Page 1: Service Manual
IMPORTANT: The IMPORTANT notice will give im- The Toro Company reserves the right to change product portant instructions which must be followed to pre- specifications or this publication without notice. vent damage to systems or components on the machine.
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Page 3: Table Of Contents
Table Of Contents Chapter 1 - Safety Chapter 5 - Electrical System General Safety Instructions ....1 - 2 General Information ......5 - 2 Jacking Instructions .
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Page 5 Chapter 1 Safety Table of Contents GENERAL SAFETY INSTRUCTIONS ... . Before Operating ......While Operating .
Page 6: General Safety Instructions
General Safety Instructions The Groundsmaster 4500-D and 4700--D have been tested and certified by TORO for compliance with exist- WARNING ing safety standards and specifications. Although haz- ard control and accident prevention partially are To reduce the potential for injury or death, dependent upon the design and configuration of the ma- comply with the following safety instructions.
Page 7: While Operating
D. Stop engine and remove key from switch. C. After engine is started, release parking brake and 6. Toro recommends that anytime the machine is keep foot off traction pedal. Machine must not move. parked (short or long term), the cutting decks should be If movement is evident, there may be a problem with lowered to the ground.
Page 8: Maintenance And Service
To assure op- er or furnace. timum performance and continued safety certification of the machine, use genuine Toro replacement parts and 5. Make sure all hydraulic line connectors are tight and accessories. Replacement parts and accessories made...
Page 9: Jacking Instructions
Jacking Instructions Jacking the Rear End CAUTION 1. Apply parking brake and chock both front tires to pre- vent the machine from moving. When changing attachments, tires or perform- 2. Place jack securely under the center of rear axle. ing other service, use correct jacks and sup- ports.
Page 10: Safety And Instruction Decals
Safety and Instruction Decals Numerous safety and instruction decals are affixed to the Groundsmaster 4500--D and 4700--D. If any decal becomes illegible or damaged, install a new decal. De- cal part numbers are listed in your Parts Catalog. Safety Page 1 - - 6 Groundsmaster 4500--D/4700--D...
Page 11: Product Records
Chapter 2 Product Records and Maintenance Table of Contents PRODUCT RECORDS ......MAINTENANCE ......EQUIVALENTS AND CONVERSIONS .
Page 12: Equivalents And Conversions
Equivalents and Conversions 0.09375 Product Records and Maintenance Groundsmaster 4500--D/4700--D Page 2 - - 2...
Page 13: Torque Specifications
For critical applications, as determined reduced by 25% for lubricated fasteners to achieve by Toro, either the recommended torque or a torque that the similar stress as a dry fastener. Torque values may is unique to the application is clearly identified and spe- also have to be reduced when the fastener is threaded cified in this Service Manual.
Page 14 Standard Torque for Dry, Zinc Plated and Steel Fasteners (Inch Series) Grade 1, 5 & SAE Grade 1 Bolts, Screws, Studs & SAE Grade 5 Bolts, Screws, Studs & SAE Grade 8 Bolts, Screws, Studs & Thread Size 8 with Thin Sems with Regular Height Nuts Sems with Regular Height Nuts Sems with Regular Height Nuts...
Page 15 Standard Torque for Dry, Zinc Plated and Steel Fasteners (Metric Series) Class 8.8 Bolts, Screws and Studs with Class 10.9 Bolts, Screws and Studs with Thread Size Regular Height Nuts Regular Height Nuts (Class 8 or Stronger Nuts) (Class 10 or Stronger Nuts) M5 X 0.8 57 + 6 in--lb 644 + 68 N--cm...
Page 16 Other Torque Specifications SAE Grade 8 Steel Set Screws Wheel Bolts and Lug Nuts Recommended Torque Thread Size Recommended Torque** Thread Size Square Head Hex Socket 7/16 -- 20 UNF 65 + 10 ft--lb 88 + 14 N--m Grade 5 1/4 -- 20 UNC 140 + 20 in--lb 73 + 12 in--lb...
Page 17: Specifications
Chapter 3 Yanmar Diesel Engine Table of Contents SPECIFICATIONS ......Models 30873 and 30874 .
Page 18: Specifications
Specifications (Models 30873 and 30874) Item Description Make / Designation Yanmar Model 4TNV84T--ZMTR: 4--Cycle, 4 Cylinder, Water Cooled, Turbocharged, Tier 4i Diesel Engine Bore 3.307 in (84 mm) Stroke 3.543 in (90 mm) Total Displacement 121.7 in (1995 cc) Firing Order 1 (closest to flywheel end) -- 3 -- 4 (farthest from flywheel) -- 2 Direction of Rotation Counterclockwise (viewed from flywheel)
Page 19 Specifications (Models 30881 and 30882) Item Description Make / Designation Yanmar Model 4TNV86CT--DTR: 4--Cycle, 4 Cylinder, Water Cooled, Turbocharged, Tier 4 Diesel Engine Bore 3.386 in (86 mm) Stroke 3.543 in (90 mm) Total Displacement 127.5 in (2090 cc) Firing Order 1 (closest to flywheel end) -- 3 -- 4 (farthest from flywheel) -- 2 Direction of Rotation Counterclockwise (viewed from flywheel)
Page 20: General Information
Authorized Toro Distributor. If no parts list is available, be prepared to provide your distrib- Most repairs and adjustments require tools which are utor with the Toro model and serial number of your ma- commonly available in many service shops. Special chine.
Page 21: Engine Electronic Control Unit (Ecu)
Contact your Toro distributor Figure 1 for assistance in Yanmar engine troubleshooting. 1. Engine (models 30873 and 30874) 2.
Page 22: Yanmar Engine: Models 30873 And 30874
Yanmar Engine: Models 30873 and 30874 The engine used on Groundsmaster models 30873 and 30874 is a Yanmar TNV Series, turbocharged, diesel engine that complies with EPA interim Tier 4 emission regulations. Engine features include an electronic con- trol unit (ECU) controlled direct fuel injection and elec- tronic governor.
Page 23 Assist regeneration occurs if the engine ECU senses When the regeneration process is completed, the In- that the DPF backpressure has increased to its maxim- foCenter will remove the stationary regeneration icon um threshold. During assist regeneration, the intake and cease periodic regeneration messages. The engine throttle valve limits the air flow into the engine while the will return to low idle speed with operator controls re- injectors add additional fuel.
Page 24: Air Cleaner System
Service and Repairs Air Cleaner System 12 to 15 in- -lb (1.4 to 1.6 N- -m) RIGHT VACUATOR FRONT DIRECTION MODELS MODELS 30881 and 30873 and 30882 30874 Figure 6 1. Air cleaner assembly 8. Flat washer (2 used) 15. Air cleaner inlet hose 2.
Page 25 Removal (Fig. 6) 1. Park machine on a level surface, lower cutting decks, stop engine, apply parking brake and remove key from the ignition switch. 2. Raise and support hood. 3. Remove air cleaner components as needed using Figure 6 as a guide. Installation (Fig.
Page 26: Fuel System
Fuel System MODEL 30881/30882 SHOWN RIGHT FRONT Figure 9 1. Fuel suction tube 10. Cap screw (2 used) 18. Flange head screw (2 used) 2. Fuel gauge 11. Clamp (2 used) 19. Flange nut (2 used) 3. Fuel hose (supply) 12.
Page 27: Check Fuel Lines And Connections
Fuel Tank Installation (Fig. 9) DANGER 1. Install fuel tank to frame using Figure 9 as a guide. If draincock (item 15) was removed from tank, apply thread sealant to threads of draincock before installing Because diesel fuel is highly flammable, use cau- it into fuel tank.
Page 28: Radiator And Oil Cooler Assembly
Radiator and Oil Cooler Assembly RIGHT FRONT Figure 11 1. Radiator/oil cooler assembly 18. Flange head screw (4 used) 35. Coolant reservoir 2. Cap screw (4 used) 19. Hydraulic tube 36. R- -clamp (2 used) 3. Washer (4 used) 20. Hydraulic tube 37.
Page 29 Removal (Fig. 11) 1. Park machine on a level surface, lower cutting decks, stop engine, engage parking brake and remove key from the ignition switch. 2. Remove hood from the machine (see Hood Removal in the Service and Repairs section of Chapter 7 -- Chas- sis).
Page 30 13.Plug all radiator/oil cooler and hose openings to pre- 7. Install engine cooling fan motor and bracket as- vent contamination. sembly, cooling fan and upper radiator shroud to ma- chine (see Engine Cooling Fan Motor in the Service and 14.If necessary, remove draincock (item 7 in Fig. 13), Repairs section of Chapter 4 - Hydraulic System).
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Page 32: Engine
Engine MODEL 30881/30882 SHOWN RIGHT FRONT Figure 14 1. LH front engine mount bracket 9. Flange nut (13 used) 16. Clamp 2. RH front engine mount bracket 10. Rebound washer (4 used) 17. Engine 3. LH rear engine mount bracket 11.
Page 33: Engine Removal
Engine Removal (Fig. 14) MODELS 30881 & 30882 1. Park machine on a level surface, lower cutting decks, stop engine, engage parking brake and remove key from the ignition switch. 2. Remove hood from the machine (see Hood Removal in the Service and Repairs section of Chapter 7 -- Chas- sis).
Page 34: Engine Installation
10.Support hydraulic pump assembly to prevent it from 3. Carefully lower engine into the machine and move shifting or falling. Remove fasteners that secure piston engine toward the hydraulic pump assembly to engage (traction) pump to engine (see Piston (Traction) Pump the pump input shaft with the coupler on the engine fly- in the Service and Repairs section of Chapter 4 -- Hy- wheel.
Page 35 13.Check position of wires, fuel lines and hydraulic 17.Prime the fuel system (see Fuel System in this sec- hoses for proper clearance with rotating, high tempera- tion). ture and moving components. 18.Start engine and operate hydraulic controls to prop- 14.Connect positive battery cable to battery first and erly fill hydraulic system (see Charge Hydraulic System then negative battery cable.
Page 36: Pump Adapter Plate
Pump Adapter Plate RIGHT FRONT 29 to 33 ft- -lb (40 to 44 N- -m) Boss 29 to 33 ft- -lb (40 to 44 N- -m) Figure 17 1. Flywheel plate 4. Cap screw (8 used) 6. Hardened washer (8 used) 2.
Page 37 Coupler Removal (Fig. 17) NOTE: The hydraulic pump assembly needs to be re- moved from engine before coupler can be removed. Engine Side Hydraulic Pump Side 1. If engine is in machine, remove hydraulic pump as- sembly (see Piston (Traction) Pump in the Service and Repairs section of Chapter 4 -- Hydraulic System).
Page 38: Exhaust System (Models 30881 And 30882)
Exhaust System (Models 30881 and 30882) 19 to 29 ft- -lb (25 to 40 N- -m) RIGHT FRONT Figure 19 1. Gasket 16. Bolt (20 used) 31. Hose clip (2 used) 2. Exhaust assembly stay 17. DPF lifter 32. Hose 3.
Page 39 C. If DPF stiffeners (items 18, 19, 20 and 21 in Fig. reconditioning process, it can be re--installed in the ex- 19) were loosened or removed, tighten fasteners haust system. Contact your Toro Distributor for informa- that secure stiffeners before tightening fasteners tion on reconditioning the DPF.
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Page 41 Chapter 4 Hydraulic System Table of Contents SPECIFICATIONS ......Priming Hydraulic Pumps ....GENERAL INFORMATION .
Page 42 Specifications Item Description Piston (Traction) Pump Sauer--Danfoss Variable Displacement Axial Piston Pump Maximum Displacement (per revolution) 2.75 in (45 cc) System Relief Pressure: Forward 4350 PSI (300 bar) System Relief Pressure: Reverse 5000 PSI (345 bar) Charge Pressure 250 PSI (17 bar) Front Wheel Motors Sauer--Danfoss 2--Position Axial Piston Motors Displacement (per revolution)
Page 43 General Information Operator’s Manual The Operator’s Manual provides information regarding the operation, general maintenance and maintenance intervals for your Groundsmaster machine. Refer to that publication for additional information when servicing the machine. Check Hydraulic Fluid The Groundsmaster 4500--D and 4700--D hydraulic systems are designed to operate on anti--wear hydraulic fluid.
Page 44: Towing Traction Unit
