA TIONS 2 ............................ GENERAL INFORMA TION 3 ..................... Operator ’s Manu al 3 ......................
Groundsmaster 4500- - D/4700 - - D Hydraulic System Page 4 - - 2 Specifications Item Description Piston (Traction ) Pump Sauer - - Danfoss V ariable Displacement Axial Piston Pump Maximum Displacement (per revolution) 2.
Groundsmaster 4500- - D/4700 - - D Hydraulic System Pa ge 4 - - 3 General Information Operator ’ s Manual The Operator ’s Manu al provides info rmation regarding the operation, general main tenance and maintenance intervals for your Ground smaster machine.
Groundsmaster 4500- - D/4700 - - D Hydraulic System Page 4 - - 4 T owing T raction Unit IMPORT ANT : If towing limits a re exceeded, severe damage to the piston pump may occur . If it becomes necessary to tow (or push) the machine, tow (or push) in a forward direc tion only , at a speed below 3 mph (4.
Groundsmaster 4500- - D/4700 - - D Hydraulic System Pa ge 4 - - 5 Relieving Hydraulic System Pressu re Before disconnectin g or performin g any work on the hy- draulic system, all pressure in the hydraulic system must be relieved.
Groundsmaster 4500- - D/4700 - - D Hydraulic System Page 4 - - 6 Hydraulic Hoses Hydraulic hoses are subject to extre me conditions su ch as pressure d ifferentials du ring operation and exposure to weather , sun, che micals, very warm s torage cond i- tions or mishandling during operation and mainte nance.
Groundsmaster 4500- - D/4700 - - D Hydraulic System Pa ge 4 - - 7 Hydraulic Hose and T ube Installation (O - - Ring Face Seal Fitting) 1. Make sure threads and sealing surfaces of the hose/ tube and the fitting are free of burrs, nicks, scratches or any foreign material.
Groundsmaster 4500- - D/4700 - - D Hydraulic System Page 4 - - 8 Hydraulic Fitting Installation (SAE S traight Thread O - - R ing Fitting into Component Port) Non - - Adjustable Fitting (Fig. 6) 1. Make sure al l threads and sealing surfaces of fitting and component port are free of burrs, nicks, scratches or any foreign m aterial.
Groundsmaster 4500- - D/4700 - - D Hydraulic System Pa ge 4 - - 9 Adjustable Fitting (Fi g. 8) 1. Make sure all thr eads and sealing surfa ces of fitting and component port are free of burrs, nicks, scratches or any foreign material.
Groundsmaster 4500- - D/4700 - - D Hydraulic System Page 4 - - 10 Hydraulic Schematics Hydraulic Schematic Groundsmaster 45 00 - - D All solenoids are shown as de - - energized NOTE: A larger hydraulic schematic is included in Chapter 9 - - F oldout Drawings 0.
Groundsmaster 4500- - D/4700 - - D Hydraulic System Page 4 - - 1 1 Hydraulic Schematic Groundsmaster 4700- - D All solenoids are shown as de - - ener giz ed NOTE: A larger hydraulic schematic is included in Cha pter 9 - - Foldout Drawings 0.630 ” ROD 1050 6.
Groundsmaster 4500- - D/4700 - - D Hydraulic System Page 4 - - 12 Hydraulic Flow Diagrams T raction Circuit: LOW Speed (GM 4500 - - D Forward Shown) Working Pressure Low Pressure (Charge) Return or Suction Flow Groundsmaster 450 0 - - D/4700 - - D 0.630” ROD 1050 1600 PSI 6.
Groundsmaster 4500- - D/4700 - - D Hydraulic System Page 4 - - 13 T raction Circuit: LOW S peed (Mow) The traction circuit piston pump is a variable d isplace- ment pump that is directly coupled to the en g ine fly- wheel.
Groundsmaster 4500- - D/4700 - - D Hydraulic System Page 4 - - 14 T raction Circuit: H I Speed (GM 4500 - - D Forward Shown) Working Pressure Low Pr ess ure (C harge) Return or Suction Flow Groundsmaster 450 0 - - D/4700 - - D 0.630” ROD 1050 1600 PSI 6.
Groundsmaster 4500- - D/4700 - - D Hydraulic System Page 4 - - 15 T raction Circuit: HI Spe ed (T ransport) The traction circuit piston pump is a variable d isplace- ment pump that is directly coupled to the en g ine fly- wheel.
Groundsmaster 4500- - D/4700 - - D Hydraulic System Page 4 - - 16 Working Pressure Low Pressure (Charge) Return or Suction Flow Ground smaster 4500 - - D Lower Cutting Decks Lift Switch Pressed to Lower Decks 0.
Groundsmaster 4500- - D/4700 - - D Hydraulic System Page 4 - - 17 Lower Cutting Decks: Groundsmaste r 4500 - - D A four section gear pump is coupled to the piston ( trac- tion) pump . The third gea r pump sectio n supplies hy - draulic flow to both the lif t control manifold and the steering control valve .
Groundsmaster 4500- - D/4700 - - D Hydraulic System Page 4 - - 18 Wo rking Pressure Low Pressure (Charge) Return or Sucti on Flow Groundsmaster 4700- - D Lower Cutting Decks All Lift Switches Pressed to Low er Decks 0.630” ROD 1050 6.2 GPM 11 . 4 G P M T PRV S1 CV FD P2 P1 ST L M1 M2 PE T R 50/50 FL OW DIVIDER FAN CONTROL MANIFOLD MANIFOLD 30.
Groundsmaster 4500- - D/4700 - - D Hydraulic System Page 4 - - 19 Lower Cutting Decks: Groundsmaste r 4700 - - D A four section gear pump is coupled to the piston ( trac- tion) pump . The third gea r pump sectio n supplies hy - draulic flow to both the lif t control manifold and the steering control valve .
Groundsmaster 4500- - D/4700 - - D Hydraulic System Page 4 - - 20 Wor king Pressure Low Pressure (Charge) Return or Suction Flow Groundsmaster 4500- - D Raise Cutting Decks Lift Switch Pressed to Raise Decks 0.
Groundsmaster 4500- - D/4700 - - D Hydraulic System Page 4 - - 21 Raise Cutting Decks: Groundsmaster 450 0 - - D A four section gear pump is coupled to the piston ( trac- tion) pump . The third gea r pump sectio n supplies hy - draulic flow to both the lif t control manifold and the steering control valve .
Groundsmaster 4500- - D/4700 - - D Hydraulic System Page 4 - - 22 Wor ki n g Pr es s u re Low Pressure (Charge) Return or Sucti on Flow Groundsmaster 4700- - D All Lift Switches Pressed to Raise Decks Raise Cutting Decks 0.630” RO D 1050 6.2 GPM 11 .
Groundsmaster 4500- - D/4700 - - D Hydraulic System Page 4 - - 23 Raise Cutting Decks: Groundsmaster 470 0 - - D A four section gear pump is coupled to the piston ( trac- tion) pump . The third gea r pump sectio n supplies hy - draulic flow to both the lif t control manifold and the steering control valve .
Groundsmaster 4500- - D/4700 - - D Hydraulic System Page 4 - - 24 Mow Circuit (GM 4500 - - D Shown) Wo rking Pressure Low Pressure (Charge) Return or Sucti on Flow Groundsmaster 4500- - D/4700 - - D 0.
Groundsmaster 4500- - D/4700 - - D Hydraulic System Page 4 - - 25 Mow Circuit Hydraulic flow for the mow circuit is supplied by the first two (2) sections of the gear pump.
Groundsmaster 4500- - D/4700 - - D Hydraulic System Page 4 - - 26 Cutting Deck Blade Braking When the operator turns th e PTO switch OFF (or if the decks are raised), deck manifold solenoid va lves (PRV1, PRV2, SV1 and SV2) are d e - - ener gized. Th e valves will shift to direct oil away from the deck motors and toward the oi l cooler and filter .
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Groundsmaster 4500- - D/4700 - - D Hydraulic System Page 4 - - 28 Steering Circuit (GM 4500 - - D Right T urn Shown) Working Pressure Low Pr ess ure (C harge) Return or Suction Flow Groundsmaster 450 0 - - D/4700 - - D 0.630” ROD 1050 1600 PSI 6.2 GPM 11 .
Groundsmaster 4500- - D/4700 - - D Hydraulic System Page 4 - - 29 Steering Circuit A four section gear pump is coupled to the piston ( trac- tion) pump . The third gea r pump sectio n supplies hy - draulic flow to the ste ering con trol valv e and the lift/lower control valve.
Groundsmaster 4500- - D/4700 - - D Hydraulic System Page 4 - - 30 Engine Cooling Fan Circuit (GM 4500 - - D Normal Fan Direction Shown) Working Pressure Low Pressure (Charge) Return or Suction Flow Groundsm aster 4500 - - D /4700 - - D 0.630” ROD 1050 1600 PSI 6.
Groundsmaster 4500- - D/4700 - - D Hydraulic System Page 4 - - 31 Engine Cooling Fan Circuit A four section gear pump is coupled to the piston ( trac- tion) pump. The fina l gear pump section (farthest from the piston pump) su pplies hydraulic fl ow for the hydrau- lic engine cooling fan m otor .
Groundsmaster 4500- - D/4700 - - D Hydraulic System Page 4 - - 32 Special T ools Order these spe cial tools from you r T oro Distribut or . Hydraulic Pressure T est Kit Use to take various pressure read ings for diagnostic tests. Quick disconnect fitti ngs provided attach directly to mating fittings on machine test ports without tools.
Groundsmaster 4500- - D/4700 - - D Hydraulic System Page 4 - - 33 40 GPM Hydraulic T ester (Pressure and Flow) Use to test hydraulic circuits and components for flow and pressure capacities as recommended in the T estin g section of this chapte r . This tester includes the f ollowing: 1.
Groundsmaster 4500- - D/4700 - - D Hydraulic System Page 4 - - 34 High Flow Hydraulic Filter Kit The high flow hydraulic filt er kit is designed with large flow (40 GPM/150 LPM) and high pre ssure (5000 PSI/345 bar) capabilities.
Groundsmaster 4500- - D/4700 - - D Hydraulic System Page 4 - - 35 Hydraulic T est Fitting Kit This kit includes a variety of O - - ring Face Seal fittings to enable you to co nnect test gauges in to the system. The kit includes: tee’ s, unions, reducers, plugs, caps and male test fittings.
Groundsmaster 4500- - D/4700 - - D Hydraulic System Page 4 - - 36 Remote Starter Switch After flushing the hydraulic system or replacing a hy- draulic component (e.g. gear pump, pi ston pump, wheel motor), it is nec essary to pr ime the hydr aulic pumps.
Groundsmaster 4500- - D/4700 - - D Hydraulic System Page 4 - - 37 T roubleshooting The charts that follow conta in information to assist in hy- draulic system troubleshooting. There may possib ly be more than one cause for a machi ne malfunction. Refer to the T esting section of this Chapter for prec au- tions and specific testing procedures.
Groundsmaster 4500- - D/4700 - - D Hydraulic System Page 4 - - 38 T raction Circuit Pr oblems NOTE: When troubleshooting tra ction circuit problems, if a problem exist s in both low (mow) an d high (transp ort) speeds, consider a faulty component that af fects the en- tire traction circuit (e.