M8 and P2 on the rear traction control mani- fold. Toro part numbers 95- -8843 (hydraulic hose), 95- -0985 (coupler fitting) (2 required) and 340- -77 (hydraulic fitting) (2 required) are needed for this connection.
Page 45 Traction Circuit Component Failure The traction circuit on Groundsmaster 4500--D and Once the Toro high flow hydraulic filter kit has been 4700--D machines is a closed loop system that includes placed in the circuit, raise and support the machine with the piston (traction) pump, two (2) front wheel motors all wheels off the ground.
Page 46: Hydraulic Hoses
Tube Installation in this section). If the hose has an el- bow at one end, tighten the swivel nut on that end before tightening the nut on the straight end of the hose. For additional hydraulic hose information, refer to Toro Service Training Book, Hydraulic Hose Servicing (Part Number 94813SL).
Page 47 Hydraulic Hose and Tube Installation (O- -Ring Face Seal Fitting) 1. Make sure threads and sealing surfaces of the hose/ C. Use a second wrench to tighten the nut to the cor- tube and the fitting are free of burrs, nicks, scratches or rect Flats From Wrench Resistance (F.F.W.R.).
Page 48 Hydraulic Fitting Installation (SAE Straight Thread O- -Ring Fitting into Component Port) Non- -Adjustable Fitting (Fig. 6) 5. If a torque wrench is not available, or if space at the port prevents use of a torque wrench, an alternate meth- 1.
Page 49 Adjustable Fitting (Fig. 8) 1. Make sure all threads and sealing surfaces of fitting and component port are free of burrs, nicks, scratches or any foreign material. 2. As a preventative measure against leakage, it is rec- ommended that the O--ring be replaced any time the connection is opened.
Page 50: Hydraulic Schematics
Hydraulic Schematics Hydraulic System Page 4 - - 10 Groundsmaster 4500--D/4700--D...
Page 51 Groundsmaster 4500--D/4700--D Page 4 - - 11 Hydraulic System...
Page 52: Hydraulic Flow Diagrams
Hydraulic Flow Diagrams Hydraulic System Page 4 - - 12 Groundsmaster 4500--D/4700--D...
Page 53 Traction Circuit: LOW Speed (Mow) The traction circuit piston pump is a variable displace- Gear pump flow for the charge circuit is directed through ment pump that is directly coupled to the engine fly- the oil filter and to the low pressure side of the closed wheel.
Page 54 Hydraulic System Page 4 - - 14 Groundsmaster 4500--D/4700--D...
Page 55 Traction Circuit: HI Speed (Transport) The traction circuit piston pump is a variable displace- Forward Direction ment pump that is directly coupled to the engine fly- With the armrest console HI/LOW speed switch in the HI wheel. This pump utilizes an integral electro--hydraulic speed (transport) position, the solenoid valve in the HI/ servo piston assembly that controls the rate and direc- LOW range control manifold is energized.
Page 56 Hydraulic System Page 4 - - 16 Groundsmaster 4500--D/4700--D...
Page 57 Lower Cutting Decks: Groundsmaster 4500- -D A four section gear pump is coupled to the piston (trac- Counterbalance tion) pump. The third gear pump section supplies hy- Once the cutting decks are fully lowered, the lift control draulic flow to both the lift control manifold and the manifold proportional relief valve (TS) maintains back steering control valve.
Page 58 Hydraulic System Page 4 - - 18 Groundsmaster 4500--D/4700--D...
Page 59 Lower Cutting Decks: Groundsmaster 4700- -D A four section gear pump is coupled to the piston (trac- Cutting Deck Float tion) pump. The third gear pump section supplies hy- Cutting deck float allows the fully lowered cutting decks draulic flow to both the lift control manifold and the to follow ground surface contours.
Page 60 Hydraulic System Page 4 - - 20 Groundsmaster 4500--D/4700--D...
Page 61 Raise Cutting Decks: Groundsmaster 4500- D A four section gear pump is coupled to the piston (trac- tion) pump. The third gear pump section supplies hy- draulic flow to both the lift control manifold and the steering control valve. Hydraulic flow from this pump section is delivered to the circuits through a proportional flow divider located in the fan control manifold.
Page 62 Hydraulic System Page 4 - - 22 Groundsmaster 4500--D/4700--D...
Page 63 Raise Cutting Decks: Groundsmaster 4700- D A four section gear pump is coupled to the piston (trac- tion) pump. The third gear pump section supplies hy- draulic flow to both the lift control manifold and the steering control valve. Hydraulic flow from this pump section is delivered to the circuits through a proportional flow divider located in the fan control manifold.
Page 64 Hydraulic System Page 4 - - 24 Groundsmaster 4500--D/4700--D...
Page 65: Mow Circuit
Mow Circuit Hydraulic flow for the mow circuit is supplied by the first The brake relief and logic cartridges control the stopping two (2) sections of the gear pump. The first gear pump rate of the blades when the solenoid valves are de--en- section P1 supplies hydraulic flow to decks 5, 3 and 2 ergized as the PTO switch is turned OFF or if the decks (also deck 7 on the GM 4700--D), while the second gear...
Page 66: Cutting Deck Blade Braking
Cutting Deck Blade Braking When the operator turns the PTO switch OFF (or if the DECK CONTROL decks are raised), deck manifold solenoid valves MANIFOLD (PRV1, PRV2, SV1 and SV2) are de--energized. The valves will shift to direct oil away from the deck motors FROM and toward the oil cooler and filter.
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Page 68 Hydraulic System Page 4 - - 28 Groundsmaster 4500--D/4700--D...
Page 69: Steering Circuit
Steering Circuit A four section gear pump is coupled to the piston (trac- ing cylinder for a right turn. The rotary meter ensures tion) pump. The third gear pump section supplies hy- that the oil flow to the cylinder is proportional to the draulic flow to the steering control valve and the lift/lower amount of the turning on the steering wheel.
Page 70 Hydraulic System Page 4 - - 30 Groundsmaster 4500--D/4700--D...
Page 71: Engine Cooling Fan Circuit
Engine Cooling Fan Circuit A four section gear pump is coupled to the piston (trac- Reverse Direction Fan Operation (Fig. 24) tion) pump. The final gear pump section (farthest from The TEC--5002 controller can reverse the cooling fan to the piston pump) supplies hydraulic flow for the hydrau- clean debris from the rear intake screen.
Page 72: Special Tools
Special Tools Order these special tools from your Toro Distributor. Hydraulic Pressure Test Kit Use to take various pressure readings for diagnostic tests. Quick disconnect fittings provided attach directly to mating fittings on machine test ports without tools. A high pressure hose is provided for remote readings.
Page 73 Refer to the Testing section of this chapter for necessary test pro- cedures when using these diagnostic fittings. Toro Part Number (traction charge, reverse traction cir- cuit reducing valve or rear traction circuit relief valve): Diagnostic Fitting 59- -7410 Figure 28 1.
Page 74 Toro Part Number: TOR6011 NOTE: This kit does not include hoses (see Hydraulic Hose Kit TOR6007 above). NOTE: Replacement filter element is Toro part number TOR6012. Filter element cannister tightening torque is 25 ft- -lb (34 N- -m). O- -Ring Kit The O--ring kit includes O--rings in a variety of sizes for face seal and port seal hydraulic connections.
Page 75: Measuring Container
This kit includes a variety of O--ring Face Seal fittings to enable you to connect test gauges into the system. The kit includes: tee’s, unions, reducers, plugs, caps and male test fittings. Toro Part Number: TOR4079 Figure 32 Measuring Container Use this container for doing hydraulic motor efficiency testing (motors with case drain lines only).
Page 76 Figure 35 A remote stater switch can also be constructed using Toro switch #106--2027, a length of 14 gauge wire, a 20 amp in--line fuse, two (2) alligator clips and necessary MACHINE connectors. Connecting the wire to switch terminals 1...
Page 77: Troubleshooting
Troubleshooting The charts that follow contain information to assist in hy- Refer to the Testing section of this Chapter for precau- draulic system troubleshooting. There may possibly be tions and specific testing procedures. more than one cause for a machine malfunction. General Hydraulic System Problems Problem Possible Cause...
Page 78: Traction Circuit Problems
Traction Circuit Problems NOTE: When troubleshooting traction circuit problems, speed (mow) but not in HI speed (transport), consider a if a problem exists in both low (mow) and high (transport) problem that only exists in mow (e.g. swashplate com- speeds, consider a faulty component that affects the en- ponents in front wheel or rear axle motor, solenoid valve tire traction circuit (e.g.
Page 79 Mow Circuit Problems Problem Possible Cause None of the cutting decks will oper- Cutting decks are not fully lowered to ground. ate. PTO switch is not in engaged position. NOTE: To engage the mow circuit, Operator seat is unoccupied. the seat must be occupied, the cut- ting deck(s) must be fully lowered, Traction system is in HI speed (transport).
Page 80: Steering Circuit Problems
Mow Circuit Problems (Continued) Problem Possible Cause All cutting decks operate slowly. Engine RPM is low. Deck motor is damaged. First and second gear pump sections are worn or damaged. Cutting deck stops under load. Relief valve in deck control manifold is bypassing. Traction speed and cutting conditions (e.g.
Page 81 Lift/Lower Circuit Problems Problem Possible Cause Cutting decks will not raise. Operator seat is unoccupied. NOTE: Operator must be in seat in Hydraulic oil level in reservoir is low. order to raise the cutting decks. Electrical problem exists that prevents lift control manifold solenoid valve operation (see Chapter 5 -- Electrical System).
Page 82 Engine Cooling Fan Circuit Problems Problem Possible Cause Cooling fan runs only in forward di- Fan control manifold solenoid cartridge valve (S1) is faulty. rection (fan does not run in reverse Electrical problem exists that prevents fan control manifold solenoid direction).
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Page 84: Testing
Testing The most effective method for isolating problems in the Precautions for Hydraulic Testing hydraulic system is by using hydraulic test equipment 1. Clean machine thoroughly before disconnecting or such as pressure gauges and flow meters in the circuits disassembling any hydraulic components. Always keep during various operational checks (See the Special in mind the need for cleanliness when working on hy- Tools section in this chapter).
Page 85 Which Hydraulic Tests Are Necessary? 2. If a cutting (mow) circuit problem exists, consider performing one or more of the following tests: Cutting Before beginning any hydraulic test, identify if the prob- Deck Circuit Pressure, Cutting Deck Circuit Relief Pres- lem is related to the traction circuit, cutting (mow) circuit, sure, Deck Motor Case Drain Leakage and/or Gear lift/lower circuit, steering circuit or engine cooling fan cir-...
Page 86 Traction Circuit Charge Pressure (Using Pressure Gauge) PRESSURE GAUGE Hydraulic System Page 4 - - 46 Groundsmaster 4500--D/4700--D...
Page 87 (Fig. 38). Thoroughly pump sur- faces around plug to prevent system contamination. 4. Remove plug from pump traction charge port and then install diagnostic test fitting (Toro part number 59--7410) into charge port. 5. Connect a 1000 PSI (70 bar) pressure gauge onto diagnostic test fitting.
Page 88 Traction Circuit Relief Pressure (Using Pressure Gauge) FORWARD DIRECTION TEST SHOWN PRESSURE GAUGE Hydraulic System Page 4 - - 48 Groundsmaster 4500--D/4700--D...