Groundsmaster 4500- - D/4700 - - D Hydraulic System Page 4 - - 39 Mow Circuit Problems Problem Possible Cause None of the cutting decks w ill oper- ate.
Groundsmaster 4500- - D/4700 - - D Hydraulic System Page 4 - - 40 Mow Circuit Problems (Continued) Problem Possible Cause All cutting decks opera te slowly . Engine RP M is low . Deck motor is damaged. First and second gear pump sections are worn or damaged.
Groundsmaster 4500- - D/4700 - - D Hydraulic System Page 4 - - 41 Lift/Lower Circuit Problems Problem Possible Cause Cutting decks will not raise. NOTE: Operator m ust be in seat in order to raise t he cutting decks. Operator seat is unoccupied. Hydraulic oil level in reservoir is low .
Groundsmaster 4500- - D/4700 - - D Hydraulic System Page 4 - - 42 Engine Cooling Fan Cir cuit Problems Problem Possible Cause Cooling fan runs on ly in forward di- r e c t i o n( f a nd o e sn o tr u ni nr e v e r s e direction). Fan control manifold so lenoid cartridge valve (S 1) is faulty .
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Groundsmaster 4500- - D/4700 - - D Hydraulic System Page 4 - - 44 Te s t i n g The most effective method for isol ating problems in the hydraulic system is by using hydraulic test equipment such as pressure gauges and flo w m eters in the ci rcuits during vari ous operatio nal checks (S ee the Special T ools section in this chapter).
Groundsmaster 4500- - D/4700 - - D Hydraulic System Page 4 - - 45 Which Hydraulic T ests Are Necessary? Before begin ning any hydra ulic test, i dentify if t he prob - lem is related to the traction circui t , cutting (mow) circuit, lift/lower circuit, steering circuit o r engine cooling fan cir- cuit.
Groundsmaster 4500- - D/4700 - - D Hydraulic System Page 4 - - 46 T raction Circuit Charge Pre ssure (Using Pressure Gauge) PRESSURE GAUGE 1050 1600 PSI 6.
Groundsmaster 4500- - D/4700 - - D Hydraulic System Page 4 - - 47 NOTE: T h et r a c t i o nc h a r g ec i r c u i ti sd e s i g n e dt or e - place loss of hydraulic fluid fro m the closed loop traction circuit. Procedure for T raction Circuit Charge Pr essure Te s t CAUTION Prevent personal injury and/or damage to equip- ment.
Groundsmaster 4500- - D/4700 - - D Hydraulic System Page 4 - - 48 T raction Circuit Relief Pr essure (Using Pressure Gauge) FORW ARD DIRECTION TEST SHOWN PRESSURE GAUGE 1050 1600 PSI 6.
Groundsmaster 4500- - D/4700 - - D Hydraulic System Page 4 - - 49 Procedure for T raction Circuit Relief Pressure Te s t CAUTION Prevent personal injury and/or damage to equip- ment. Read all W ARNINGS, CAUTIONS and Pre - cautions for Hydraulic T esting at the beginning of this section.
Groundsmaster 4500- - D/4700 - - D Hydraulic System Page 4 - - 50 Reverse T raction Circuit Reducing V alve (PR) Pressure (Using Pressu re Gauge) 1050 1600 PSI 6.
Groundsmaster 4500- - D/4700 - - D Hydraulic System Page 4 - - 51 Procedure for Revers e T raction Circuit Reducing Va l v e ( P R ) P r e s s u r e Te s t NOTE: When in reverse, pressure reducing valve (P R) limits the pressure to the rear axle motor to 450 PSI (31 bar) so the rear wheels will no t scuff the t urf.
Groundsmaster 4500- - D/4700 - - D Hydraulic System Page 4 - - 52 Rear T raction Circuit Re lief (R V) Pressure (Us ing Pressure Gauge) PRESSURE GAUGE 1050 1600 PSI 6.
Groundsmaster 4500- - D/4700 - - D Hydraulic System Page 4 - - 53 Procedure for Rear T raction Circuit Relief V alve (R V) Pressure Te s t NOTE: Adjustable relief valve (RV) in the rear traction control manifo ld reduces rear axle motor pressure created in down hill, dynamic braking conditions to pre- vent rear wheel lock up.
Groundsmaster 4500- - D/4700 - - D Hydraulic System Page 4 - - 54 Piston (T raction) Pump Flow (Using T ester with Pressur e Gauge & Flow Mete r) TESTER 4350 PSI 250 PSI 5 000 PSI EU - - 2600 / 1200 RPM 0.
Groundsmaster 4500- - D/4700 - - D Hydraulic System Page 4 - - 55 Procedure for Piston (T raction) Pump Flow Te s t This test me asures pisto n (tractio n) pump ou tput (flow) . During this tes t, pump load is creat ed at the flow meter using the adjustable loa d v alve on the tester .
Groundsmaster 4500- - D/4700 - - D Hydraulic System Page 4 - - 56 Cutting Deck Circuit Pressure (Using Pressu re Gauge) DECKS 1 AND 4 SHOWN TEST FO R GM4500 - - D PRESSURE GAUGE 6.2 GPM 11 . 4 G P M 3500 PSI 3500 PSI 1500 PSI 1500 PSI P1 P2 T1 G1 PRV1 PRV2 LC1 LC2 M1 M2 M3 M4 RV0 9 T2 FRONT LEFT FRONT RIGHT REAR LEFT RV8 4350 PSI 30.
Groundsmaster 4500- - D/4700 - - D Hydraulic System Page 4 - - 57 Procedure for Cutting Deck Circuit Pressure Te s t CAUTION Prevent personal injury and/or damage to equip- ment. Read all W ARNINGS, CAUTIONS and Pre - cautions for Hydraulic T esting at the beginning of this section.
Groundsmaster 4500- - D/4700 - - D Hydraulic System Page 4 - - 58 Cutting Deck Circuit Relief Pre ssure (Using T ester with Pressure Ga uge & Flow Meter) SECOND PUMP SECTION SHOWN TEST F OR GM4500 - - D TESTER 6.
Groundsmaster 4500- - D/4700 - - D Hydraulic System Page 4 - - 59 Procedure for Cutting Deck Cir cuit Relief Pressure Te s t CAUTION Prevent personal injury and/or damage to equip- ment. Read all W ARNINGS, CAUTIONS and Pre - cautions for Hydraulic T esting at the beginning of this section.
Groundsmaster 4500- - D/4700 - - D Hydraulic System Page 4 - - 60 Deck Motor Case Drain Leakage (Usin g T es ter with Pressure Gauge & Flow Meter) MEASURING CONT AINER DECK MOTOR #1 SHOWN TEST FOR.
Groundsmaster 4500- - D/4700 - - D Hydraulic System Page 4 - - 61 Procedure for Deck Motor Case Dr ain Leakage Te s t NOTE: Over a period of time, a de ck motor can wear in- ternally . A worn motor may bypass oil to its case drain causing the motor to be less efficien t.
Groundsmaster 4500- - D/4700 - - D Hydraulic System Page 4 - - 62 Steering Cir cuit Relief Pressure (Us ing Pressure Gauge) (STEERING WHEEL TURNED TEST FOR GM4500 - - D SHOWN FOR RIGHT TURN) CAP STEEL PRESSURE GAUGE 1050 1600 PSI 6.
Groundsmaster 4500- - D/4700 - - D Hydraulic System Page 4 - - 63 Procedure for Steering Circuit Relief Pressure Te s t The steering circuit relief pressure test shou ld be per- formed to make sure that the ste ering circuit relief pres- sure is correct.
Groundsmaster 4500- - D/4700 - - D Hydraulic System Page 4 - - 64 Steeri ng Cylinder Inter nal Leakage 1050 PE T R STEERING CYLINDER 6.1 CIR L CONTROL VA LV E STEERING PSI FROM COMBINA TION MANIFOLD T.
Groundsmaster 4500- - D/4700 - - D Hydraulic System Page 4 - - 65 The steering cy linder intern al leakage test should be performed if a steering problem is identified.
Groundsmaster 4500- - D/4700 - - D Hydraulic System Page 4 - - 66 Lift/Lower Circuit Relief Press ure (Using P ressure Gauge) GM 4500 - - D SHOWN PRESSURE GAUGE 1050 1600 PSI 6.
Groundsmaster 4500- - D/4700 - - D Hydraulic System Page 4 - - 67 Procedure for Lift/Lower Circuit Relief Pressure Te s t The lift/lower circuit relief pressure test should be per- formed to make sure that the cutting unit lift and lower circuit relief pressure is correct.
Groundsmaster 4500- - D/4700 - - D Hydraulic System Page 4 - - 68 Engine Cool ing Fan Circuit (Using Pr essure Gauge and Phototac) GM 4500 - - D SHOWN PRESSURE GAUGE 1050 1600 PSI 6.
Groundsmaster 4500- - D/4700 - - D Hydraulic System Page 4 - - 69 Procedure for Engine Cooling Fan Circuit T est The engine cooling fan circui t test should be performed to make sure that the engine cooling fan circuit has the correct system pressure and fan speed.
Groundsmaster 4500- - D/4700 - - D Hydraulic System Page 4 - - 70 Gear Pump Flow (Using T ester with Pressure Gauge & Flow Meter) SECOND GEAR PUMP SECTION TESTER 4350 PSI 250 PSI 5000 PSI EU - - 2600 / 1200 RPM 0.56 CID 0.56 CID 1.03 CID 1.03 CID 2.
Groundsmaster 4500- - D/4700 - - D Hydraulic System Page 4 - - 71 Procedure for Gear Pump Flow Te s t CAUTION Prevent personal injury and/or damage to equip- ment. Read all W ARNINGS, CAUTIONS and Pre - cautions for Hydraulic T esting at the beginning of this section.
Groundsmaster 4500- - D/4700 - - D Hydraulic System Page 4 - - 72 Adjustments Adjust Control Ma nifold Relie f V alves Several of the hydraulic control manifolds on your Groundsmaster include a djustable relief valves. The fol- lowing procedure can be used to adjust th ese r elief valves.
Groundsmaster 4500- - D/4700 - - D Hydraulic System Page 4 - - 73 Service and Repairs General Precautions for R emoving and In stalling Hydraulic System Components Before Repair or Re placement of Components 1.
Groundsmaster 4500- - D/4700 - - D Hydraulic System Page 4 - - 74 Check Hydraulic Li nes and Hoses W ARNING Keep body and hands away from pin hole leaks or nozzles that eject hydraulic fluid under high pressure. Use pape r or cardboard, not hands, to search fo r leaks.
Groundsmaster 4500- - D/4700 - - D Hydraulic System Page 4 - - 75 Flush Hydraulic Sy stem IMPORT ANT : Flush the hydraulic system any time there is a severe com p onent failure or the system is contaminated (oil appear s milky , black or contains metal particles).
Groundsmaster 4500- - D/4700 - - D Hydraulic System Page 4 - - 76 Filtering Closed - - Loop T raction Circuit Filtering of a closed - - loop hydraulic system after a major component failure ( e.g. traction (piston) pump, front wheel motor o r rear axle mot or) is a req uiremen t to pre- vent debris from transmitting throughout the syst em.
Groundsmaster 4500- - D/4700 - - D Hydraulic System Page 4 - - 77 Charge Hydraul ic System NOTE: When initially starting the hydraulic syst em with new or rebuilt compon ents such as pumps, motors or lift cylinders, it is important that the hydraulic system be charged properly .
Groundsmaster 4500- - D/4700 - - D Hydraulic System Page 4 - - 78 Gear Pump 1. Piston pump assembly 2. Flat washer (4 used) 3. Gear pump assembly 4. 90 o hydraulic fitting (2 used) 5. 90 o hydraulic fitting (2 used) 6. 90 o hydraulic fitting 7. O - - ring 8.
Groundsmaster 4500- - D/4700 - - D Hydraulic System Page 4 - - 79 Removal (Fig. 63) 1. Park machine on a level s urface, lower cu tting decks, stop engine, engage parking brake and remove key from the ignition switch . 2. Gain access to gear p ump from below the machine.
Groundsmaster 4500- - D/4700 - - D Hydraulic System Page 4 - - 80 5. Remove caps and pl ugs from hydraulic lines and fit- tings. Install hydraulic lines to gear pump (see Hydraulic Hose and Tube Installation in the General Information section of this chapter).
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Groundsmaster 4500- - D/4700 - - D Hydraulic System Page 4 - - 82 Gear Pump Se rvice 1. Dust seal 2. Retaining ring 3. Flange washer 4. Shaft seal 5. Front cover 6. Dowel pin (16 used) 7. Pressure seal 8. Back - - up gasket 9. Thrus t plate (8 use d) 10.
Groundsmaster 4500- - D/4700 - - D Hydraulic System Page 4 - - 83 IMPORT ANT : Use caution when clamping gear pump in a vise to avoid distorting any pump compo- nents . 3 . S e c u r et h e f r o n tc o v e ro ft h ep u m pi nav i s ew i t ht h e drive shaft pointing down.
Groundsmaster 4500- - D/4700 - - D Hydraulic System Page 4 - - 84 Piston (T raction) Pump Figure 68 FRONT RIGHT 1. Piston pump assembly 2. Flat washer (4 used) 3. Gear pump assembly 4. 90 o hydraulic fitting (2 used) 5. 90 o hydraulic fitting (2 used) 6.
Groundsmaster 4500- - D/4700 - - D Hydraulic System Page 4 - - 85 5. For assembly purposes, l abel all hydraulic lines con- n e c t e dt og e a rp u m pa n dt r a c t i o np u m pf i t t i n g s . 6. Put a drain pan be low the pump assembly . Remove hydraulic hoses connected to piston and gear pumps.
Groundsmaster 4500- - D/4700 - - D Hydraulic System Page 4 - - 86 IMPORT ANT : A case drain exists in the piston (trac- tion) pump and a suction port is near the input shaft of the gear pump (Fig. 70). Before the gear pump is installed to the piston pump, make sure tha t plugs placed in both of t hese ports are remove d.
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Groundsmaster 4500- - D/4700 - - D Hydraulic System Page 4 - - 88 Piston (T raction) Pump Service Figure 72 2 3 6 8 9 10 11 13 1 5 7 12 14 15 16 17 18 19 20 4 21 22 23 24 25 26 27 28 29 30 31 32 33 34.
Groundsmaster 4500- - D/4700 - - D Hydraulic System Page 4 - - 89 1. Scre en (2 used ) 2. Plug with O - - ring (2 used) 3. Plug with O - - ring (2 used) 4. Cylinder block assembly 5. V a lve plat e 6. Serv o piston 7. Scre w (4 used ) 8 . O r i f i c e( 2u s e d ) 9.
Groundsmaster 4500- - D/4700 - - D Hydraulic System Page 4 - - 90 Rear T raction Control Manifold 1. Rear traction control manifold 2. Cap screw (2 used) 3. Flange nut (2 used) 4. HI/LOW range control manifo ld 5. Lift circuit junction manifold 6. Hydraulic tube 7.
Groundsmaster 4500- - D/4700 - - D Hydraulic System Page 4 - - 91 Removal (Fig. 73) NOTE: The ports on the rear tra ction control manifold are marked for easy identification of components. Refer to the Hydraulic Schematics in Chapter 9 - - Foldout Drawings to identify the function of the hydraulic lines and cartridge valves at eac h port.
Groundsmaster 4500- - D/4700 - - D Hydraulic System Page 4 - - 92 Rear T raction Co ntrol Manifo ld Service 1. Rear traction manifold body 2. Relief valve (port RV) 3. Pressure reducing valve (port PR) 4. #4 ze ro leak p lug wi th O - - ri ng 5. #6 ze ro leak p lug wi th O - - ri ng 6.
Groundsmaster 4500- - D/4700 - - D Hydraulic System Page 4 - - 93 Control Manifold Cartr idge V alve Service 1. Make sure the contr ol manifold is clean before re- moving the cartridge val ve from the control manifold. 2. If cartr idge valve is solenoid ope rated, remove nut securing solenoid coil to th e cartridge valve.
Groundsmaster 4500- - D/4700 - - D Hydraulic System Page 4 - - 94 HI/LOW Range Control Manifold 1. HI/LOW range control manifo ld 2. Cap screw (2 used) 3. Flange nut (2 used) 4. Rear traction control manifold 5. Lift circuit junction manifold 6. Hydraulic tube 7.
Groundsmaster 4500- - D/4700 - - D Hydraulic System Page 4 - - 95 Removal (Fig. 75) 1. Read the General Pre cautions for Removing an d Installing Hydraulic System Components at the begin- ning of the Service and Repairs section of this chapter .
Groundsmaster 4500- - D/4700 - - D Hydraulic System Page 4 - - 96 Rear Axle Motor 1. Rear axle motor 2. O - - ring 3. Pinion gear 4. External snap ring (2 used) 5. O - - ring 6. Hydraulic fitting 7. O - - ring 8. 90 o hydraulic fitting 9. Cap s crew (2 used ) 10.
Groundsmaster 4500- - D/4700 - - D Hydraulic System Page 4 - - 97 Removal (Fig. 78) 1. Park machine on a level s urface, lower cu tting decks, stop engine, engage parking brake and remove key from the ignition switch .
Groundsmaster 4500- - D/4700 - - D Hydraulic System Page 4 - - 98 Front Wheel Motors 1. Flange head screw (6 per planetary) 2. Splined brake shaft 3. Planetary assembly 4. Wheel assembly 5. Lug nut (8 per wheel) 6. Retaining ring 7. Spring plate 8. Compression spring 9.
Groundsmaster 4500- - D/4700 - - D Hydraulic System Page 4 - - 99 7. Remove and discard O - - ring (item 16) from flange of wheel motor . 8. If hydrauli c fittings are to be removed from wheel mo- tor , mark fitting orientation to allow correct assembly (Figs.
Groundsmaster 4500- - D/4700 - - D Hydraulic Syst em Page 4 - - 100 Rear Axle and Front Wheel Motor Service Figure 82 2 3 6 8 9 10 11 13 1 5 7 12 14 15 16 17 18 19 20 4 21 22 23 21 25 1. Plu g with O - - ring 2. Minimum angle stop 3. Bias spring 4. Serv o piston 5.
Groundsmaster 4500- - D/4700 - - D Hydraulic System Page 4 - - 1 01 NOTE: The fr ont whee l motors a re ident ical (shown in Figure 82). The rear axle motor inclu des a flushing valve for cooling of the closed loop traction ci rcuit and there- fore has some dif ferences from the front motors (Fig.
Groundsmaster 4500- - D/4700 - - D Hydraulic Syst em Page 4 - - 102 Cutting Deck Motor The hydraulic motors used on all cutting decks are the same. Removal 1. Park machine on a level surface, lower cutting decks, stop engine, engage parking brake and remove key from the ignition switch.
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Groundsmaster 4500- - D/4700 - - D Hydraulic Syst em Page 4 - - 104 Cutting Deck Motor Service 1. Dust seal (2 used) 2. Retaining ring 3. Flange washer 4. Shaft seal 5. Front flange 6. Pressure seal 7. Backup gasket 8. Front wear plate 9. Drive gear 10.
Groundsmaster 4500- - D/4700 - - D Hydraulic System Page 4 - - 1 05 5. Remove motor from the vise. T urn motor so that the shaft end is facing down. Rem ove cap screws. 6. Separate rear cove r from body . Lift rear co ver from motor . 7. Carefully remove bo dy .
Groundsmaster 4500- - D/4700 - - D Hydraulic Syst em Page 4 - - 106 Assembly (Fig. 86) NOTE: When assembling t he motor , check the ma rker line on each part to make sure the parts are properly aligned during assembly . 1. Lubricate O- - rings, pressure seals, ba ck - - up gaskets and wear plat e grooves with a thin coat of p etroleum jel- ly .
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Groundsmaster 4500- - D/4700 - - D Hydraulic Syst em Page 4 - - 108 Deck Control Manifold 1. Deck control manifold 2. Filter mount bracket 3. Flange head screw (2 used) 4. Hydraulic oil filter assembly 5. V alve mount bracket 6. Flange head screw (2 used) 7.
Groundsmaster 4500- - D/4700 - - D Hydraulic System Page 4 - - 1 09 Removal (Fig. 90) NOTE: The ports on the deck control manifold are marked for easy identification of components.
Groundsmaster 4500- - D/4700 - - D Hydraulic System Page 4 - - 1 10 Deck Control Man ifold Service (GM 4500 - - D) 1. Manifold body 2. Proportional relief (PRV1 & PRV2) 3. Solenoid coil 4. Relief valve (RV8 & RV9) 5. Logic valve (LC1 & LC2) 6.
Groundsmaster 4500- - D/4700 - - D Hydraulic System Page 4 - - 1 1 1 NOTE: The deck control manifol d uses several zer o leak plugs. These plugs have a tapered sealing sur face on the plug head that is designed to resist vibrati on in- duced plug loo sening.
Groundsmaster 4500- - D/4700 - - D Hydraulic System Page 4 - - 1 12 Deck Control Man ifold Service (GM 4700 - - D) 1. Manifold body 2. Nut (4 used) 3. Zero leak plug (#6) 4. Zero leak plug (#8) 5. Zero leak plug (#4) 6. Propor tional r elief ( PRV2 & PRV2) 7.
Groundsmaster 4500- - D/4700 - - D Hydraulic System Page 4 - - 1 13 For solenoid and control valve service procedures, se e Control Manifold Cartridge V alve Service in this section. Refer to Figures 95 and 96 for cartridge valve and plug installation torque.
Groundsmaster 4500- - D/4700 - - D Hydraulic System Page 4 - - 1 14 Steering Contro l V alve 1. Steering wheel cover 2. Lock nut 3. Steering wheel 4. Flat washer 5. Socket head screw (4 used) 6. Flange head screw (4 used) 7. Steering column 8. Steering control valve 9.
Groundsmaster 4500- - D/4700 - - D Hydraulic System Page 4 - - 1 15 CAUTION Before open ing hydraul ic system, operat e all hy - draulic controls to relieve sy stem pressure and avoid injury from pressurized hydraulic oil. See Relieving Hydraulic System Pressure in the Gen- eral Information se ction of this chapter .