Page 89 Procedure for Traction Circuit Relief Pressure Test 7. Release traction pedal and stop engine. Record test results. CAUTION 8. If traction pressure is too low, makes sure that by- pass valve on traction pump is fully seated and then in- spect traction pump relief valve in piston (traction) pump Prevent personal injury and/or damage to equip- (Fig.
Page 90 Reverse Traction Circuit Reducing Valve (PR) Pressure (Using Pressure Gauge) PRESSURE GAUGE Hydraulic System Page 4 - - 50 Groundsmaster 4500--D/4700--D...
Page 91 1. Front frame 2. Rear traction manifold move #6 zero leak plug on the inside of rear traction manifold and install diagnostic fitting (Toro part number 59--7410) into manifold port. 4. Connect a 1000 PSI (70 bar) pressure gauge with hy- draulic hose attached to installed diagnostic fitting.
Page 92: Rear Traction Circuit Relief Pressure
Rear Traction Circuit Relief (RV) Pressure (Using Pressure Gauge) PRESSURE GAUGE Hydraulic System Page 4 - - 52 Groundsmaster 4500--D/4700--D...
Page 93 (Fig. 43). Re- move #6 zero leak plug on inside of rear traction mani- Figure 43 fold and install diagnostic fitting (Toro part number 1. Front frame 2. Rear traction manifold 59--7410) into manifold port.
Page 94 Piston (Traction) Pump Flow (Using Tester with Pressure Gauge & Flow Meter) TESTER Hydraulic System Page 4 - - 54 Groundsmaster 4500--D/4700--D...
Page 95 Procedure for Piston (Traction) Pump Flow Test 7. Have second person watch pressure gauge on test- er carefully while slowly closing the flow control valve This test measures piston (traction) pump output (flow). until 1000 PSI (69 bar) is obtained. Verify with the In- During this test, pump load is created at the flow meter foCenter display that the engine speed is still at the cor- using the adjustable load valve on the tester.
Page 96 Cutting Deck Circuit Pressure (Using Pressure Gauge) TEST FOR GM4500- -D DECKS 1 AND 4 SHOWN PRESSURE GAUGE Hydraulic System Page 4 - - 56 Groundsmaster 4500--D/4700--D...
Page 97 Procedure for Cutting Deck Circuit Pressure Test GM 4500- -D 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. 1. Make sure hydraulic oil is at normal operating tem- FRONT perature by operating the machine for approximately ten (10) minutes.
Page 98 Cutting Deck Circuit Relief Pressure (Using Tester with Pressure Gauge & Flow Meter) TEST FOR GM4500- -D SECOND PUMP SECTION SHOWN TESTER Hydraulic System Page 4 - - 58 Groundsmaster 4500--D/4700--D...
Page 99 Procedure for Cutting Deck Circuit Relief Pressure 9. As the circuit relief valve lifts, system pressure Test should be from 3400 to 3750 PSI (235 to 258 bar). 10.Open the tester flow control valve, disengage cutting CAUTION decks and stop the engine. Record test results. 11.
Page 100 Deck Motor Case Drain Leakage (Using Tester with Pressure Gauge & Flow Meter) TEST FOR GM4500- -D DECK MOTOR #1 SHOWN TESTER TO HYDRAULIC TANK STEEL CAP MEASURING CONTAINER Hydraulic System Page 4 - - 60 Groundsmaster 4500--D/4700--D...
Page 101 Procedure for Deck Motor Case Drain Leakage Test 5. Sit on seat and start the engine. Increase engine speed to high idle speed. Engage cutting decks. NOTE: Over a period of time, a deck motor can wear in- ternally. A worn motor may bypass oil to its case drain 6.
Page 102 Steering Circuit Relief Pressure (Using Pressure Gauge) TEST FOR GM4500- -D SHOWN (STEERING WHEEL TURNED FOR RIGHT TURN) STEEL PRESSURE GAUGE Hydraulic System Page 4 - - 62 Groundsmaster 4500--D/4700--D...
Page 103 Procedure for Steering Circuit Relief Pressure Test 9. If steering relief pressure is incorrect, inspect steer- ing relief valve located in the steering control valve (see The steering circuit relief pressure test should be per- Steering Control Valve Service in the Service and Re- formed to make sure that the steering circuit relief pres- pairs section of this chapter).
Page 104 Steering Cylinder Internal Leakage CYLINDER FULLY STEERING EXTENDED CYLINDER LOOK FOR LEAKAGE STEEL CAP STEERING WHEEL TURNED FOR RIGHT TURN STEERING 1050 CONTROL VALVE TO GEAR FROM COMBINATION TO TRACTION PUMP MANIFOLD CHARGE INLET CIRCUIT Hydraulic System Page 4 - - 64 Groundsmaster 4500--D/4700--D...
Page 105 The steering cylinder internal leakage test should be 4. Place a drain pan under the steering cylinder. Re- performed if a steering problem is identified. This test move hydraulic hose from the fitting on the rod end of the will determine if the steering cylinder is faulty. steering cylinder.
Page 106 Lift/Lower Circuit Relief Pressure (Using Pressure Gauge) GM 4500- -D SHOWN PRESSURE GAUGE Hydraulic System Page 4 - - 66 Groundsmaster 4500--D/4700--D...
Page 107 Procedure for Lift/Lower Circuit Relief Pressure 8. If specification is not met, adjust or clean relief valve Test located in the lift control manifold (see Lift Control Man- ifold Service in the Service and Repairs section of this The lift/lower circuit relief pressure test should be per- chapter).
Page 108 Engine Cooling Fan Circuit (Using Pressure Gauge and Phototac) GM 4500- -D SHOWN Hydraulic System Page 4 - - 68 Groundsmaster 4500--D/4700--D...
Page 109 Procedure for Engine Cooling Fan Circuit Test 7. If pressure rises to approximately 3000 PSI (207 bar) but fan speed is low, consider that the hydraulic fan The engine cooling fan circuit test should be performed motor is worn or damaged. If pressure and fan speed to make sure that the engine cooling fan circuit has the are both low, consider that final gear pump section is correct system pressure and fan speed.
Page 110 Gear Pump Flow (Using Tester with Pressure Gauge & Flow Meter) SECOND GEAR PUMP SECTION FLOW TEST SHOWN TESTER The gear pump flow test should be performed to make NOTE: Over a period of time, the gears and wear plates sure that the mow, steering, lift/lower, cooling fan and in the gear pump can wear.
Page 111 Procedure for Gear Pump Flow Test 12.After testing is completed, disconnect flow tester from hydraulic hose and fitting in gear pump section. Re- connect hose to the pump fitting. CAUTION 13.Lower and secure operator seat. Prevent personal injury and/or damage to equip- ment.
Page 112: Adjustments
Adjustments Adjust Control Manifold Relief Valves Several of the hydraulic control manifolds on your Groundsmaster include adjustable relief valves. The fol- lowing procedure can be used to adjust these relief valves. Refer to the Testing section of this chapter for in- formation on testing relief pressure.
Page 113: Service And Repairs
Service and Repairs General Precautions for Removing and Installing Hydraulic System Components Before Repair or Replacement of Components After Repair or Replacement of Components 1. Before removing any parts from the hydraulic sys- 1. Check oil level in the hydraulic reservoir and add cor- tem, park machine on a level surface, engage parking rect oil if necessary.
Page 114: Check Hydraulic Lines And Hoses
Check Hydraulic Lines and Hoses IMPORTANT: Check hydraulic lines and hoses daily for leaks, kinked lines, loose mounting supports, WARNING wear, loose fittings or deterioration. Make all neces- sary repairs before operating the machine. Keep body and hands away from pin hole leaks or nozzles that eject hydraulic fluid under high pressure.
Page 115 Flush Hydraulic System IMPORTANT: Flush the hydraulic system any time 6. Connect all hydraulic hoses, tubes and components there is a severe component failure or the system is that were disconnected while draining system. contaminated (oil appears milky, black or contains NOTE: Use only hydraulic fluids specified in the Trac- metal particles).
Page 116 Toro high flow hydraulic filter and hydraulic hose kit brakes to increase pressure in traction circuit. While are recommended (see Special Tools in this chapter).
Page 117 Charge Hydraulic System NOTE: When initially starting the hydraulic system with 8. After the hydraulic system starts to show signs of fill, new or rebuilt components such as pumps, motors or lift actuate lift control switch until the lift cylinders move in cylinders, it is important that the hydraulic system be and out several times.
Page 118: Gear Pump
Gear Pump RIGHT FRONT Figure 63 1. Piston pump assembly 8. Hydraulic tee fitting 15. O- -ring 2. Flat washer (4 used) 9. 90 hydraulic fitting 16. 45 hydraulic fitting (2 used) 3. Gear pump assembly 10. 45 hydraulic fitting 17.
Page 119 Removal (Fig. 63) Remove plugs before installing 1. Park machine on a level surface, lower cutting gear pump to piston pump decks, stop engine, engage parking brake and remove key from the ignition switch. 2. Gain access to gear pump from below the machine. 3.
Page 120 5. Remove caps and plugs from hydraulic lines and fit- 8. Prime hydraulic pumps (see Priming Hydraulic tings. Install hydraulic lines to gear pump (see Hydraulic Pumps in this section). Hose and Tube Installation in the General Information 9. Properly fill hydraulic system (see Charge Hydraulic section of this chapter).
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Page 122: Gear Pump Service
Gear Pump Service 33 ft- -lb (45 N- -m) Figure 66 1. Dust seal 10. Seal (8 used) 19. Body (2 pump section) 2. Retaining ring 11. Idler gear 20. Body (3 pump section) 3. Flange washer 12. Drive shaft 21.
Page 123 IMPORTANT: Use caution when clamping gear 8. Clean all parts. Check all components for burrs, pump in a vise to avoid distorting any pump compo- scoring, nicks and other damage. nents. 9. Replace the entire pump assembly if parts are ex- 3.
Page 124 Piston (Traction) Pump RIGHT FRONT Figure 68 1. Piston pump assembly 8. Hydraulic tee fitting 15. O- -ring 2. Flat washer (4 used) 9. 90 hydraulic fitting 16. 45 hydraulic fitting (2 used) 3. Gear pump assembly 10. 45 hydraulic fitting 17.
Page 125 5. For assembly purposes, label all hydraulic lines con- nected to gear pump and traction pump fittings. 6. Put a drain pan below the pump assembly. Remove hydraulic hoses connected to piston and gear pumps. Put plugs or caps on disconnected hydraulic hoses and fittings to prevent contamination of the system.
Page 126 IMPORTANT: A case drain exists in the piston (trac- 10.Install new hydraulic filter and fill hydraulic reservoir tion) pump and a suction port is near the input shaft with correct oil. of the gear pump (Fig. 70). Before the gear pump is IMPORTANT: Refer to Traction Circuit Component installed to the piston pump, make sure that plugs Failure in the General Information section of this...
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Page 128 Piston (Traction) Pump Service Figure 72 Hydraulic System Page 4 - - 88 Groundsmaster 4500--D/4700--D...
Page 129 Figure 72 (Continued) 1. Screen (2 used) 20. Bearing 38. O- ring 2. Plug with O- ring (2 used) 21. Screw (4 used) 39. Seal carrier 3. Plug with O- ring (2 used) 22. Thrust plate 40. Retaining ring 4. Cylinder block assembly 23.
Page 130 Rear Traction Control Manifold RIGHT FRONT Figure 73 1. Rear traction control manifold 9. O- -ring 16. Hydraulic tee fitting 2. Cap screw (2 used) 10. Hydraulic tube 17. O- -ring 3. Flange nut (2 used) 11. O- -ring 18. Hydraulic hose 4.
Page 131 Removal (Fig. 73) Installation (Fig. 73) NOTE: The ports on the rear traction control manifold 1. If fittings were removed from control manifold, lubri- are marked for easy identification of components. Refer cate and place new O--rings onto fittings. Install fittings to the Hydraulic Schematics in Chapter 9 -- Foldout into manifold ports using marks made during the remov- Drawings to identify the function of the hydraulic lines...
Page 132 Rear Traction Control Manifold Service 25 ft- lb 50 ft- lb (67 N- m) (34 N- m) 20 ft- lb (27 N- m) 115 ft- lb (156 N- m) 25 ft- lb (34 N- m) Figure 74 1. Rear traction manifold body 4.
Page 133 Control Manifold Cartridge Valve Service 1. Make sure the control manifold is clean before re- 6. Clean cartridge valve using clean mineral spirits. moving the cartridge valve from the control manifold. Submerge valve in clean mineral spirits to flush out con- tamination.
Page 134 HI/LOW Range Control Manifold RIGHT FRONT Figure 75 1. HI/LOW range control manifold 6. Hydraulic tube 10. Hydraulic tube 2. Cap screw (2 used) 7. O- -ring 11. O- -ring 3. Flange nut (2 used) 8. Hydraulic tube 12. O- -ring 4.
Page 135 Removal (Fig. 75) 30 in- -lb 25 ft- -lb 1. Read the General Precautions for Removing and (3.4 N- -m) (34 N- -m) Installing Hydraulic System Components at the begin- ning of the Service and Repairs section of this chapter. 2.
Page 136: Rear Axle Motor
Rear Axle Motor RIGHT FRONT Figure 78 1. Rear axle motor 7. O- -ring 13. O- -ring 2. O- -ring 8. 90 hydraulic fitting 14. O- -ring 3. Pinion gear 9. Cap screw (2 used) 15. 90 hydraulic fitting 4. External snap ring (2 used) 10.
Page 137 Removal (Fig. 78) Installation (Fig. 78) 1. Park machine on a level surface, lower cutting 1. If fittings were removed from axle motor, lubricate decks, stop engine, engage parking brake and remove and place new O--rings onto fittings. Install fittings into key from the ignition switch.
Page 138: Front Wheel Motors
Front Wheel Motors RIGHT FRONT Figure 79 1. Flange head screw (6 per planetary) 7. Spring plate 13. Piston wheel motor (2 used) 2. Splined brake shaft 8. Compression spring 14. Flat washer (2 per motor) 3. Planetary assembly 9. Jam nut 15.
Page 139 7. Remove and discard O--ring (item 16) from flange of wheel motor. LEFT WHEEL 8. If hydraulic fittings are to be removed from wheel mo- tor, mark fitting orientation to allow correct assembly (Figs. 80 and 81). Remove fittings from motor and dis- card O--rings.
Page 140: Rear Axle And Front Wheel Motor Service
Rear Axle and Front Wheel Motor Service Figure 82 1. Plug with O- -ring 10. Dowel pin 18. Housing 2. Minimum angle stop 11. Bearing 19. Bearing 3. Bias spring 12. Gasket 20. Retaining ring 4. Servo piston 13. Valve plate 21.
Page 141 NOTE: The front wheel motors are identical (shown in REAR AXLE MOTOR FLUSHING VALVE Figure 82). The rear axle motor includes a flushing valve for cooling of the closed loop traction circuit and there- fore has some differences from the front motors (Fig. 83).
Page 142: Cutting Deck Motor
Cutting Deck Motor The hydraulic motors used on all cutting decks are the same. Removal 1. Park machine on a level surface, lower cutting decks, stop engine, engage parking brake and remove key from the ignition switch. 2. Read the General Precautions for Removing and Installing Hydraulic System Components at the begin- ning of the Service and Repairs section of this chapter.
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Page 144: Cutting Deck Motor Service
Cutting Deck Motor Service 33 ft- -lb (45 N- -m) 26 ft- -lb (35 N- -m) 26 ft- -lb (35 N- -m) Figure 86 1. Dust seal (2 used) 8. Front wear plate 14. Rear wear plate 2. Retaining ring 9.
Page 145 5. Remove motor from the vise. Turn motor so that the B. Gear teeth should be free of excessive scoring shaft end is facing down. Remove cap screws. and wear. Any broken or nicked gear teeth must be replaced. 6. Separate rear cover from body. Lift rear cover from motor.
Page 146 Assembly (Fig. 86) 9. Apply a light coating of petroleum jelly to new O-- rings and O--ring grooves in the body. Install new O-- NOTE: When assembling the motor, check the marker rings to the body. line on each part to make sure the parts are properly aligned during assembly.
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Page 148: Deck Control Manifold
Deck Control Manifold GROUNDSMASTER 4500- -D SHOWN RIGHT FRONT Figure 90 1. Deck control manifold 4. Hydraulic oil filter assembly 7. Lift control manifold 2. Filter mount bracket 5. Valve mount bracket 8. Flange head screw (2 used) 3. Flange head screw (2 used) 6.
Page 149 Removal (Fig. 90) 75 ft- -lb 75 ft- -lb 50 ft- -lb (101 N- -m) NOTE: The ports on the deck control manifold are (101 N- -m) (68 N- -m) marked for easy identification of components. Example: P1 is the gear pump connection port (see Hydraulic Schematics in Chapter 9 -- Foldout Drawings to identify the function of the hydraulic lines and cartridge valves at each port).
Page 150 Deck Control Manifold Service (GM 4500- -D) 5 ft- -lb (6.8 N- -m) 20 ft- -lb (27 N- -m) 25 ft- -lb (34 N- -m) 25 ft- -lb (34 N- -m) 20 ft- -lb (27 N- -m) 25 ft- -lb (34 N- -m) 25 ft- -lb (34 N- -m)
Page 151 NOTE: The deck control manifold uses several zero leak plugs. These plugs have a tapered sealing surface 20 ft- -lb on the plug head that is designed to resist vibration in- (27 N- -m) duced plug loosening. The zero leak plugs also have an O--ring as a secondary seal.
Page 152 Deck Control Manifold Service (GM 4700- -D) 5 ft- -lb (6.8 N- -m) 25 ft- -lb 20 ft- -lb (34 N- -m) (27 N- -m) 25 ft- -lb 25 ft- -lb (34 N- -m) (34 N- -m) 5 ft- -lb (6.8 N- -m) 20 ft- -lb 20 ft- -lb...
Page 153 For solenoid and control valve service procedures, see Control Manifold Cartridge Valve Service in this section. 20 ft- -lb Refer to Figures 95 and 96 for cartridge valve and plug (27 N- -m) 20 ft- -lb installation torque. (27 N- -m) IMPORTANT: A pilot piston (item 6) is placed be- neath each of the relief valves in deck control man- ifold ports RV8, RV9, RV10 and RV11.
Page 154: Steering Control Valve
Steering Control Valve RIGHT FRONT 20 to 26 ft- -lb (28 to 35 N- -m) Antiseize Lubricant 7 to 10 ft- -lb (9.5 to 13.5 N- -m) Antiseize Lubricant Figure 97 1. Steering wheel cover 6. Flange head screw (4 used) 11.
Page 155 6. Lubricate new O--rings and connect hydraulic lines CAUTION to fittings on steering control valve (see Hydraulic Hose and Tube Installation in the General Information section of this chapter). Before opening hydraulic system, operate all hy- 7. Position steering column brace (item 12) to machine draulic controls to relieve system pressure and and secure with four (4) flange head screws.
Page 156: Steering Control Valve Service
Steering Control Valve Service 20 to 24 ft- -lb (27 to 33 N- -m) Figure 100 1. Relief valve assembly 9. Cross pin 16. Inner gearwheel 2. Dust seal ring 10. Sleeve 17. End cover 3. Steering valve housing 11. Spool 18.
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Page 158: Steering Cylinder
Steering Cylinder RIGHT 100 to 125 ft- -lb FRONT (136 to 169 N- -m) Figure 101 1. Steering cylinder 7. 90 hydraulic fitting 12. Axle washer 2. Ball joint 8. O- -ring 13. Slotted hex nut 3. Ball joint 9. O- -ring 14.
Page 159 Removal (Fig. 101) Installation (Fig. 101) 1. Park machine on a level surface, lower cutting 1. If fittings were removed from steering cylinder, lubri- decks, stop engine, engage parking brake and remove cate and place new O--rings onto fittings. Install fittings key from the ignition switch.
Page 160: Steering Cylinder Service
Steering Cylinder Service 30 to 36 ft- -lb (41 to 48 N- -m) Figure 102 1. Tube assembly 6. Piston 10. Head 2. Lock nut 7. O- -ring 11. Wiper 3. Seal 8. Back- -up seal 12. Retaining ring 4. O- -ring 9.
Page 161 Disassembly (Fig. 102) Assembly (Fig. 102) 1. Remove oil from steering cylinder into a drain pan by 1. Make sure all cylinder components are clean before slowly pumping the cylinder shaft. Plug both ports and assembly. clean the outside of the cylinder. 2.
Page 162: Engine Cooling Fan Motor
Engine Cooling Fan Motor RIGHT FRONT Figure 103 1. Cap screw (4 used) 9. Radiator/oil cooler assembly 16. Hydraulic tube 2. Fan 10. Air intake hose 17. Hydraulic tube 3. Flange head screw (4 used) 11. Washer (4 used) 18. Hydraulic tube 4.
Page 163 Removal (Fig. 103) 1. Park machine on a level surface, lower cutting RIGHT decks, stop engine, apply parking brake and remove key from the ignition switch. FRONT 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.
Page 164 Installation (Fig. 103) 4. Install upper radiator shroud (Fig. 103): 1. If fittings were removed from fan motor, lubricate and A. Place support shim (item 10) on hydraulic tubes place new O--rings onto fittings. Install fittings into port connected to fan motor. openings.
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Page 166: Engine Cooling Fan Motor Service
Engine Cooling Fan Motor Service 33 ft- -lb (45 N- -m) Figure 105 1. Flange washer 7. Shaft seal 12. Idler gear 2. O- -ring 8. Backup gasket 13. Cap screw (4 used) 3. Front flange 9. Pressure seal 14. Dowel (2 used) 4.
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Page 168: Fan Control Manifold
Fan Control Manifold RIGHT FRONT Figure 107 1. Fan control manifold 6. Deck manifold (GM 4500- -D shown) 10. Hydraulic tube 2. Support bracket 7. Hydraulic hose 11. Hydraulic tube 3. Flange head screw (2 used) 8. Hydraulic hose 12. Hydraulic tube 4.
Page 169 Removal (Fig. 107) 50 ft- -lb NOTE: The ports on the fan control manifold are (68 N- -m) marked for easy identification of components. Example: P1 is the gear pump connection port (see Hydraulic Schematics in Chapter 9 -- Foldout Drawings to identify the function of the hydraulic lines and cartridge valves at each manifold port).
Page 170: Fan Control Manifold Service
Fan Control Manifold Service 5 ft- -lb 5 ft- -lb 50 ft- -lb (6.8 N- -m) (6.8 N- -m) (68 N- -m) 25 ft- -lb (34 N- -m) 25 ft- -lb (34 N- -m) 25 ft- -lb (34 N- -m) 25 ft- -lb (34 N- -m) 20 ft- -lb...
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Page 172: Lift Control Manifold
Lift Control Manifold GROUNDSMASTER 4500- -D SHOWN RIGHT FRONT Figure 110 1. Deck control manifold 4. Hydraulic oil filter assembly 7. Lift control manifold 2. Filter mount bracket 5. Valve mount bracket 8. Flange head screw (2 used) 3. Flange head screw (2 used) 6.
Page 173 Removal (Fig. 110) 4. Connect wire harness electrical connectors to the solenoid valve coils. 1. Park machine on a level surface, lower cutting decks, stop engine, apply parking brake and remove 5. Lower and secure operator seat. key from the ignition switch. IMPORTANT: To prevent unexpected deck lower- GROUNDSMASTER 4500- -D ing, make sure that cutting decks are fully lowered...
Page 174 Lift Control Manifold Service (GM 4500- -D) 5 ft- -lb (6.8 N- -m) 5 ft- -lb (6.8 N- -m) 25 ft- -lb (34 N- -m) 20 ft- -lb (27 N- -m) 25 ft- -lb (34 N- -m) 20 ft- -lb (27 N- -m) 20 ft- -lb (27 N- -m)
Page 175 NOTE: The lift control manifold includes several zero For solenoid and control valve service procedures, see leak plugs. These plugs have a tapered sealing surface Control Manifold Cartridge Valve Service in this section. on the plug head that is designed to resist vibration in- Refer to Figure 113 for cartridge valve and plug installa- duced plug loosening.
Page 176 Lift Control Manifold Service (GM 4700- -D) 20 ft- -lb (27 N- -m) 25 ft- -lb 5 ft- -lb (34 N- -m) (6.8 N- -m) 20 ft- -lb (27 N- -m) 20 ft- -lb (27 N- -m) 5 ft- -lb (6.8 N- -m) 25 ft- -lb (34 N- -m)
Page 177 NOTE: The lift control manifold uses several zero leak 25 ft- -lb 25 ft- -lb plugs. These plugs have a tapered sealing surface on 20 ft- -lb (34 N- -m) (34 N- -m) the plug head that is designed to resist vibration induced (27 N- -m) plug loosening.
Page 178: Lift Circuit Junction Manifold
Lift Circuit Junction Manifold RIGHT FRONT Figure 116 1. Lift circuit junction manifold 3. HI/LOW range control manifold 4. Rear traction control manifold 2. Flange head screw (2 used) Hydraulic System Page 4 - - 138 Groundsmaster 4500--D/4700--D...
Page 179 Removal (Fig. 116) 2. Install hydraulic manifold to the frame using Figure 116 as guide. 1. Park machine on a level surface, lower cutting decks, stop engine, engage parking brake and remove 3. Remove caps and plugs from fittings and hydraulic key from the ignition switch.