Groundsmaster 4500- - D/4700 - - D Hydraulic System Page 4 - - 1 16 Steering Contro l V alve Service 1. Relief valve assembly 2. Dust seal ring 3. Steering valve housing 4. Shaft seal 5. Thrust washer 6. Bearing race 7. Ring 8. Spring set 9. Cro ss pin 10.
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Groundsmaster 4500- - D/4700 - - D Hydraulic System Page 4 - - 1 18 Steer ing Cylinde r 1. Steering cylinder 2. Ball joint 3. Ball joint 4. Retaining ring 5. Grease fitting 6. Grease fitting 7. 90 o hydraulic fitting 8. O - - ring 9. O - - ring 10. Drive axle assembly 1 1.
Groundsmaster 4500- - D/4700 - - D Hydraulic System Page 4 - - 1 19 Removal (Fig. 101) 1. Park machine on a level s urface, lower cu tting decks, stop engine, engage parking brake and remove key from the ignition switch .
Groundsmaster 4500- - D/4700 - - D Hydraulic Syst em Page 4 - - 120 Steering Cylinder Service 1. T ube assembly 2. Lock nut 3. Seal 4. O - - r ing 5. O - - r ing 6. Pisto n 7. O - - ring 8. Back - - up seal 9. Seal 10. Head 11 . W i p e r 12. Retaining ring 13.
Groundsmaster 4500- - D/4700 - - D Hydraulic System Page 4 - - 1 21 Disassembly (Fig. 102) 1. Remove oil from steering cylinder into a drain pan by slowly pumping the cylin der shaft. Plug both ports and clean the outside of the cyl inder . IMPORT ANT : Prevent damage when clamping the cylinder in a vise; clamp on the clevis only .
Groundsmaster 4500- - D/4700 - - D Hydraulic Syst em Page 4 - - 122 Engine Cooling Fan Motor 1. Cap screw (4 used) 2. Fan 3. Flange head screw (4 used) 4. Flange nut (4 used) 5. Fan motor and bracket assembly 6. Flange head screw (8 used) 7. Flat washer (8 used) 8.
Groundsmaster 4500- - D/4700 - - D Hydraulic System Page 4 - - 1 23 Removal (Fig. 103) 1. Park machine on a level s urface, lower cu tting decks, stop engine, apply parking brake and remove key from the ignition switch .
Groundsmaster 4500- - D/4700 - - D Hydraulic Syst em Page 4 - - 124 Installation (Fig. 103) 1. If fittings were removed fro m fan motor , lubricate an d place new O- - rings onto fittin gs. Install fittings into port openings. T ighten fittings (see Hydraul ic Fitting Installa- tion in the General Information sectio n of t his chapter).
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Groundsmaster 4500- - D/4700 - - D Hydraulic Syst em Page 4 - - 126 Engine Cooling Fan Motor S ervice 1. Flange washer 2. O - - ring 3. Front flange 4. Dust seal 5. Retaining ring 6. Front wear plate 7. Shaf t seal 8. Backup gasket 9. Pressure seal 10.
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Groundsmaster 4500- - D/4700 - - D Hydraulic Syst em Page 4 - - 128 Fan Control Manifold 1. Fan control manifold 2. Support bracket 3. Flange head screw (2 used) 4. Battery support 5. Air cleaner mount 6. Deck manifold (GM 4500 - - D shown) 7. Hydraulic hose 8.
Groundsmaster 4500- - D/4700 - - D Hydraulic System Page 4 - - 1 29 Removal (Fig. 107) NOTE: The ports on the fan cont rol manifold are marked for easy identification of components.
Groundsmaster 4500- - D/4700 - - D Hydraulic Syst em Page 4 - - 130 Fan Control M anifold Service 1. Manifold body 2. Zero leak plug (#6) (3 used) 3. Zero leak plug (#4) (2 used) 4. Check valve (port CV) 5. Flow divider cartridge (port FD) 6. Solenoid coil (2 used) 7.
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Groundsmaster 4500- - D/4700 - - D Hydraulic Syst em Page 4 - - 132 Lift Control Manifold 1. Deck control manifold 2. Filter mount bracket 3. Flange head screw (2 used) 4. Hydraulic oil filter assembly 5. V alve mount bracket 6. Flange head screw (2 used) 7.
Groundsmaster 4500- - D/4700 - - D Hydraulic System Page 4 - - 1 33 Removal (Fig. 1 10) 1. Park machine on a level s urface, lower cu tting decks, stop engine, apply parking brake and remove key from the ignition switch .
Groundsmaster 4500- - D/4700 - - D Hydraulic Syst em Page 4 - - 134 Lift Control Manifold Service (GM 4500 - - D) 1. Manifold body 2. Proportional relief valve (port TS) 3. Solenoid valve (port S6) 4. Solenoid coil (2 used) 5. Check valve (port CV) 6.
Groundsmaster 4500- - D/4700 - - D Hydraulic System Page 4 - - 1 35 NOTE: The lift control manifold includes sev eral zero leak plugs. These plugs have a tapered sealing sur face on the plug head that is designed to resist vibrati on in- duced plug loo sening.
Groundsmaster 4500- - D/4700 - - D Hydraulic Syst em Page 4 - - 136 Lift Control Manifold Service (GM 4700 - - D) 1. Manifold body 2. Nut 3. Zero leak plug (#4) 4. Relief valve (port R1) 5. Proportional relief valve (port TS) 6. Solenoid valve (ports S2, S3, S7, S8) 7.
Groundsmaster 4500- - D/4700 - - D Hydraulic System Page 4 - - 1 37 NOTE: The lift control manifold uses several zero l eak plugs. These plugs have a tapered sealing surface on t h ep l u gh e a dt h a ti sd e s i g n e dt or e s i s tv i b r a t i o ni n d u c e d plug loosening.
Groundsmaster 4500- - D/4700 - - D Hydraulic Syst em Page 4 - - 138 Lift Circuit Junction Manifold 1. Lift circuit junction manifold 2. Flange head screw (2 used) 3.
Groundsmaster 4500- - D/4700 - - D Hydraulic System Page 4 - - 1 39 Removal (Fig. 1 16) 1. Park machine on a level s urface, lower cu tting decks, stop engine, engage parking brake and remove key from the ignition switch .
Groundsmaster 4500- - D/4700 - - D Hydraulic Syst em Page 4 - - 140 Lift Cylinders: Decks #1, #4 and #5 1. Lift arm (deck #4) 2. Flange nut 3. Lift arm (deck #1) 4. Cylinder pin (3 used) 5. Flange head screw 6. O - - ring 7. 90 o hydraulic fitting (2 per cylinder) 8.
Groundsmaster 4500- - D/4700 - - D Hydraulic System Page 4 - - 1 41 Removal (Fig. 1 19) 1. Park machine on a level s urface, lower cu tting decks, stop engine, engage parking brake and remove key from the ignition switch .
Groundsmaster 4500- - D/4700 - - D Hydraulic Syst em Page 4 - - 142 Lift Cylinders: Decks #2 and #3 1. Flange head screw 2. Flange nut 3. Cylinder pin 4. Lift cylinder 5. Retaining ring 6. Cylinde r pin 7. Lift arm (deck #2) 8. Lift arm (deck #3) 9. O - - ring 10.
Groundsmaster 4500- - D/4700 - - D Hydraulic System Page 4 - - 1 43 Removal (Fig. 121) 1. Park machine on a level s urface, lower cu tting decks, stop engine, engage parking brake and remove key from the ignition switch .
Groundsmaster 4500- - D/4700 - - D Hydraulic Syst em Page 4 - - 144 Lift Cylinders: Decks #6 and #7 (GM 4700 - - D) 1. Lift cylinder 2. Lock nut (2 used per side) 3. Rear link 4. Link assembly 5. Plastic roller 6. Retaining ring 7. Cylinde r pin 8. 90 o hydraulic fitting 9.
Groundsmaster 4500- - D/4700 - - D Hydraulic System Page 4 - - 1 45 Removal (Fig. 123) 1. Park machine on a level s urface, lower cu tting decks, stop engine, engage parking brake and remove key from the ignition switch .
Groundsmaster 4500- - D/4700 - - D Hydraulic Syst em Page 4 - - 146 Lift Cylinder Service 1. T ube assembly 2. Lock nut 3. Wear ring 4. Seal 5. Piston 6. O - - ring 7. O - - ring 8. Back - - up ring 9. Seal 10. Retaining ring 11 . H e a d 12. Wiper 13.
Groundsmaster 4500- - D/4700 - - D Hydraulic System Page 4 - - 1 47 Disassembly (Fig. 125) 1. Remove oil fro m lift cylinder i nto a drain pan by slowly pumping th e cylinder s haft. Plug both ports and clean the outside of the cy linder . IMPORT ANT : Prevent damage when clamping the cylinder in a vise; clamp on the clevis only .
Groundsmaster 4500- - D/4700 - - D Hydraulic Syst em Page 4 - - 148 Hydraulic Reservoir 1. Plug 2. O - - ring 3. Dipstick 4. Breather 5. Screen filter 6. Hydraulic reservoir 7. Reservoir strainer 8. O - - ring 9. O - - ring 10. Straight hydraulic fitting 11 .
Groundsmaster 4500- - D/4700 - - D Hydraulic System Page 4 - - 1 49 Removal (Fig. 126) 1. Park machine on a level s urface, lower cu tting decks, stop engine, engage parking brake and remove key from the ignition switch .
Groundsmaster 4500- - D/4700 - - D Hydraulic Syst em Page 4 - - 150 Radiator and Oil Cooler Assem bly 1. Radiator/oil cooler assembly 2. Cap screw (4 used) 3. W asher (4 used) 4. Fan 5. Plenum assembly 6. Cap screw (6 used) 7. Flange nut (6 used) 8. Air intake hose 9.
Groundsmaster 4500- - D/4700 - - D Hydraulic System Page 4 - - 1 51 NOTE: The hydra ulic oil cooler on y our Groundsm aster is combined with the radiator . See Radiator and Oil Cooler Assembly in the Service and Repairs section of Chapter 3 - - Diesel Engine for inform ation on removal and installation of th e radiator/oil cooler assembly .
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Groundsmaster 4500- - D/4700 - - D Page 5 - - 1 Elec trical Sys tem Chapter 5 Electrical System T able o f Contents GENERAL INFORMA TION 2 ..................... Operator ’s Manu al 2 .......................... Electrical Drawings 2 .................
Groundsmaster 4500- - D/4700 - - D Page 5 - - 2 Electrical Syste m General Information Operator ’ s Manual The Operator’s Manual provi des information reg arding the operation, general maintenance and maintenance intervals for your Ground smaster machine.
Groundsmaster 4500- - D/4700 - - D Page 5 - - 3 Elec trical Sys tem Y anmar Engine Electr onic Control Unit (ECU) The Y anmar engine that powers the Groundsmaster 4500 - - D and 4700 - - D uses an electronic control u nit (ECU) for engine management and a lso t o communi- cate with the TEC controller s and the InfoCenter Display on the machi ne.