Page 180 Lift Cylinders: Decks #1, #4 and #5 RIGHT FRONT Figure 119 1. Lift arm (deck #4) 5. Flange head screw 9. Lift arm (deck #5) 2. Flange nut 6. O- -ring 10. Lift cylinder (decks #4 and #5) 3. Lift arm (deck #1) 7.
Page 181 Removal (Fig. 119) Installation (Fig. 119) 1. Park machine on a level surface, lower cutting 1. If fittings were removed from lift cylinder, lubricate decks, stop engine, engage parking brake and remove and place new O--rings onto fittings. Install fittings into key from the ignition switch.
Page 182 Lift Cylinders: Decks #2 and #3 RIGHT FRONT Figure 121 1. Flange head screw 6. Cylinder pin 10. Hydraulic fitting 2. Flange nut 7. Lift arm (deck #2) 11. O- -ring 3. Cylinder pin 8. Lift arm (deck #3) 12. 90 hydraulic fitting 4.
Page 183 Removal (Fig. 121) 2. Position cylinder barrel clevis to frame and insert cyl- inder pin (item 6) with one (1) retaining ring installed 1. Park machine on a level surface, lower cutting through the frame and cylinder clevis. Secure pin with decks, stop engine, engage parking brake and remove second retaining ring.
Page 184 Lift Cylinders: Decks #6 and #7 (GM 4700- -D) RIGHT FRONT Figure 123 1. Lift cylinder 6. Retaining ring 10. O- -ring 2. Lock nut (2 used per side) 7. Cylinder pin 11. Lift arm assembly (deck #6 shown) 3. Rear link 8.
Page 185 Removal (Fig. 123) 2. Position cylinder barrel clevis to lift arm and insert cylinder pin (item 7) into lift arm support and cylinder 1. Park machine on a level surface, lower cutting clevis. Secure pin with retaining ring (item 6). Make sure decks, stop engine, engage parking brake and remove that retaining ring is fully installed in groove in pin.
Page 186: Lift Cylinder Service
Lift Cylinder Service See text for torque specification Figure 125 1. Tube assembly 6. O- -ring 11. Head 2. Lock nut 7. O- -ring 12. Wiper 3. Wear ring 8. Back- -up ring 13. Rod assembly 4. Seal 9. Seal 14.
Page 187 Disassembly (Fig. 125) Assembly (Fig. 125) 1. Remove oil from lift cylinder into a drain pan by slowly 1. Make sure all cylinder components are clean before pumping the cylinder shaft. Plug both ports and clean assembly. the outside of the cylinder. 2.
Page 188: Hydraulic Reservoir
Hydraulic Reservoir RIGHT FRONT 35 to 47 ft- -lb (48 to 63 N- -m) Figure 126 1. Plug 9. O- -ring 17. Bumper 2. O- -ring 10. Straight hydraulic fitting 18. Flat washer 3. Dipstick 11. O- -ring 19. O- -ring 4.
Page 189 Removal (Fig. 126) Inspection 1. Park machine on a level surface, lower cutting 1. Clean hydraulic reservoir and suction strainer with decks, stop engine, engage parking brake and remove solvent. key from the ignition switch. 2. Inspect reservoir for leaks, cracks or other damage. 2.
Page 190 Radiator and Oil Cooler Assembly RIGHT FRONT Figure 127 1. Radiator/oil cooler assembly 18. Flange head screw (4 used) 35. Coolant reservoir 2. Cap screw (4 used) 19. Hydraulic tube 36. R- -clamp (2 used) 3. Washer (4 used) 20. Hydraulic tube 37.
Page 191 NOTE: The hydraulic oil cooler on your Groundsmaster is combined with the radiator. See Radiator and Oil Cooler Assembly in the Service and Repairs section of Chapter 3 -- Diesel Engine for information on removal and installation of the radiator/oil cooler assembly. Figure 128 1.
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Page 193 Cutting Deck Lift Switches ....Toro Electronic Controllers (TEC) ... . . Headlight Switch .
Page 194: General Information
Groundsmaster 4500--D and 4700--D machines are lo- cated in Chapter 9 -- Foldout Drawings. Toro Electronic Controllers (TEC) Groundsmaster 4500--D machines use a single Toro Electronic Controller (TEC--5002) to manage machine electrical functions. Groundsmaster 4700--D machines uses two (2) TEC controllers for machine operation (TEC--5002 and TEC--5001).
Page 195: Yanmar Engine Electronic Control Unit (Ecu)
Yanmar Engine Electronic Control Unit (ECU) The Yanmar engine that powers the Groundsmaster 4500--D and 4700--D uses an electronic control unit (ECU) for engine management and also to communi- cate with the TEC controllers and the InfoCenter Display on the machine. All engine ECU electrical connectors should be plugged into the controller before the machine ignition switch is moved from the OFF position to either the ON or START position.
Page 196: Yanmar Engine Electrical Components
CAN- -bus Communications The Toro TEC controller(s), the Yanmar Engine Control- CAN identifies the Controller Area Network that is used ler and the InfoCenter Display used on the Ground- between the controllers on the Groundsmaster. Two (2) smaster 4500--D and 4700--D communicate with each specially designed, twisted wires form the bus.
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Page 198: Special Tools
The multimeter can test electrical components and cir- cuits for current (amps), resistance (ohms) or voltage. Obtain this tool locally. NOTE: Toro recommends the use of a DIGITAL Volt-- Ohm--Amp multimeter when testing electrical circuits. The high impedance (internal resistance) of a digital me- ter in the voltage mode will make sure that excess cur- rent is not allowed through the meter.
Page 199 Battery Hydrometer Use the battery hydrometer when measuring specific gravity of battery electrolyte. Obtain this tool locally. Figure 7 Groundsmaster 4500--D/4700--D Page 5 - - 7 Electrical System...
Page 200: Infocenter Display
InfoCenter Display The InfoCenter Display used on your Groundsmaster is Power for the InfoCenter is available when energized by a LCD device that is located on the console. The Info- the TEC controller (ignition switch in the START or ON Center provides information for the machine operator position).
Page 201 Main Information Screens The two (2) InfoCenter main information screens (Figs. 10 and 11) are displayed after the initial splash screens have been displayed for several seconds. During nor- mal machine operation, the main information screens provide machine information for the operator. Toggling between the main information screens is done by press- ing the right button on the InfoCenter.
Page 202: Main Menu Screen
Main Menu Screen The main menu screen can be accessed from the Info- Center main information or splash screen by pressing and releasing the menu/back button (left button) on the display. Once to the main menu screen (Fig. 12), naviga- Main Menu Faults tion to the five (5) different menu items can occur.
Page 203 Service Screen The service screen (Fig. 14) contains machine opera- D Fan - - Oil identifies the number of times that hydraul- tional information including hours and counts. Values ic oil temperature caused the fan speed to change. listed for these service menu items cannot be changed. The protected menu items include the following: If the machine PIN has been entered to allow access to protected menu items in the settings screen, the protec-...
Page 204: Diagnostics Screen
Diagnostics Screen The diagnostics screen (Fig. 15) lists the various states D Hi/Low Range identifies machine requirements to of machine electrical components. The diagnostics allow high or low speed range to be engaged. Inputs in- screen should be used to check operation of machine dicate whether the PTO is off and the state of the hi/low controls and to verify that switches and circuit wiring are switch.
Page 205 NOTE: The initial PIN will either be 1234 or 0000. If the PIN has been changed and is forgotten, a temporary PIN can be obtained from your Toro distributor. Protect settings allows the settings for auto idle, mow speed, transport speed and counterbalance to be hid-...
Page 206: About Screen
About Screen The about screen (Fig. 18) identifies the machine model number, serial number and software revisions for the TEC controllers, InfoCenter and engine electronic con- trol unit (if available). The about screen also lists the About CAN--bus status. Additional information is identified if Model: 30882 313000103...
Page 207: Troubleshooting
Troubleshooting For effective troubleshooting and repairs, there must be a good understanding of the electrical circuits and com- CAUTION ponents used on this machine. If the machine has any interlock switches by--passed, Remove all jewelry, especially rings and reconnect the switches for proper safety and trouble- watches, before doing any electrical trouble- shooting.
Page 208: Fault Codes
Main power relay is faulty Ignition switch was held in the START position for more than 30 seconds or the ignition switch is faulty TEC software needs to be reprogrammed (contact Toro Distributor) Alternator charging is too high Alternator charging is too low...
Page 209 Fault Code Fault Description Forward piston (traction) pump output has open or short to ground Reverse piston (traction) pump output has open or short to ground Reverse engine cooling fan output has open or short to ground LH PTO output has open or short to ground RH PTO output has open or short to ground Solenoid valve S1 (GM 4700--D lift/lower enable) output has open or short to ground...
Page 210: Starting Problems
Starting Problems NOTE: Check InfoCenter Display for possible operator advisories or faults whenever diagnosing machine elec- trical problems. Problem Possible Causes No electrical power to machine (including gauges). Battery is discharged. Battery cables are loose or corroded. Fuse D--1 (2 Amp) is faulty. Fuse D--2 (2 Amp) is faulty.
Page 211 Starting Problems (continued) Problem Possible Causes Engine cranks, but does not start. Fuel tank is empty. Engine is not cranking fast enough. Fuel pump or circuit wiring is faulty. Engine or fuel system is malfunctioning (see Yanmar Service Manual). Starter cranks, but should not when the traction pedal Traction pedal position sensor is out of adjustment.
Page 212: Cutting Deck Operating Problems
Cutting Deck Operating Problems NOTE: Check InfoCenter Display for possible operator advisories or faults whenever diagnosing machine elec- trical problems. Problem Possible Causes Cutting decks run, but should not, when raised. Decks The cutting deck position switch or circuit wiring is shut off with PTO switch.
Page 213: Cutting Deck Lift/Lower Problems
Cutting Deck Lift/Lower Problems NOTE: Check InfoCenter Display for possible operator NOTE: To lower a cutting deck, the operator must be in advisories or faults whenever diagnosing machine elec- the operator seat and the traction speed must be in the trical problems.
Page 214 Cutting Deck Lift/Lower Problems (Continued) Problem Possible Causes On Groundsmaster 4700--D, center cutting decks will The center deck lift switch or circuit wiring is faulty. not raise or lower, but both wing cutting decks will Fuse(s) for TEC controller are faulty (fuse C--1). raise and lower.
Page 215: Electrical System Quick Checks
Replace any malfunctioning switches before op- ter. erating the machine. NOTE: Use the InfoCenter Display (see InfoCenter Display in this chapter) to test Toro Electronic Controller inputs and outputs before further troubleshooting of an electrical problem on your Groundsmaster. Groundsmaster 4500--D/4700--D...
Page 216: Adjustments
Adjustments Traction Pedal Adjustment The traction pedal includes a neutral assembly that is used to adjust the traction neutral position (Fig. 19). Traction pedal adjustment may be necessary to make sure that traction pedal movement provides the correct full reverse and full forward positions for the traction pedal position sensor.
Page 217 6. After any adjustment of the spring shaft and rod end bearing, use the InfoCenter Display Diagnostics menu to obtain and select the Traction Pedal menu item (see InfoCenter Display in this chapter). Choose Outputs and Traction Pedal the InfoCenter display will identify the traction pedal po- Forward Range: sition (Fig.
Page 218: Traction Pedal Position Sensor Calibration