Groundsmaster 4500- - D/4700 - - D Page 5 - - 4 Electrical Syste m Y anmar Engine Electrical Components When servicing or troublesh ooting the engine electrical components, use the c orrect engine service manu a l and troubleshoo ting manual.
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Groundsmaster 4500- - D/4700 - - D Page 5 - - 6 Electrical Syste m Special T ools Order special tools fro m your T oro distribut or . Some tools may also be available from a local supplier . Multimet er The multimeter can test ele ctrical components and cir- cuits for current ( amps), resistance (ohms) or voltage.
Groundsmaster 4500- - D/4700 - - D Page 5 - - 7 Elec trical Sys tem Battery Hydrometer Use the batter y hydrome ter when meas uring specific gravity of battery electrolyte.
Groundsmaster 4500- - D/4700 - - D Page 5 - - 8 Electrical Syste m InfoCenter Display The InfoCenter Display us ed on your Groundsmaster is a LCD device that is located on the consol e.
Groundsmaster 4500- - D/4700 - - D Page 5 - - 9 Elec trical Sys tem Main Information Scr eens The two (2) InfoCenter main information scre ens (Figs. 10 and 1 1) are displayed after the initial splash screens have been displayed for several seconds.
Groundsmaster 4500- - D/4700 - - D Page 5 - - 1 0 Electrical Syste m Main Menu Screen The main menu screen can be accessed from the Info- Center main informatio n or splash screen by pressing and releasing th e menu/back button (left button) on the display .
Groundsmaster 4500- - D/4700 - - D Page 5 - - 1 1 Electri cal System Service Screen The service scree n (Fig. 14 ) contains m achine oper a- tional information including hou rs and counts. V alues listed for these service menu items cannot be change d.
Groundsmaster 4500- - D/4700 - - D Page 5 - - 1 2 Electrical Syste m Diagnos tics Scr een The diagnostics scr een (Fig. 15) list s the various st ates of machine electrical c omponents. The diagnostics screen should be used to check operation of machi ne controls and to ver ify that switches and cir cuit wir ing are functioning correctly .
Groundsmaster 4500- - D/4700 - - D Page 5 - - 13 E lectrical System Settings Screen The settings screen iden tifies the InfoCenter la nguage and decks (English or Metric). The settings screen also allows the operator to customize the backlight (bright- ness) and contrast settings f or the InfoCenter displa y .
Groundsmaster 4500- - D/4700 - - D Page 5 - - 1 4 Electrical Syste m About Screen The about scree n (Fig. 18) ide ntifies the ma chine model number , serial number and software revision s for the TEC controllers, InfoCenter and engine electroni c con- trol unit (if available).
Groundsmaster 4500- - D/4700 - - D Page 5 - - 15 E lectrical System T roubleshooting CAUTION Remove all jewelry , especially rings and watches, before doing any elec t rical trouble- shooting or testing. Disconnect the battery cables unless the tes t requires battery voltage.
Groundsmaster 4500- - D/4700 - - D Page 5 - - 1 6 Electrical Syste m Fault Codes The list below identifies the fault codes that are gener- ated by the TEC controller to identify an electrical sys- tem malfunction (fault) that occurred durin g machine operation.
Groundsmaster 4500- - D/4700 - - D Page 5 - - 17 E lectrical System Fault Code Fault Description 33 Forward piston (traction) pump o utput has open or short to grou nd 34 Reverse piston (traction) pum.
Groundsmaster 4500- - D/4700 - - D Page 5 - - 1 8 Electrical Syste m Starting Probl ems NOTE: Check InfoCenter Display for possi ble operator advisories or faults whenever diag nosing machine elec- trical pr oblems. Problem Possible Causes No electrical power to machine (including gauges).
Groundsmaster 4500- - D/4700 - - D Page 5 - - 19 E lectrical System Starting Problems (c ontinued) Problem Possible Causes Engine cranks, bu t does not start. Fuel tank is empty . Engine is not c ranking fast enoug h. Fuel pump or circuit wir ing is faulty .
Groundsmaster 4500- - D/4700 - - D Page 5 - - 2 0 Electrical Syste m Cutting Deck Operatin g Problems NOTE: Check InfoCenter Display for possi ble operator advisories or faults whenever diag nosing machine elec- trical pr oblems. Problem Possible Causes Cutting decks run, but sho uld not, when raised.
Groundsmaster 4500- - D/4700 - - D Page 5 - - 21 E lectrical System Cutting Deck Lift/Lower Problems NOTE: Check InfoCenter Display for possible operator advisories or faults whenever diagnosing machine elec- trical p roblems .
Groundsmaster 4500- - D/4700 - - D Page 5 - - 2 2 Electrical Syste m Cutting Deck Lift/Lower Problems (Continued) Problem Possible Causes On Groundsmaster 4700- - D, center cutting decks will not raise or lower , but bo th wing cutting decks w ill raise and lower .
Groundsmaster 4500- - D/4700 - - D Page 5 - - 23 E lectrical System Electrical System Quick Checks Battery T est (Open Circuit T est) Use a multimeter to measure the voltage between th e battery terminals. Set multimeter to t he DC volts settin g. The batter y should be at a tempera ture of 60 o to 100 o F( 1 6 o to 38 o C).
Groundsmaster 4500- - D/4700 - - D Page 5 - - 2 4 Electrical Syste m Adjustments T raction Pedal Adjustment The traction pedal includes a neutra l assembly that is used to adjust the traction neutral position (Fig.
Groundsmaster 4500- - D/4700 - - D Page 5 - - 25 E lectrical System 6. After any adju stment of the spring shaft and rod en d bearing, use the InfoCenter Displa y Diagnostics menu to obtain and se lect the Traction Pedal menu item (see InfoCenter Display in this ch apter).
Groundsmaster 4500- - D/4700 - - D Page 5 - - 2 6 Electrical Syste m T raction Pedal Position Sensor Calibration IMPORT ANT : A properly installed and calibrated traction pedal position sensor i s critical to accurate traction system respons e and for reliable sensor life.
Groundsmaster 4500- - D/4700 - - D Page 5 - - 27 E lectrical System Component T esting For accurate resistance and/or continuity checks, elec- trically disconnect the c omponent being tested from the circuit (e.g. unplug the ig nition switch connector before checking continuity of the switch t erminals).
Groundsmaster 4500- - D/4700 - - D Page 5 - - 2 8 Electrical Syste m Fuses Groundsmaster 4500 - - D and 4700 - - D use numerous fuses for circuit protection. The fuses reside in the power center behind the operator’s seat. Fuse Identification and Function (Fig.
Groundsmaster 4500- - D/4700 - - D Page 5 - - 29 E lectrical System Fusible Link Harnes s Y our Groundsmaster uses two (2) fusible links for circuit protection . These fusible links ar e located in a har ness that connects the starter B+ terminal to the wire harness (Fig.
Groundsmaster 4500- - D/4700 - - D Page 5 - - 3 0 Electrical Syste m PTO Switch The two position P TO switch is located on the console arm (Fig. 30). The PT O switch is pulled up to engage the PT O and pushed in to d isengage the PTO.
Groundsmaster 4500- - D/4700 - - D Page 5 - - 31 E lectrical System Hi/Low Speed, Engine Speed Request and Cutting Deck Lift Switches The Hi/Low speed, engine spee d request and cutting deck lift switches are all identical. These switches are located on the console arm (Fig.
Groundsmaster 4500- - D/4700 - - D Page 5 - - 3 2 Electrical Syste m Headlight Switch The headlight switch is locate d on the operator side of the console arm (Fig. 34). This two (2) position rocker switch allows the headl ights to be turned on and off.
Groundsmaster 4500- - D/4700 - - D Page 5 - - 33 E lectrical System Seat Switch The seat switch is normally open and closes wh en the operator is on the se at.
Groundsmaster 4500- - D/4700 - - D Page 5 - - 3 4 Electrical Syste m Parking Brake Switch The parking brake switch is a normally open pr oximity switch.
Groundsmaster 4500- - D/4700 - - D Page 5 - - 35 E lectrical System Cutting Deck Position Switches The cutting deck positi on switches are normally o pen proximity switches that are located on the tra ction unit frame (Fig. 39). The sensing pl ate is located on the cut- ting deck lift ar m.
Groundsmaster 4500- - D/4700 - - D Page 5 - - 3 6 Electrical Syste m Relays with Four (4) T erminals Y our Groundsmaster uses a number of el ectrical relays that have four (4) terminals. A tag near the wire harn ess relay connector can be used t o identify each relay .
Groundsmaster 4500- - D/4700 - - D Page 5 - - 37 E lectrical System 6. Connect multimeter (ohms setting ) leads to relay ter- minals 30 and 87. Ground terminal 86 an d apply +12 VDC to terminal 8 5 . The relay shoul d make and break continuity betwe en terminals 30 an d 87 as +12 VDC is applied and remove d from terminal 85.
Groundsmaster 4500- - D/4700 - - D Page 5 - - 3 8 Electrical Syste m Relays with Five (5) T erminals Y our Groundsmaster uses a number of el ectrical relays that have five (5 ) termin als. A tag near the wire ha rness relay connector can be used t o identify each relay .
Groundsmaster 4500- - D/4700 - - D Page 5 - - 39 E lectrical System T raction Pedal Positi on Sensor The traction pedal position sensor is connected to the traction peda l assembly (Fig. 46). This position s ensor determines the neutra l band for the tra ction pedal, the direction of travel des ired by the operator and the trac- tion speed.
Groundsmaster 4500- - D/4700 - - D Page 5 - - 4 0 Electrical Syste m T oro Electronic Controllers (TEC) Groundsmaster 4500 - - D and 4700 - - D machines use a T oro Electronic Contro ller ( TEC - - 5002) to control electri- cal system operation.
Groundsmaster 4500- - D/4700 - - D Page 5 - - 41 E lectrical System The connection termin al functions for the TEC control- lers are shown in F igures 48 (T EC - - 5002) an d 49 (TEC - - 5001). Note that electrical po wer for controller outputs is provided through three (3) connector termin- als (PWR 2, PWR 3 and PWR 4) each protected with a 7.
Groundsmaster 4500- - D/4700 - - D Page 5 - - 4 2 Electrical Syste m Hydraulic Solenoid V alve Coils Figure 51 1. Deck c ontr ol manif old 2. Lift control manifold 3.
Groundsmaster 4500- - D/4700 - - D Page 5 - - 43 E lectrical System Solenoid Coil T esting 1. Park machine on a level s urface, lower cu tting decks, stop engine, engage parking brake and remove key from the ignition switch . 2. Locate hydraulic solenoid valve coil to be tested (Fig.
Groundsmaster 4500- - D/4700 - - D Page 5 - - 4 4 Electrical Syste m Piston (T raction) Pump Contr ol Solenoid Coils The piston (tract ion) pump us es an electronic contr ol as- sembly for swash plate rotation. Electrical outputs from the machine TEC controlle r are provided to two (2) solenoid coils for pump control.
Groundsmaster 4500- - D/4700 - - D Page 5 - - 45 E lectrical System Hydraulic Oil T emperature Sender A temperature sender is used as an input for the TEC controller to identify if the hyd r aulic oil temp erature has reached an excessive level.