Traction Pedal Position Sensor Calibration IMPORTANT: A properly installed and calibrated traction pedal position sensor is critical to accurate traction system response and for reliable sensor life. Use care when removing, installing and cali- brating the traction pedal position sensor. Calibration of the traction pedal position sensor ensures that the TEC controller can identify the traction neutral, forward and reverse positions.
Page 219: Component Testing
Component Testing For accurate resistance and/or continuity checks, elec- CAUTION trically disconnect the component being tested from the circuit (e.g. unplug the ignition switch connector before checking continuity of the switch terminals). When testing electrical components for continu- NOTE: For engine component testing information, see ity with a multimeter (ohms setting), make sure the Yanmar Service Manual and Yanmar Troubleshoot- that power to the circuit has been disconnected.
Page 220: Fuses
Fuses Groundsmaster 4500--D and 4700--D use numerous Fuse D--1 (2 Amp) protects logic power circuits for the fuses for circuit protection. The fuses reside in the power ignition switch and TEC--5002 controller. center behind the operator’s seat. Fuse D--2 (2 Amp) protects logic power circuits for the Fuse Identification and Function (Fig.
Page 221: Fusible Link Harness
Fusible Link Harness Your Groundsmaster uses two (2) fusible links for circuit protection. These fusible links are located in a harness that connects the starter B+ terminal to the wire harness (Fig. 28). If either of these links should fail, current to the protected circuits will cease.
Page 222: Pto Switch
PTO Switch The two position PTO switch is located on the console 5. If PTO switch tests correctly and circuit problem still arm (Fig. 30). The PTO switch is pulled up to engage the exists, check wire harness (see Electrical Schematics PTO and pushed in to disengage the PTO.
Page 223: Hi/Low Speed, Engine Speed Request And Cutting Deck Lift Switches
Hi/Low Speed, Engine Speed Request and Cutting Deck Lift Switches The Hi/Low speed, engine speed request and cutting SWITCH CLOSED OPEN deck lift switches are all identical. These switches are POSITION CIRCUITS CIRCUITS located on the console arm (Fig. 32). FRONT OF 2 + 3 2 + 1...
Page 224: Headlight Switch
Headlight Switch The headlight switch is located on the operator side of the console arm (Fig. 34). This two (2) position rocker switch allows the headlights to be turned on and off. Testing 1. Park machine on a level surface, lower cutting decks, engage parking brake and stop engine.
Page 225: Seat Switch
Seat Switch The seat switch is normally open and closes when the operator is on the seat. The seat switch and its electrical connector are located in the seat assembly. If the trac- tion system or PTO switch is engaged when the operator raises out of the seat, an operator advisory will be dis- played on the InfoCenter.
Page 226: Parking Brake Switch
Parking Brake Switch The parking brake switch is a normally open proximity switch. The parking brake switch is attached to the bot- tom of the RH brake pedal (Fig. 37). When the parking brake is not applied, the parking brake detent is positioned near the target end of the parking brake switch so the switch is closed.
Page 227: Cutting Deck Position Switches
Cutting Deck Position Switches The cutting deck position switches are normally open proximity switches that are located on the traction unit frame (Fig. 39). The sensing plate is located on the cut- ting deck lift arm. The Groundsmaster 4500--D uses two (2) cutting deck position switches: for decks 4 and 5.
Page 228: Relays With Four (4) Terminals
Relays with Four (4) Terminals Your Groundsmaster uses a number of electrical relays that have four (4) terminals. A tag near the wire harness relay connector can be used to identify each relay. The main power relay is used to provide current to most of the fuse protected circuits (operator seat, InfoCenter display, engine electronic control unit (ECU), power point and optional electric equipment).
Page 229 6. Connect multimeter (ohms setting) leads to relay ter- minals 30 and 87. Ground terminal 86 and apply +12 VDC to terminal 85. The relay should make and break continuity between terminals 30 and 87 as +12 VDC is applied and removed from terminal 85. 7.
Page 230: Relays With Five (5) Terminals
Relays with Five (5) Terminals Your Groundsmaster uses a number of electrical relays 9. After testing, disconnect voltage and multimeter test that have five (5) terminals. A tag near the wire harness leads from the relay terminals. Secure relay to mounting relay connector can be used to identify each relay.
Page 231: Traction Pedal Position Sensor
Traction Pedal Position Sensor The traction pedal position sensor is connected to the traction pedal assembly (Fig. 46). This position sensor determines the neutral band for the traction pedal, the direction of travel desired by the operator and the trac- tion speed.
Page 232: Toro Electronic Controllers (Tec)
Toro Electronic Controllers (TEC) Groundsmaster 4500--D and 4700--D machines use a Toro Electronic Controller (TEC--5002) to control electri- cal system operation. Groundsmaster 4700--D ma- chines use an additional TEC--5001 controller for electrical control of the rear cutting decks (PTO and lift/ lower functions).
Page 233 Groundsmaster 4700--D are matched for correct ma- Figure 49 chine operation. If either of these components are re- placed for any reason, system software needs to be reprogrammed by your Toro Distributor. WIRE HARNESS CONNECTOR FOR TEC- -5002 CONTROLLER IMPORTANT: Before performing welding on the ma-...
Page 234: Hydraulic Solenoid Valve Coils
Hydraulic Solenoid Valve Coils GROUNDSMASTER 4500- -D SHOWN RIGHT FRONT Figure 51 1. Deck control manifold 3. Fan control manifold 4. HI/LOW range control manifold 2. Lift control manifold Numerous hydraulic solenoid valve coils are used on NOTE: To assist in troubleshooting, identical solenoid the hydraulic control manifolds of Groundsmaster coils can be exchanged.
Page 235 Solenoid Coil Testing 1. Park machine on a level surface, lower cutting decks, stop engine, engage parking brake and remove key from the ignition switch. 2. Locate hydraulic solenoid valve coil to be tested (Fig. 51). 3. Disconnect wire harness connector from solenoid valve coil.
Page 236: Piston (Traction) Pump Control Solenoid Coils
Piston (Traction) Pump Control Solenoid Coils The piston (traction) pump uses an electronic control as- C. Slide new coil with O--rings onto the solenoid sembly for swash plate rotation. Electrical outputs from stem. the machine TEC controller are provided to two (2) D.
Page 237: Hydraulic Oil Temperature Sender
Hydraulic Oil Temperature Sender A temperature sender is used as an input for the TEC 5. Check resistance of the sender with a multimeter controller to identify if the hydraulic oil temperature has (ohms setting) as the oil temperature increases. reached an excessive level.
Page 238: Fuel Pump (Models 30873 And 30874)
Fuel Pump (Models 30873 and 30874) The fuel pump is attached to the air cleaner mount below the fuel water separator (Fig. 57). FRONT Operational Test 1. Park machine on a level surface, lower cutting decks, stop engine and apply parking brake. Raise hood to access fuel pump.
Page 239: Fuel Pump (Models 30881 And 30882)
Fuel Pump (Models 30881 and 30882) The fuel pump is attached to the air cleaner mount below FRONT the fuel water separator (Fig. 58). Operational Test 1. Park machine on a level surface, lower cutting decks, stop engine and apply parking brake. Raise hood to access fuel pump.
Page 240: Can--Bus Termination Resistor
CAN- -bus Termination Resistor System communication between electrical components on Groundsmaster 4500--D and 4700--D machines is Termination accomplished on a CAN--bus communication system. Resistor Two (2) specially designed, twisted cables form the bus for the network used on the machine. These wires pro- vide the data pathways between machine components.
Page 241: Diode Assemblies
(see engine wire harness drawing in Chapter 9 -- Foldout Drawings). The resistor assemblies can be identified by their gray color, resistor symbol and Toro part number on the end of the resistor assembly body. Testing The resistor can be tested using a digital multimeter (ohms setting).
Page 242: Service And Repairs
B. Coat battery posts and cable connectors with bat- chine is stored in a location where temperatures are ex- tery terminal protector (Toro Part No. 107--0392) or tremely high, the battery will discharge more rapidly petroleum jelly to prevent corrosion.
Page 243: Battery Service
Battery Service The battery is the heart of the electrical system. With regular and proper service, battery life can be extended. Additionally, battery and electrical component failure can be prevented. CAUTION When working with batteries, use extreme cau- tion to avoid splashing or spilling electrolyte. Electrolyte can destroy clothing and burn skin or eyes.
Page 244: Battery Testing
Battery Testing C. Make sure battery terminals are free of corrosion. 1. Conduct a hydrometer test of the battery electrolyte. D. Measure the temperature of the center battery cell. IMPORTANT: Make sure the area around the cells is clean before opening the battery caps. E.
Page 245: Battery Charging
Battery Charging CAUTION To minimize possible damage to the battery and allow the battery to be fully charged, the slow charging meth- od is presented here. This charging method can be ac- Do not charge a frozen battery because it can ex- complished with a constant current battery charger plode and cause injury.
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Page 247 Chapter 6 Axles, Planetaries and Brakes Table of Contents SPECIFICATIONS ......GENERAL INFORMATION .
Page 248: Specifications
Specifications Item Specification Tire pressure (front and rear) 20 psi (138 kPa) Rear wheel toe--in 0.125 in (3 mm) Wheel lug nut torque (front and rear) 85 to 100 ft--lb (116 to 135 N--m) Steering cylinder bolt torque 100 to 125 ft--lb (136 to 169 N--m) Planetary wheel drive mounting screw torque 75 to 85 ft--lb (102 to 116 N--m) Brake housing mounting screw torque...
Page 249: General Information
General Information Operator’s Manual The Traction Unit Operator’s Manual provides informa- tion regarding the operation, general maintenance and maintenance intervals for your Groundsmaster ma- chine. Refer to this publication for additional information when servicing the machine. Groundsmaster 4500--D/4700--D Page 6 - - 3 Axles, Planetaries and Brakes...
Page 250: Adjustments
Adjustments Planetary Wheel Drive End Play A front planetary wheel drive assembly that is properly 3. Grasp front wheel and check for endplay in the plan- operating should have no endplay. Any endplay in a etary assembly as indicated by axial wheel movement. planetary assembly indicates that there are potential Make sure that there is no endplay in assembly.
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Page 252: Service And Repairs
Service and Repairs Brake Assembly 75 to 85 ft- -lb (102 to 116 N- -m) RIGHT 75 to 85 ft- -lb (102 to 116 N- -m) 85 to 100 ft- -lb FRONT (116 to 135 N- -m) Figure 1 1. Flange head screw (6 per planetary) 7.
Page 253 Brake Assembly Removal (Fig. 1) 1. Park machine on a level surface and raise cutting decks to allow easier access to front brake assembly. Stop engine, engage parking brake and remove key from the ignition switch. 2. Drain oil from planetary wheel drive/brake assembly (Figs.
Page 254 4. Install flange head screws (item 11) to secure brake assembly to frame. Tighten screws in a crossing pattern to a torque from 75 to 85 ft- -lb (102 to 116 N- -m). 5. Install brake cable to pull rod on brake assembly. Brake cable end should be completely threaded onto pull rod before tightening jam nut.
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Page 256: Brake Inspection And Repair
Brake Inspection and Repair Figure 6 1. Brake housing (LH shown) 6. Hitch pin (2 used) 11. Rotating actuator 2. Seal 7. Stationary disc (4 used) 12. Extension spring (3 used) 3. Pull rod 8. Rotating disc (3 used) 13. Ball (3 used) 4.
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Page 258: Planetary Wheel Drive Assembly
Planetary Wheel Drive Assembly 75 to 85 ft- -lb (102 to 116 N- -m) RIGHT 75 to 85 ft- -lb (102 to 116 N- -m) 85 to 100 ft- -lb FRONT (116 to 135 N- -m) Figure 7 1. Flange head screw (6 per planetary) 7.
Page 259 4. Remove front wheel assembly. 5. Remove hydraulic wheel motor (see Front Wheel Motors in the Service and Repairs section of Chapter 4 -- Hydraulic System). 6. Remove brake assembly (see Brake Assembly in this section). 7. Support planetary assembly to prevent it from falling. Loosen and remove six (6) flange head screws that se- cure planetary assembly to frame.
Page 260: Planetary Wheel Drive Service
Planetary Wheel Drive Service 118 to 144 in- -lb (13.3 to 16.3 N- -m) Figure 11 1. Spindle 11. Outer bearing cup 20. End cap 2. Boot seal 12. Outer bearing cone 21. Thrust plug 3. Oil seal 13. O- -ring 22.
Page 261 NOTE: The planetary wheel drive assembly can be ser- viced with the planetary installed to machine. If the spindle (item 1) needs to be removed from machine, see Planetary Wheel Drive Assembly in this section. Disassembly (Figs. 11 and 12) 1.
Page 262 F. Lightly oil bearing journals on spindle shaft. Slide 5. If primary gear (item 24) was removed from drive housing assembly onto spindle (item 1) taking care shaft, slide gear onto shaft and secure with retaining ring to not damage seal or spindle. Make sure that inner (item 23).
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Page 264: Rear Axle Assembly
Rear Axle Assembly 70 ft- -lb (94 N- -m) maximum 85 to 100 ft- -lb (116 to 135 N- -m) RIGHT 85 to 100 ft- -lb (116 to 135 N- -m) FRONT Figure 13 1. Rear axle motor 15. 90 hydraulic fitting 29.
Page 265 Remove Rear Axle (Fig. 13) 1. Park machine on a level surface, lower cutting decks, stop engine, engage parking brake and remove key from the ignition switch. 2. Drain oil from rear axle and rear axle gearbox (Figs. 14 and 15). CAUTION Figure 14 1.
Page 266 2. If removed, install the tie rod to rear axle (Fig. 16). Tighten ball joint castle nuts and install new cotter pins. 3. Support axle under machine with a jack. Position axle assembly to rear frame mount. 4. Install rear axle pivot pin to secure axle to frame. Make sure to install thrust washer (item 42) between axle pivot and frame on both ends of the pivot.
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Page 268: Rear Axle Service
Rear Axle Service Figure 19 Axles, Planetaries and Brakes Page 6 - - 22 Groundsmaster 4500--D/4700--D...
Page 269 Figure 12 (Continued) 1. LH axle support 23. RH axle support 44. Bevel gear (17 tooth) 2. Flange bushing (2 used) 24. Input shaft assembly 45. Bevel gear shaft 3. Axle vent 25. Bolt (8 used) 46. Axle case (LH shown) 4.
Page 270: Bevel Gear Case And Axle Case
Bevel Gear Case and Axle Case The following procedures assume the rear axle assem- 35 to 41 ft- -lb bly has been removed from the machine. (47 to 56 N- -m) Removal 1. Remove the mounting screws, nuts and lock wash- ers.
Page 271 5. Remove the knuckle pin mounting screws and the 17 to 20 ft- -lb knuckle pin. Remove the gasket and any remaining gas- (23 to 27 N- -m) ket material from either mating surface (Fig. 23). 6. While holding the bevel gear case, tap the upper end of the bevel gear shaft out of the upper bearing and up- per bevel gear.
Page 272 Installation 1. Coat new shaft seal with grease and install in axle case as shown (Fig. 25). Figure 25 1. Axle case 3. Shaft seal 2. Bevel gear case 2. Install the lower bevel gear and bevel gear shaft in the axle case cover.
Page 273 5. Determine necessary quantity of support shims. 57 to 67 ft- -lb A. Lubricate the axle case support bushing with a (77 to 91 N- -m) thin coat of grease and slide axle case support onto knuckle pin. B. Position support shims that were removed during VERTICAL disassembly between axle case support and axle ENDPLAY...
Page 274: Differential Shafts
9. Remove the bevel gear case/axle case assembly NOTE: Axle bearing shims are available in 0.008 in. from the axle support. Coat a new O-ring with grease (0.2 mm), 0.012 in. (0.3 mm) and 0.020 in. (0.5 mm) and temporarily install the axle cover assembly. Position thickness.
Page 275: Axle Shafts
Axle Shafts The following procedures assume the rear axle assem- 17 to 20 ft- -lb bly has been removed from the machine. (23 to 27 N- -m) Removal 1. Remove the axle cover mounting screws. Remove the axle cover from the axle case as an assembly (Fig.
Page 276: 11. Input Shaft/Pinion Gear
Input Shaft/Pinion Gear 35 to 41 ft- -lb (47 to 56 N- -m) 35 to 41 ft- -lb (47 to 56 N- -m) Figure 35 1. Nut (2 used) 8. Seal collar 15. Gear case 2. Lock washer (2 used) 9.
Page 277 5. Install a new stake washer. Install the lock nut finger tight. 6. Set the bearing preload by securing the bearing case in a vise. Thread a M12 x 1.5 hex head cap screw into the splined end of the input shaft/pinion gear and slowly 0.040 in.
Page 278: Differential Gear
Differential Gear The following procedures assume the rear axle assem- 35 to 41 ft- -lb bly has been removed from the machine. (47 to 56 N- -m) Removal 1. Remove bevel gear case/axle case assemblies (see Bevel Gear Case/Axle Case Assembly in this section of this manual).
Page 279 Inspection 1. Measure the differential side gear O.D. and the dif- ferential case I.D. to determine the side gear to case clearance (Fig. 42). Replace components as necessary. SIDE GEAR TO CASE CLEARANCE: 0.002 to 0.012 in. (0.05 to 0.30 mm) SIDE GEAR O.D.
Page 280 Installation 1. If the ring gear was removed from the differential case, use medium strength Loctite thread locker and tighten the mounting screws from 22 to 25 ft-lb (30 to 34 N- -m). 2. Apply molybdenum disulfide lubricant (Three Bond 1901 or equivalent) to the splines and bearing surfaces of the differential pinion gears, pinion washers and side gears.
Page 281: Pinion Gear To Ring Gear Engagement
Pinion Gear to Ring Gear Engagement The final position of the pinion gear is verified by using PROFILE the gear contact pattern method as described in the fol- TOP LAND lowing procedure. GEAR TOOTH DEFINITIONS (Fig. 46): Toe -- the portion of the tooth surface at the end to- LENGTHWISE wards the center.
Page 282 Gear Pattern Movement Summary Heel Contact Base Contact Every gear has a characteristic pattern. The illustrations show typical patterns only and explain how patterns shift as gear location is changed. 1. If contact is toward the heel or base of the gear (Fig. 49): A.
Page 283 Chapter 7 Chassis Table of Contents GENERAL INFORMATION ..... Operator’s Manual ......Cutting Deck Identification .
Page 284: General Information
General Information Operator’s Manual The Traction Unit and Cutting Deck Operator’s Manuals provide information regarding the operation, general maintenance and maintenance intervals for your Groundsmaster machine. Refer to these publications for additional information when servicing the machine. Cutting Deck Identification Cutting decks on the Groundsmaster 4500--D and 4700--D are identified as shown in Figure 1.
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Page 286: Service And Repairs
Service and Repairs Steering Column RIGHT FRONT 20 to 26 ft- -lb (28 to 35 N- -m) Antiseize Lubricant 7 to 10 ft- -lb (9.5 to 13.5 N- -m) Antiseize Lubricant Figure 2 1. Steering wheel cover 5. Socket head screw (4 used) 9.
Page 287 9. Loosen and remove four (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. 11.
Page 288: Traction Pedal
Traction Pedal RIGHT FRONT Figure 5 Washer head screw (2 used) 12. Cap screw (4 used) 23. Spring retainer Reverse pedal pad 13. Flange bearing mount 24. Compression spring Pedal assembly 14. Flange nut (2 used) 25. Flat washer Spring pin 15.
Page 289 IMPORTANT: A properly assembled and calibrated 3. Plug machine wire harness connector into traction traction pedal position sensor is critical to accurate pedal position sensor (item 29 in Fig. 5). traction system response and for reliable sensor 4. After assembly of the traction pedal, calibrate the life.
Page 290: Console Arm
Console Arm RIGHT FRONT Figure 8 1. Console arm frame 15. Flange nut (2 used) 29. Headlight switch 2. LH cover 16. Flange head screw (2 used) 30. Screw (2 used) 3. RH cover 17. Flange nut (2 used) 31. Bag holder 4.
Page 291 Disassembly (Fig. 8) 1. Park machine on a level surface, lower cutting decks, stop engine and engage parking brake. Remove key from ignition switch. 2. Remove two (2) flange head screws (item 8) and then cover plate (item 7) from outside of console arm. Locate and retrieve two (2) flange spacers (item 36).
Page 292: Lift Arms For Cutting Decks #1, #4 And #5
Lift Arms for Cutting Decks #1, #4 and #5 RIGHT FRONT Figure 10 1. Flat washer 13. Slotted roll pin 25. Deck position switch 2. Flange nut 14. Lift cylinder pin 26. Switch plate 3. Lift arm (#1 deck) 15. Flange nut 27.
Page 293 5. Loosen and remove lock nut (item 11) from lift arm pivot pin. #4 Deck #1 Deck #5 Deck 6. Support lift arm and pull lift arm pivot pin from lift arm and frame. Locate and remove thrust washers from both sides of lift arm during pivot pin removal.
Page 294: Lift Arms For Cutting Decks #2 And #3
Lift Arms for Cutting Decks #2 and #3 RIGHT FRONT Loctite #242 Figure 13 1. Grease fitting 7. Pivot pin 13. Flange nut 2. Set screw (2 used per stop) 8. Bumper 14. Thrust washer 3. Rotation stop 9. Thrust washer 15.
Page 295 Removal (Fig. 13) NOTE: Install thrust washer (item 9) on deck pivot shaft before installing cutting deck on pivot shaft. 1. Park machine on a level surface, lower cutting decks, stop engine, engage parking brake and remove 5. Position and install cutting deck to lift arm (see Cut- key from the ignition switch.
Page 296: Lift Arms For Cutting Decks #6 And #7 (Groundsmaster 4700--D)
Lift Arms for Cutting Decks #6 and #7 (Groundsmaster 4700- -D) 135 to 165 ft- -lb (184 to 223 N- -m) 135 to 165 ft- -lb (184 to 223 N- -m) RIGHT FRONT Figure 15 1. Retaining ring 15. Thrust washer 29.
Page 297 Removal (Fig. 15) 1. Park machine on a level surface, lower cutting #4 Deck #1 Deck #5 Deck decks, stop engine, engage parking brake and remove key from the ignition switch. 2. Remove cutting deck from lift arm (see Cutting Deck Operator’s Manual).
Page 298: Operator Seat
Operator Seat RIGHT FRONT Figure 17 1. Seat frame 12. Hair pin 23. Arm support 2. Seat plate 13. Seat pivot shaft 24. Support bracket 3. Torsion spring 14. Screw (2 used) 25. Manual tube 4. Seat plate latch 15. Flat washer (2 used) 26.
Page 299 Removal (Fig. 17) 3. Position and secure console arm assembly to seat. Install all fasteners before fully tightening them. 1. Park machine on a level surface, lower cutting decks, stop engine, apply parking brake and remove A. Secure support bracket (item 24) and support key from the ignition switch.
Page 300: Operator Seat Service
Operator Seat Service Figure 19 1. Backrest cushion 12. Cap screw (2 used) 22. RH adjustment rail 2. Seat cushion 13. Seat 23. Rail stop 3. LH armrest cover 14. Nut 24. Torx screw 4. LH armrest 15. Spring (2 used) 25.
Page 301 Disassembly (Fig. 19) Assembly (Fig. 19) 1. Remove seat from machine for service (see Opera- 1. Assemble operator seat using Figure 19 as a guide. tor Seat Removal in this section). 2. Install seat to machine (see Operator Seat Installa- 2.