Groundsmaster 4500- - D/4700 - - D Page 5 - - 4 6 Electrical Syste m Fuel Pump (Models 30873 and 30874) The fuel pump i s attached to th e air cleaner m ount below the fuel water separator (Fig. 5 7). Operational T est 1. Park machine on a level surface, lower cutting decks, stop engine and apply parking brake.
Groundsmaster 4500- - D/4700 - - D Page 5 - - 47 E lectrical System Fuel Pump (Models 30881 and 30882) The fuel pump is attached to the air clean er mount below the fuel water se parator (Fig. 58). Operatio nal T es t 1. Park machine on a level s urface, lower cu tting decks, stop engine and apply parking brake.
Groundsmaster 4500- - D/4700 - - D Page 5 - - 4 8 Electrical Syste m CAN - - bus T e rmination Resistor System communication between electri cal components on Groundsmaster 4500 - - D and 4700 - - D machines is accomplished on a CAN - - bus communication system.
Groundsmaster 4500- - D/4700 - - D Page 5 - - 49 E lectrical System Diode Assemblies The Groundsmaster engi ne wire harness contains a diode assembly that is u sed for circuit protection fro m voltage spikes whe n the engine starter solenoid is de - - energized.
Groundsmaster 4500- - D/4700 - - D Page 5 - - 5 0 Electrical Syste m Service and Repairs NOTE: For engine compone nt repair informati on (e.g. starter mo tor), re fer to the Y anmar Se rvice M anual that is correct for your G r oundsmaster model. Battery Care 1.
Groundsmaster 4500- - D/4700 - - D Page 5 - - 51 E lectrical System Battery Service The battery is the heart of the electrical system. With regular and proper service, batter y life can be extended. Additionally , battery and electrical component failure c a nb ep r e v e n t e d .
Groundsmaster 4500- - D/4700 - - D Page 5 - - 5 2 Electrical Syste m Battery T esting 1. Conduct a hydr ometer tes t of the battery elect rolyte. IMPORT ANT : Make sure the area around the cells is clean before opening the batter y caps. A. Measure the specific gravity of each cell with a hydrometer .
Groundsmaster 4500- - D/4700 - - D Page 5 - - 53 E lectrical System Battery Charging T o minimize possible damage to the battery and allow the battery to be fully charged, the slow ch arging meth- od is presented here. This charging me thod can be ac- complishe d with a constan t current bat tery charg er which is available in most loca tions.
Groundsmaster 4500- - D/4700 - - D Page 5 - - 5 4 Electrical Syste m This page is intentionally blank..
Groundsmaster 4500- - D/4700 - - D Page 6 - - 1 Ax les, Planetarie s and Brakes Chapter 6 Axles, Planetaries and Brakes T able o f Contents SPECIFICA TIONS 2 ............................ GENERAL INFORMA TION 3 ..................... Operator ’s Manu al 3 .
Groundsmaster 4500- - D/4700 - - D Page 6 - - 2 Axles, Planetaries and Brakes Specifications Item Specification T ire pressure (front and rear) 20 psi (138 kPa) Rear wheel toe - - in 0 .
Groundsmaster 4500- - D/4700 - - D Page 6 - - 3 Ax les, Planetarie s and Brakes General Information Operator ’ s Manual The T raction Unit Operator ’s Manual provides informa- tion regarding th e operation, gen eral maintenan ce and maintenance intervals for your Groundsmaster ma- chine.
Groundsmaster 4500- - D/4700 - - D Page 6 - - 4 Axles, Planetaries and Brakes Adjustments Planetary Wheel Drive End Play A front planetary wheel drive assembly that is properly operating should have no en dplay . Any endplay in a planetary assembly indicates tha t t here are potential problems with the planetary .
Groundsmaster 4500- - D/4700 - - D Page 6 - - 5 Ax les, Planetarie s and Brakes This page is intentionally blank. Axles, Planetaries and Brakes.
Groundsmaster 4500- - D/4700 - - D Page 6 - - 6 Axles, Planetaries and Brakes Service and Repairs Brake Assembly 1. Flange head screw (6 per planetary) 2. Splined brake shaft 3. Planetary assembly (2 used) 4. Front wheel assembly (2 used) 5. Lug nut (8 per wheel) 6.
Groundsmaster 4500- - D/4700 - - D Page 6 - - 7 Ax les, Planetarie s and Brakes Brake Assembly Rem oval (Fig. 1) 1. Park machine on a level surface and raise cut ting decks to allow easier access to front brake assembly . Stop engine, engage parking brake and remove key from the ignition s witch.
Groundsmaster 4500- - D/4700 - - D Page 6 - - 8 Axles, Planetaries and Brakes 4. Install flange he ad screws (item 1 1) to secure brake assembly to frame. Tighte n screws in a crossing pattern to a torque from 75 to 85 ft - - lb (102 to 1 16 N - - m) .
Groundsmaster 4500- - D/4700 - - D Page 6 - - 9 Ax les, Planetarie s and Brakes This page is intentionally blank. Axles, Planetaries and Brakes.
Groundsmaster 4500- - D/4700 - - D Page 6 - - 1 0 Axles, Planetaries and Brakes Brake Inspection and Repair 1. Brake housing (LH shown) 2. Seal 3. Pull ro d 4. Clevis pin (2 used) 5. Link (2 used) 6. Hit ch pin ( 2 used) 7. Stationary disc (4 used) 8.
Groundsmaster 4500- - D/4700 - - D Page 6 - - 1 1 Axles, Planetaries and Brakes This page is intentionally blank. Axles, Planetaries and Brakes.
Groundsmaster 4500- - D/4700 - - D Page 6 - - 1 2 Axles, Planetaries and Brakes Planetary Wheel Drive Assembly Figure 7 FRON T RIGHT 1. Flange head screw (6 per planetary) 2. Splined brake shaft 3. Planetary assembly (2 used) 4. Front wheel assembly (2 used) 5.
Groundsmaster 4500- - D/4700 - - D Page 6 - - 13 Axles, Planetaries a nd Brakes 4. Remove front wheel assembly . 5. Remove hydraulic whe el motor (see Front Wheel Motors in the Service and Repairs section of Chapte r 4 - - Hydraulic System). 6. Remove brak e assembly (see Brake Assembl y in this section).
Groundsmaster 4500- - D/4700 - - D Page 6 - - 1 4 Axles, Planetaries and Brakes Planetary Wheel Drive Service 1. Spindle 2. Boot seal 3. Oil seal 4. Inner bearing cone 5. Inner bearing cup 6. Whee l stud (8 u sed) 7. Socket head screw (16 used) 8. Lock washer (16 used) 9.
Groundsmaster 4500- - D/4700 - - D Page 6 - - 15 Axles, Planetaries a nd Brakes NOTE: The planetary wheel drive assem b ly can be ser- viced with the p lanetary installed to machine. If th e spindle (item 1) needs t o be removed fr om machine, see Planetary Wheel Drive A ssembly in this section.
Groundsmaster 4500- - D/4700 - - D Page 6 - - 1 6 Axles, Planetaries and Brakes F . Lightly oil bearing journals on spindle shaft. Slide housing assembly onto spindle (item 1) taking care to not damage seal or spindle. Make sure that inner bearing in housing fully seats against spin dle shaft shoulder .
Groundsmaster 4500- - D/4700 - - D Page 6 - - 17 Axles, Planetaries a nd Brakes This page is intentionally blank. Axles, Planetaries and Brakes.
Groundsmaster 4500- - D/4700 - - D Page 6 - - 1 8 Axles, Planetaries and Brakes Rear Axle Assembly Figure 13 70 ft - - lb (94 N - - m) m aximum FRON T RIGHT 85 to 100 ft - - lb (1 16 to 135 N - - m) 1. Rear a xle mot or 2. O - - ring 3. Pinion gea r 4.
Groundsmaster 4500- - D/4700 - - D Page 6 - - 19 Axles, Planetaries a nd Brakes Remove Rear Axle (Fig. 13) 1. Park machine on a level s urface, lower cu tting decks, stop engine, engage parking brake and remove key from the ignition switch . 2. Drain oil from rear axle an d rear axle gearbox (Figs.
Groundsmaster 4500- - D/4700 - - D Page 6 - - 2 0 Axles, Planetaries and Brakes 2. If removed, install the tie r od to rear axle (Fig. 1 6). T ighten b all joint castle nuts a nd install new cott er pins. 3. Support axle under machine with a jack. Position axle assembly to rear fra me mount.
Groundsmaster 4500- - D/4700 - - D Page 6 - - 21 Axles, Planetaries a nd Brakes This page is intentionally blank. Axles, Planetaries and Brakes.
Groundsmaster 4500- - D/4700 - - D Page 6 - - 2 2 Axles, Planetaries and Brakes Rear Axle Service Figure 19 3 2 4 5 6 7 8 9 10 14 13 12 11 15 1 10 11 8 9 8 13 16 17 18 19 21 22 23 24 25 26 27 28 29 30.
Groundsmaster 4500- - D/4700 - - D Page 6 - - 23 Axles, Planetaries a nd Brakes 1. LH axle support 2. Flange bushing (2 used) 3. Axle vent 4. Filter 5. V ent extension 6. Cap screw (4 used per gear case) 7. Shi m set 8. Seal washer 9. Plug 10. Lock nut 1 1.
Groundsmaster 4500- - D/4700 - - D Page 6 - - 2 4 Axles, Planetaries and Brakes Bevel Gear Case and Axle Case The following proce dures assume the rear axle assem- bly has been re moved from the machine. Removal 1. Remove the moun ting screws, nuts and lock wash- ers.
Groundsmaster 4500- - D/4700 - - D Page 6 - - 25 Axles, Planetaries a nd Brakes 5. Remove the knuckl e pin mounting screws and th e knuckle pin. Remove the g asket and any remaining gas- ket mater ial from either m ating surface (Fig.
Groundsmaster 4500- - D/4700 - - D Page 6 - - 2 6 Axles, Planetaries and Brakes Installation 1. Coat new shaft seal with grease and install in axle case as shown (Fig. 25). 1. Axle case 2. Bevel gear case 3. Sh aft sea l Figure 25 1 2 3 2. Install the lower beve l gear and bevel gear shaft in the axle case cover .
Groundsmaster 4500- - D/4700 - - D Page 6 - - 27 Axles, Planetaries a nd Brakes 5. Determine necessary qu antity of support shims. A . L u b r i c a t et h ea x l ec a s es u p p o r tb u s h i n gw i t ha thin coat of grease and slide axle case suppo rt onto knuckle pin.
Groundsmaster 4500- - D/4700 - - D Page 6 - - 2 8 Axles, Planetaries and Brakes 9. Remove th e bevel gear c ase/axle case assembly from the axle suppo rt. Coat a new O- ring with grease and temporar ily install the ax le cover assembly . Position a dial indica tor at the tooths center .
Groundsmaster 4500- - D/4700 - - D Page 6 - - 29 Axles, Planetaries a nd Brakes Axle Shafts The following p rocedure s assume t he rear a xle assem- bly has been removed fr om the machine. Removal 1. Remove the axle cover mounting screws. Remove t h ea x l ec o v e rf r o mt h ea x l ec a s ea sa na s s e m b l y (Fig.
Groundsmaster 4500- - D/4700 - - D Page 6 - - 3 0 Axles, Planetaries and Brakes Input Shaft/Pinion Gea r Figure 35 1 1. Nut (2 used) 2. Lock washer (2 used) 3. Stud (2 used) 4. Lock nut 5. Stake washer 6. Oil seal 7. O-ring 8. Seal collar 9. Beari ng 10.
Groundsmaster 4500- - D/4700 - - D Page 6 - - 31 Axles, Planetaries a nd Brakes 5. Instal l a new stake washer . Install the lock nut finge r tight. 6.
Groundsmaster 4500- - D/4700 - - D Page 6 - - 3 2 Axles, Planetaries and Brakes Differentia l Gear The following proce dures assume the rear axle assem- bly has been re moved from the machine. Removal 1. Remove bevel gear case/axle case assemblies (see Bevel Gear Case/Axle Case Assembly in this section of this manual).
Groundsmaster 4500- - D/4700 - - D Page 6 - - 33 Axles, Planetaries a nd Brakes Inspection 1. Measure the dif ferential side gear O.D. and the dif- ferential case I.D. to determine the side gear to ca se clearance (Fig. 42) . Replace components as ne cessary .
Groundsmaster 4500- - D/4700 - - D Page 6 - - 3 4 Axles, Planetaries and Brakes Installation 1. If the r ing gear was removed from th e differ ential case, use medium strength Loctite thread locker and tighten the mountin g screws from 22 to 25 ft -lb (30 to 34 N - - m) .
Groundsmaster 4500- - D/4700 - - D Page 6 - - 35 Axles, Planetaries a nd Brakes Pinion Gear to Ring Gear Engagement The final position o f the pinion gear is verified b y using the gear contact pattern method as de scribed in the fol- lowing procedure.
Groundsmaster 4500- - D/4700 - - D Page 6 - - 3 6 Axles, Planetaries and Brakes Gear Patter n Movement Sum mary Every gear has a characteristic pattern. The il lustrations show typical patte rns only and exp lain how patt erns shift as gear location is chan ged.
Groundsmaster 4500- - D/4700 - - D Page 7 - - 1 Chassis Chapter 7 Chassis T able o f Contents GENERAL INFORMA TION 2 ..................... Operator ’s Manu al 2 .......................... Cutting Deck Identification 2 .................... SERVICE AND REP AIRS 4 .
Groundsmaster 4500- - D/4700 - - D Page 7 - - 2 Chassis General Information Operator ’ s Manual The T raction Unit and Cutting Deck Operator ’s Manuals provide information regard ing the operation, general maintenance and mainten ance intervals for your Groundsmaster machine.
Groundsmaster 4500- - D/4700 - - D Page 7 - - 3 Chassis This page is intentionally blank. Chassis.
Groundsmaster 4500- - D/4700 - - D Page 7 - - 4 Chassis Service and Repairs Steering Column 1. Steering wheel cover 2. Lock nut 3. Steering wheel 4. Flat washer 5. Socket head screw (4 used) 6. Flange head screw (4 used) 7. Steering column 8. Steering control valve 9.
Groundsmaster 4500- - D/4700 - - D Page 7 - - 5 Chassis 9. Loosen and remove fou r (4) socket head screws (item 5) that secure steering control valve to steering column. 10. Loosen and remove four (4) socket head screws (item 9) and flange nuts (item 10) that secure steering column to machine.
Groundsmaster 4500- - D/4700 - - D Page 7 - - 6 Chassis Tr a c t i o n P e d a l 1. Washer head screw (2 used) 2. Reverse pedal pad 3. Pedal assembly 4. Spring pin 5. Forward pedal pad 6. Accelerator pedal 7. Cap screw 8. Flat washer 9. Jam nut 10. Rod end bearing 1 1.
Groundsmaster 4500- - D/4700 - - D Page 7 - - 7 Chassis IMPORT ANT : A properly assembled and calibr ated traction pedal position sensor is critical to accur ate traction system response a nd for reliable sensor life. Use care when rem oving, assembling and cali - brating the traction pedal position s ensor .
Groundsmaster 4500- - D/4700 - - D Page 7 - - 8 Chassis Console Arm 1. Console arm frame 2. LH cover 3. RH cover 4. W asher head screw (10 used) 5. Phillips head screw 6. Lock nut 7. Cover plate 8. Flange head screw (2 used) 9. Mount 10. U - - nut (5 used) 1 1.
Groundsmaster 4500- - D/4700 - - D Page 7 - - 9 Chassis Disassembly (Fig. 8) 1. Park machine on a level s urface, lower cu tting decks, stop engine and engage parking brake. Remove key from igni tion switch. 2. Remove two (2) flange head screws (item 8) and then cover plate (item 7) from outside of console arm.
Groundsmaster 4500- - D/4700 - - D Page 7 - - 10 Chassis Lift Arms for Cutting Decks #1, #4 and #5 1. Flat washer 2. Flange nut 3. Lift arm (#1 deck) 4. Lift cylinder pin 5. Flange head screw 6. Flange nut 7. Cap screw 8. Lift cylinder (#4 and #5 decks) 9.
Groundsmaster 4500- - D/4700 - - D Page 7 - - 1 1 Chassis 5. Loosen and remo ve lock nut (item 1 1) from lift arm pivot pin. 6. Support lift arm and pull lift arm pivot pin from lift arm and frame. Locate and remove thr ust washers from bot h sides of lift arm during p ivot pin removal.
Groundsmaster 4500- - D/4700 - - D Page 7 - - 12 Chassis Lift Arms for Cutting Decks #2 and #3 1. Grease fitting 2. Set screw (2 used per stop) 3. Rotation stop 4. Flange head screw 5. Lock nut 6. Slotted roll pin 7. Pivo t pin 8. Bumper 9. Thrust washer 10.
Groundsmaster 4500- - D/4700 - - D Page 7 - - 13 Chassis Removal (Fig. 13) 1. Park machine on a level s urface, lower cu tting decks, stop engine, engage parking brake and remove key from the ignition switch . 2. Remove cutti ng deck from lift arm (see Cutting Deck Operat or ’s Manu al).
Groundsmaster 4500- - D/4700 - - D Page 7 - - 14 Chassis Lift Arms for Cutting Decks #6 and #7 (Groundsmaster 4700 - - D) 1. Retaining ring 2. Flat washer (4 used per support arm) 3. Cap screw (4 used per support arm) 4. Flange bushing 5. Lift cylinder 6.
Groundsmaster 4500- - D/4700 - - D Page 7 - - 15 Chassis Removal (Fig. 15) 1. Park machine on a level s urface, lower cu tting decks, stop engine, engage parking brake and remove key from the ignition switch . 2. Remove cutti ng deck from lift arm (see Cutting Deck Operat or ’s Manu al).
Groundsmaster 4500- - D/4700 - - D Page 7 - - 16 Chassis Operator Seat 1. Seat frame 2. Seat plate 3. T orsion spring 4. Seat plate latch 5. Clevis pin 6. Flat washer 7. Cotter pin 8. Hair pin (4 used) 9. Seat frame rod (2 used) 10. R - - clamp (2 used) 1 1.
Groundsmaster 4500- - D/4700 - - D Page 7 - - 17 Chassis Removal (Fig. 17) 1. Park machine on a level s urface, lower cu tting decks, stop engine, apply parking brake and remove key from the ignition switch . 2. Disconnect seat electrical connector from machine wire harness.
Groundsmaster 4500- - D/4700 - - D Page 7 - - 18 Chassis Operator Seat Service 1. Backrest cushion 2. Seat cushion 3. LH armrest cover 4. LH armrest 5. Bushing (2 used) 6. Backrest 7. Plug (2 used) 8. Cable tie (3 used) 9. LH adjustment rail 10. Bumper (2 used) 11 .
Groundsmaster 4500- - D/4700 - - D Page 7 - - 19 Chassis Disassembly (Fig. 19) 1. Remove seat from ma chine for service (see Opera- tor Seat Removal in this section). 2. Disassemble operator sea t a s necessary using Fig- u r e1 9a sag u i d e . Assembly (Fig.
Groundsmaster 4500- - D/4700 - - D Page 7 - - 20 Chassis Operator Seat Suspension 1. Cover 2. Cover 3. Level control 4. Air control valve 5. Shock absorber 6. Air spring 7. Air tube assembly 8. Wire harness 9. Compressor 10. Bellows 11 . S t o p 12. Bumper set (2 used) 13.
Groundsmaster 4500- - D/4700 - - D Page 7 - - 21 Chassis NOTE: Most of the seat suspension com ponents can be serviced with the seat suspension base mounte d to the seat plate. If the air spring assembly (item 6) requires removal, the seat suspension base will have to be re- moved from t he seat plat e.
Groundsmaster 4500- - D/4700 - - D Page 7 - - 22 Chassis Hood 1. Screen 2. Latch keeper 3. Pop rivet (2 used) 4. Hood 5. Plastic plug (20 used) 6. Hood screen 7. Radiator mount 8. Flange head screw 9. Hair pin (2 used) 10. Rear bumper 1 1. Washer (2 used) 12.
Groundsmaster 4500- - D/4700 - - D Page 7 - - 23 Chassis Removal (Fig. 22) 1. Park machine on a level s urface, lower cu tting decks, stop engine, engage parking brake and remove key from the ignition switch . 2. Release hood la tches and raise hood. 3.
Groundsmaster 4500- - D/4700 - - D Page 7 - - 24 Chassis This page is intentionally blank..
Groundsmaster 4500- - D/4700 - - D Cutting D ecks Page 8 - - 1 Chapter 8 Cutting Decks T able o f Contents SPECIFICA TIONS 2 ............................ GENERAL INFORMA TION 3 ..................... Operator ’s Manu al 3 .......................... TROUBLESHOOTING 4 .
Groundsmaster 4500- - D/4700 - - D Cutting Decks Page 8 - - 2 Specifications Groundsmaste r 4700 - - D Groundsmaster 4500 - - D MOUNTING: All cutting decks are supporte d by inde- pendent lift arms and are interch angeable to any cutting deck positions.
Groundsmaster 4500- - D/4700 - - D Cutting D ecks Page 8 - - 3 General Information CAUTION Never install or work on the cuttin g decks or lift arms with the engine running.
Groundsmaster 4500- - D/4700 - - D Cutting Decks Page 8 - - 4 T roubleshooting There are a number of factors th at can contribute to un- satisfactory quali ty of cut, some of which may be tu rf conditions.
Groundsmaster 4500- - D/4700 - - D Cutting D ecks Page 8 - - 5 Special T ools Order special tools f rom your T oro Distributor . Rear Roller Bearing and Seal Installation T ools These tools are used to assemble the c utting deck rear roller .
Groundsmaster 4500- - D/4700 - - D Cutting Decks Page 8 - - 6 Adjustments CAUTION Never install or work on the cutting decks or lift arms with the engine running.
Groundsmaster 4500- - D/4700 - - D Cutting D ecks Page 8 - - 7 This page is intentionally blank. Cutting Decks.