Page 302: Operator Seat Suspension
Operator Seat Suspension RIGHT FRONT Figure 20 1. Cover 14. Washer (2 used) 27. Clamp (2 used) 2. Cover 15. Tether 28. Hose nipple 3. Level control 16. Rivet (2 used) 29. Screw 4. Air control valve 17. Washer (4 used) 30.
Page 303 NOTE: Most of the seat suspension components can be serviced with the seat suspension base mounted to the seat plate. If the air spring assembly (item 6) requires removal, the seat suspension base will have to be re- moved from the seat plate. Disassembly (Fig.
Page 304: Hood
Hood RIGHT FRONT Figure 22 1. Screen 11. Washer (2 used) 21. LH hood frame tube 2. Latch keeper 12. Rubber bumper (2 used) 22. RH hood frame tube 3. Pop rivet (2 used) 13. Flange nut (2 used) 23. LH hood frame tube 4.
Page 305 Removal (Fig. 22) Installation (Fig. 22) 1. Park machine on a level surface, lower cutting 1. If components were removed from hood, assemble decks, stop engine, engage parking brake and remove hood using Figure 22 as a guide. key from the ignition switch. 2.
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Page 307 Chapter 8 Cutting Decks Table of Contents SPECIFICATIONS ......GENERAL INFORMATION ..... Operator’s Manual .
Page 308: Specifications
Specifications Groundsmaster 4500- -D Groundsmaster 4700- -D MOUNTING: All cutting decks are supported by inde- DISCHARGE: Clippings are discharged from the rear of pendent lift arms and are interchangeable to any cutting the mowing decks. Pre--drilled mounting holes allow at- deck positions.
Page 309: General Information
General Information 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. Operator’s Manual The Cutting Deck Operator’s Manual provides informa- tion regarding the operation, general maintenance and maintenance intervals for the cutting deck on your Groundsmaster machine.
Page 310: Troubleshooting
Troubleshooting There are a number of factors that can contribute to un- Remember that the “effective” or actual height--of--cut satisfactory quality of cut, some of which may be turf depends on cutting deck weight, counterbalance setting conditions. Turf conditions such as excessive thatch, and turf conditions.
Page 311: Special Tools
Special Tools Order special tools from your Toro Distributor. Rear Roller Bearing and Seal Installation Tools These tools are used to assemble the cutting deck rear roller. Toro Part Numbers: Inner Seal Tool 115- -0852 Bearing/Outer Seal Tool 115- -0853...
Page 312: Adjustments
Adjustments CAUTION Never install or work on the cutting decks or lift arms with the engine running. Always stop en- gine and remove key from ignition switch first. See the Cutting Deck Operator’s Manual for adjustment procedures for cutting decks on the Groundsmaster 4500--D and Groundsmaster 4700--D.
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Page 314: Service And Repairs
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 Assembly RIGHT 88 to 108 ft- -lb (120 to 146 N- -m) FRONT Figure 4 1.
Page 315 Removal (Fig. 4) 1. Park machine on a level surface, lower cutting decks, stop engine, engage parking brake and remove key from the ignition switch. 2. Remove two (2) socket head screws and flat wash- ers that secure hydraulic motor to the cutting deck (Fig. 5).
Page 316: Blade Spindle Service
Blade Spindle Service Disassembly (Fig. 6) 1. Remove blade spindle from cutting deck (see Blade Spindle Removal in this section). 2. Loosen and remove spindle nut from top of spindle 131 to 159 ft- -lb shaft. (178 to 215 N- -m) 3.
Page 317 3. Using an arbor press, push the bearing cups into the top and bottom of the spindle housing. The top bearing PRESS cup must contact the outer bearing spacer previously installed, and the bottom bearing cup must contact the large snap ring. Make sure that the assembly is correct by supporting the first bearing cup and pressing the sec- ond cup against it (Fig 8).
Page 318: Rear Roller
Rear Roller 29 to 35 ft- -lb (40 to 47 N- -m) RIGHT FRONT 29 to 35 ft- -lb (40 to 47 N- -m) Figure 10 1. Deck frame 4. Roller shaft screw 7. Skid bracket 2. Rear roller assembly 5.
Page 319 Removal (Fig. 10) 30 ft- -lb 1. Park machine on a level surface, lower cutting (41 N- -m) decks, stop engine, engage parking brake and remove key from the ignition switch. 2. If cutting deck is equipped with a roller scraper (Fig. 29 to 35 ft- -lb 11), remove fasteners securing left and right scraper rod (40 to 47 N- -m)
Page 320: Rear Roller Service
Rear Roller Service Disassembly (Fig. 12) 50 to 60 ft- -lb 1. Remove bearing lock nut from each end of roller (68 to 81 N- -m) shaft. 2. Loosely secure roller assembly in bench vise and lightly tap one end of roller shaft until outer seals and bearing are removed from opposite end of roller tube.
Page 321 3. From the roller tube end with only the inner seal NOTE: After roller is installed to cutting deck, lubricate installed, carefully install the roller shaft into the roller roller grease fittings, rotate roller to properly distribute tube. Make sure that seals are not damaged as shaft is grease in bearings and clean excess grease from roller installed.
Page 322: Front Roller Service
Front Roller Service Disassembly (Fig. 18) 1. Remove roller mounting bolt. 2. Remove roller assembly from carrier frame. 3. To remove bearings and bearing spacer: A. Insert punch through end of roller and drive oppo- site bearing out by alternating taps to opposite side of inner bearing race.
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Page 324: Cutting Deck Carrier Frame
Cutting Deck Carrier Frame Decks #2 and #3 Decks #1, #4 and #5 Decks #6 and #7 RIGHT FRONT Figure 19 1. Carrier frame 7. Hardened washer (2 used per deck) 13. Lock nut 2. Lynch pin 8. Cap screw (2 used per deck) 14.
Page 325 Removal and Installation (Fig. 19) Each cutting deck is suspended from a carrier frame. #4 Deck #1 Deck #5 Deck The cutting deck carrier frame is attached to the lift arm and allows the cutting deck to pivot on the lift arm pivot shaft.
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Page 327: Electrical Drawing Designations
Chapter 9 Foldout Drawings Table of Contents ELECTRICAL DRAWING DESIGNATIONS ..HYDRAULIC SCHEMATICS Groundsmaster 4500--D ..... Groundsmaster 4500--D with Optional Flow Divider Kit .
Page 328 Electrical Drawing Designations The following abbreviations are used for wire harness colors on the electrical schematics and wire harness drawings in this chapter. ABBREVIATION COLOR BLACK BR or BN BROWN BLUE GREEN GRAY ORANGE PINK R or RD VIOLET W or WH WHITE Y or YE YELLOW...
Page 329 LIFT 2.00” BORE STEERING CYLINDERS 4.20” STROKE CYLINDER 1.500” BORE 1.500” BORE 1.500” BORE 0.630” ROD 7.00” STROKE 4.00” STROKE 7.00” STROKE 0.630” ROD 0.630” ROD 0.630” ROD .080 JUNCTION MANIFOLD .030 .055 .030 STEERING CONTROL 1050 PSI VALVE 3.1 GPM 1500 PRV2 3500...
Page 330 LIFT 2.00” BORE STEERING CYLINDERS 4.20” STROKE CYLINDER 1.500” BORE 1.500” BORE 1.500” BORE 0.630” ROD 7.00” STROKE 4.00” STROKE 7.00” STROKE 0.630” ROD 0.630” ROD 0.630” ROD .080 JUNCTION MANIFOLD .030 .055 .030 STEERING CONTROL 1050 PSI VALVE 3.1 GPM 1500 3500 PRV2...
Page 331 LIFT 2.00” BORE 2.00” BORE 2.00” BORE STEERING CYLINDERS 9.00” STROKE 9.00” STROKE 4.20” STROKE CYLINDER 0.750” ROD 0.750” ROD 1.500” BORE 1.500” BORE 1.500” BORE 0.630” ROD 7.00” STROKE 4.00” STROKE 7.00” STROKE LEFT WING RIGHT WING 0.630” ROD 0.630”...
Page 332 LIFT 2.00” BORE 2.00” BORE 2.00” BORE STEERING CYLINDERS 9.00” STROKE 9.00” STROKE 4.20” STROKE CYLINDER 0.750” ROD 0.750” ROD 1.500” BORE 1.500” BORE 1.500” BORE 0.630” ROD 7.00” STROKE 4.00” STROKE 7.00” STROKE LEFT WING RIGHT WING 0.630” ROD 0.630”...
Page 333 NOTE: REFER TO ELECTRICAL DRAWING DESIGNATIONS IN THIS CHAPTER FOR WIRE COLOR ABBREVIATIONS. TRACTION PEDAL POSITION SENSOR RH (#5) DECK LH (#4) DECK TRACTION PEDAL POSITION SENSOR Groundsmaster 4500--D/4700--D All relays and solenoids GM4700- D Electrical Schematic are shown as de- - energized. All ground wires are black.
Page 334 All relays and solenoids are shown as de- - energized. All ground wires are black. NOTE: REFER TO ELECTRICAL DRAWING DESIGNATIONS IN THIS CHAPTER FOR WIRE COLOR ABBREVIATIONS. TRACTION PEDAL POSITION SENSOR RH (#5) DECK LH (#4) DECK TRACTION PEDAL POSITION SENSOR LH (#7) DECK POSITION SWITCH RH (#6) DECK POSITION SWITCH...
Page 335 All relays and solenoids are shown as de- - energized. All ground wires are black. Groundsmaster 4500--D/4700--D NOTE: REFER TO ELECTRICAL DRAWING Electrical Schematic DESIGNATIONS IN THIS CHAPTER FOR WIRE COLOR ABBREVIATIONS. Optional Operator Cab Page 9 - 9...
Page 336 HEADLIGHT LH HEADLIGHT RH TRACTION PEDAL PARKING BRAKE POSITION SENSOR SWITCH RH (#5) DECK POSITION SWITCH HYDRAULIC TEMP SENDER FUEL PUMP TO ENGINE COUNTER BALANCE LH (#4) DECK POSITION SWITCH HYDROSTAT C DECK FLOAT DECK PTO 1 FAN DIRECTION INTERCONNECT GM4700 DECK PTO 2 HYDROSTAT...
Page 337 RH (#5) DECK POSITION SWITCH LH (#4) DECK POSITION SWITCH TRACTION PEDAL POSITION SENSOR NOTE: THIS DRAWING IDENTIFIES WIRE GAUGE Groundsmaster 4500--D/4700--D SIZE AND WIRE COLOR. REFER TO ELECTRICAL DRAWING DESIGNATIONS IN THIS CHAPTER FOR ADDITIONAL INFORMATION. Main Wire Harness Page 9 - 11...
Page 338 Groundsmaster 4500--D/4700--D Seat and Console Wire Harness Page 9 - 12...
Page 339 NOTE: THIS DRAWING IDENTIFIES WIRE GAUGE SIZE AND WIRE COLOR. REFER TO ELECTRICAL DRAWING DESIGNATIONS IN THIS CHAPTER FOR ADDITIONAL INFORMATION. Groundsmaster 4500--D/4700--D Seat and Console Wire Harness Page 9 - 13...
Page 340 Groundsmaster 4500--D/4700--D Power Center Wire Harness Page 9 - 14...
Page 341 NOTE: THIS DRAWING IDENTIFIES WIRE GAUGE SIZE AND WIRE COLOR. REFER TO ELECTRICAL DRAWING DESIGNATIONS IN THIS CHAPTER FOR ADDITIONAL INFORMATION. Groundsmaster 4500--D/4700--D Power Center Wire Harness Page 9 - 15...
Page 342 RH (#6) DECK POSITION SWITCH LH (#7) DECK POSITION SWITCH PIN AND BACKSHELL ORIENTATION (TEC--5001) NOTE TAB POSITION Groundsmaster 4700--D Deck 6 and 7 Wire Harness Page 9 - 16...
Page 343 NOTE: THIS DRAWING IDENTIFIES WIRE GAUGE SIZE AND WIRE COLOR. REFER TO ELECTRICAL DRAWING DESIGNATIONS IN THIS CHAPTER FOR ADDITIONAL INFORMATION. RH (#6) DECK POSITION SWITCH LH (#7) DECK POSITION SWITCH Groundsmaster 4700--D Deck 6 and 7 Wire Harness Page 9 - 17...
Page 344 PIN AND BACKSHELL ORIENTATION FOR P01 & P02 Groundsmaster 4500--D/4700--D (Models 30881 and 30882) Engine Wire Harness Drawing Page 9 - 18...
Page 345 NOTE: THIS DRAWING IDENTIFIES WIRE GAUGE SIZE AND WIRE COLOR. REFER TO ELECTRICAL DRAWING DESIGNATIONS IN THIS CHAPTER FOR ADDITIONAL INFORMATION. Groundsmaster 4500--D/4700--D (Models 30881 and 30882) Engine Wire Harness Diagram Page 9 - 19...
Page 346 PIN AND BACKSHELL ORIENTATION FOR P23 Groundsmaster 4500--D/4700--D (Models 30873 and 30874) Engine Wire Harness Drawing Page 9 - 20...
Page 347 NOTE: THIS DRAWING IDENTIFIES WIRE GAUGE SIZE AND WIRE COLOR. REFER TO ELECTRICAL DRAWING DESIGNATIONS IN THIS CHAPTER FOR ADDITIONAL INFORMATION. Groundsmaster 4500--D/4700--D (Models 30873 and 30874) Engine Wire Harness Diagram Page 9 - 21...

This manual is also suitable for:

30882 Groundsmaster 4700-d 30873 30881 30874

Toro Groundsmaster 4500-D Service Manual

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Chapter 1 - Safety

Chapter 2 - Product Records and Maintenance

Chapter 3 Yanmar Diesel Engine

Chapter 4 - Hydraulic System

Chapter 5 Electrical System

Chapter 6 Axles, Planetaries and Brakes

Chapter 7 Chassis

Chapter 8 Cutting Decks

Chapter 9 - Foldout Drawings

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Service Manual

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Troubleshooting

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Summary of Contents for Toro Groundsmaster 4500-D