Groundsmaster 4500- - D/4700 - - D Cutting Decks Page 8 - - 8 Service and Repairs CAUTION Never install or work on the cutting decks or lift arms with the engine running. Always stop en- gine and remove key from ignition switch first. Blade Spindle A ssembly 1.
Groundsmaster 4500- - D/4700 - - D Cutting D ecks Page 8 - - 9 Removal (Fig. 4) 1. Park machine on a level s urface, lower cu tting decks, stop engine, engage parking brake and remove key from the ignition switch . 2. Remove two (2) socket hea d screws and flat wash- ers that secure hydraulic motor to the cutti ng deck (Fig.
Groundsmaster 4500- - D/4700 - - D Cutting Decks Page 8 - - 10 Blade Spindle Ser vice Disassembly (Fig. 6) 1. Remove blade spin d le from cutting deck (see Blade Spindle Removal in this section). 2. Loosen and remo ve spindle nut from t op of spindle shaft.
Groundsmaster 4500- - D/4700 - - D Cutting D ecks Page 8 - - 1 1 3. Using an arbor press, push the bearing cups into th e top and bottom of the spindle housin g. The t op bearing cup must contact the outer bearing s pacer previously installed, and the bottom bearing cup must contact the large snap ring.
Groundsmaster 4500- - D/4700 - - D Cutting Decks Page 8 - - 12 Rear Roller 1. Deck frame 2. Rear roller assembly 3. Grease fitting 4. Roller shaft screw 5.
Groundsmaster 4500- - D/4700 - - D Cutting D ecks Page 8 - - 13 Removal (Fig. 10) 1. Park machine on a level s urface, lower cu tting decks, stop engine, engage parking brake and remove key from the ignition switch . 2. If cutting deck is eq u ipped with a roller scraper (Fig.
Groundsmaster 4500- - D/4700 - - D Cutting Decks Page 8 - - 14 Rear Roller Service Disassembly (Fig. 12) 1. Remove bearing lock nut from ea ch end of roller shaft. 2. Loosely secure roll er assembly in bench vise and lightly ta p one end of roller shaft until outer seals and bearing are remove d from opposite end of roller tube.
Groundsmaster 4500- - D/4700 - - D Cutting D ecks Page 8 - - 15 3. From the r oller tube end with o nly the inner seal installed, carefully install th e roller shaft into the roller tube. Make sure that seals are not damaged as sh aft is installed. 4.
Groundsmaster 4500- - D/4700 - - D Cutting Decks Page 8 - - 16 Front Roller Service Disassembly (Fig. 18) 1. Remove roller moun ting bolt. 2. Remove roller assembly from carrier frame.
Groundsmaster 4500- - D/4700 - - D Cutting D ecks Page 8 - - 17 This page is intentionally blank. Cutting Decks.
Groundsmaster 4500- - D/4700 - - D Cutting Decks Page 8 - - 18 Cutting Deck Carrier Frame 1. Carr ier fr ame 2. L ynch pin 3. Thrust washer 4. Pivot shaft 5. Lift arm (#4 shown) 6. Flange nut (2 used p er deck) 7. Hardened washer (2 used per deck) 8. Cap screw (2 used per deck) 9.
Groundsmaster 4500- - D/4700 - - D Cutting D ecks Page 8 - - 19 Removal an d Insta llation ( Fig. 19) Each cutting deck is suspended from a carrier frame. The cutt ing deck car rier frame is attached to the lif t arm and allows the cutting de ck to pivot on the lift arm pivot shaft.
Groundsmaster 4500- - D/4700 - - D Cutting Decks Page 8 - - 20 This page is intentionally blank..
Groundsmaster 4500- - D/4700 - - D Foldout Drawings Page 9 - 1 Chapter 9 Foldout Drawings T able o f Contents ELECTRICAL DRA WING DESIGNA TIONS 2 ....... HYDRAULIC SCHEMA TICS Groundsmaster 45 00 - - D 3 ..................... Groundsmaster 4500- - D with Optional Flow Divider Kit 4 .
Groundsmaster 4500- - D/4700 - - D Foldout Drawings Page 9 - 2 Electrical Drawing Designations The following a bbreviations are us ed for wire harness colors on the electrical sch ematics and wire harness drawings in this chapter .
Page 9 - 3 Hydr aulic S chem atic Groundsmaster 4500 - - D 1. FLOWS SHOWN ARE CALCUL A TED A T HI GH IDLE AND 95% PUMP EFFICIENCY UNLE SS OTHERWISE NOTED 0.
Page 9 - 4 Hydr aulic S chem atic With Optional Flow Di vider Kit 1. FLOWS SHOWN ARE CALCUL A TED A T HI GH IDLE AND 95% PUMP EFFICIENCY UNLE SS OTHERWISE NOTED 0.
Page 9 - 5 Hydr aulic S chem atic Groundsmaster 4700 - - D 1. FLOWS SHOWN ARE CALCUL A TED A T HI GH IDLE AND 95% PUMP EFFICIENCY UNLE SS OTHERWISE NOTED 0.630” ROD 0.630” ROD 1050 PSI 6.2 GPM 11 . 4 G P M T PRV S1 CV FD P2 P1 ST L M1 M2 PE T R 50/50 FLOW DIVIDER FAN CONTR OL MANIFO LD MANIFO LD 4350 PSI 30.
Page 9 - 6 1. FLOWS SHOWN ARE CALCUL A TED A T HI GH IDLE AND 95% PUMP EFFICIENCY UNLE SS OTHERWISE NOTED 0.630” ROD 0.630” ROD 1050 PSI 6.2 GPM 11 . 4 G P M T PRV S1 CV FD P2 P1 ST L M1 M2 PE T R 50/50 FLOW DIVIDER FAN CONTR OL MANIFO LD MANIFO LD 4350 PSI 30.
Page 9 - 7 Electr ical Schematic Groundsmaster 4500 - - D/4700 - - D Models 30881 and 30882 GM4700- D TRACTION PEDAL POSITI ON SENSOR TRACTION PEDAL POSITI ON SENSOR LH (#4) DECK RH (#5) DECK All r elays and so lenoids are shown as de - - energiz ed. All gr ound wir es are black.
Page 9 - 8 Electr ical Schematic Groundsmaster 4500 - - D/4700 - - D Models 30873 and 30874 All r elays and so lenoids are shown as de - - energiz ed. All gr ound wir es are black.
Page 9 - 9 Electr ical Schematic Groundsmaster 4500 - - D/4700 - - D Optional Operator Cab All r elays and so lenoids are shown as de - - energiz ed. All gr ound wir es are black.
Page 9 - 10 Groundsmaster 4500 - - D/4700 - - D Ma in Wi re Ha rn es s P26 DECK PTO 1 P24 DECK PTO 2 P19 S5 P20 S6 P89 INTERCONNECT T O SEA T/ CONSOLE P04 HEADLIGHT RH P79 HEADLIGHT LH P07 RH (#5 ) DE.
Page 9 - 1 1 Groundsmaster 4500 - - D/4700 - - D Ma in Wi re Ha rn es s DRAWING DESIGNA TIONS IN THIS CHAPTER NOTE: T HIS DRAWING IDENTIFIES WIRE GAUGE SIZE AND WIRE COLOR.
Page 9 - 12 Groundsmaster 4500 - - D/4700 - - D Seat and Console Wire Har n ess.
Page 9 - 13 Groundsmaster 4500 - - D/4700 - - D Seat and Console Wire Har n ess DRAWING DESIGNA TIONS IN THIS CHAPTER NOTE: T HIS DRAWING IDENTIFIES WIRE GAUGE SIZE AND WIRE COLOR.
Page 9 - 14 Groundsmaster 4500 - - D/4700 - - D Power Center Wir e Harness.
Page 9 - 15 Groundsmaster 4500 - - D/4700 - - D Power Center Wir e Harness DRAWING DESIGNA TIONS IN THIS CHAPTER NOTE: T HIS DRAWING IDENTIFIES WIRE GAUGE SIZE AND WIRE COLOR.
Page 9 - 16 D e c k6a n d7W i r eH a r n e s s Groundsmaster 4700 - - D LH (#7) DECK RH (#6) DECK POSI TIO N SWITCH POSI TIO N SWITCH 1 11 21 31 41 30 20 10 40 50 NO TE T AB POS ITION PIN AND BACKSHEL.
Page 9 - 17 D e c k6a n d7W i r eH a r n e s s Groundsmaster 4700 - - D DRAWING DESIGNA TIONS IN THIS CHAPTER NOTE: T HIS DRAWING IDENTIFIES WIRE GAUGE SIZE AND WIRE COLOR.
Page 9 - 18 (Models 30881 and 30882) Engi ne Wire H arnes s Dr awing Groundsmaster 4500 - - D/4700 - - D PIN AND BACKSHELL ORIEN T A TION FOR P01 & P02.
Page 9 - 19 (Models 30881 and 30882) Engi ne Wire H arnes s Dia gram DRAWING DESIGNA TIONS IN THIS CHAPTER NOTE: T HIS DRAWING IDENTIFIES WIRE GAUGE SIZE AND WIRE COLOR.
Page 9 - 20 (Models 30873 and 30874) Engi ne Wire H arnes s Dr awing Groundsmaster 4500 - - D/4700 - - D PIN AND BACKSHELL ORIEN T A TION FOR P23.
Page 9 - 21 DRAWING DESIGNA TIONS IN THIS CHAPTER NOTE: T HIS DRAWING IDENTIFIES WIRE GAUGE SIZE AND WIRE COLOR. REFER TO ELECTRICAL FOR ADDITIO NAL INFORMA TION.
Un punto importante, dopo l’acquisto del dispositivo (o anche prima di acquisto) è quello di leggere il manuale. Dobbiamo farlo per diversi motivi semplici:
Se non hai ancora comprato il Toro 30873 è un buon momento per familiarizzare con i dati di base del prodotto. Prime consultare le pagine iniziali del manuale d’uso, che si trova al di sopra. Dovresti trovare lì i dati tecnici più importanti del Toro 30873 - in questo modo è possibile verificare se l’apparecchio soddisfa le tue esigenze. Esplorando le pagine segenti del manuali d’uso Toro 30873 imparerai tutte le caratteristiche del prodotto e le informazioni sul suo funzionamento. Le informazioni sul Toro 30873 ti aiuteranno sicuramente a prendere una decisione relativa all’acquisto.
In una situazione in cui hai già il Toro 30873, ma non hai ancora letto il manuale d’uso, dovresti farlo per le ragioni sopra descritte. Saprai quindi se hai correttamente usato le funzioni disponibili, e se hai commesso errori che possono ridurre la durata di vita del Toro 30873.
Tuttavia, uno dei ruoli più importanti per l’utente svolti dal manuale d’uso è quello di aiutare a risolvere i problemi con il Toro 30873. Quasi sempre, ci troverai Troubleshooting, cioè i guasti più frequenti e malfunzionamenti del dispositivo Toro 30873 insieme con le istruzioni su come risolverli. Anche se non si riesci a risolvere il problema, il manuale d’uso ti mostrerà il percorso di ulteriori procedimenti – il contatto con il centro servizio clienti o il servizio più vicino.
