Page 1 Form No. 19245SL Rev A Groundsmaster ® 4500-D/4700-D (Models 30885, 30887, 30893, 30893TE, 30899 and 30899TE) © 2020—The Toro® Company Original Instructions (EN) 8111 Lyndale Avenue South Contact us at www.Toro.com. Bloomington, MN 55420 All Rights Reserved...
Page 2 Revision History Revision Date Description Initial issue. 04/2020 Revision History Page 2 Groundsmaster ® 4500-D/4700-D 19245SL Rev A...
Page 3 Reader Comments The Toro Company Technical Assistance Center maintains a continuous effort to improve the quality and usefulness of its publications. To do this effectively, we encourage user feedback. Please comment on the completeness, accuracy, organization, usability, and readability of this manual by an e-mail servicemanuals@toro.com...
Page 4 NOTES NOTES Page 4 Groundsmaster ® 4500-D/4700-D 19245SL Rev A...
Page 5 Catalogs for your machine and its accessories with this Service Manual for reference. Additional copies of the Operator’s Manuals and Parts Catalogs are available at www.toro.com. The Toro Company reserves the right to change the product specifications or this publication without notice. DANGER This safety symbol means danger.
Page 6 Service Procedure Icons The following icons appear throughout this Service Manual to bring attention to specific important details of a service procedure. Critical Process This icon is used to highlight: • installing safety equipment (shields, guards, seat belts, brakes and R.O.P.S. components) that may have been removed.
Page 7: Table Of Contents
Table of Contents Preface ........................ 5 Chapter 1: Safety .................... 1–1 Safety Instructions ..................1–2 Safety and Instructional Decals ..............1–9 Chapter 2: Specifications and Maintenance ............ 2–1 Specifications ....................2–2 Torque Specifications ................... 2–8 Shop Supplies .................... 2–14 Special Tools ....................2–16 Chapter 3: Troubleshooting ................
Page 8 Electric Schematic - Groundsmaster 4500-D/4700-D (Models 30885 and 30887) ......................A–5 Electric Schematic - Groundsmaster 4500-D/4700-D (Models 30893, 30893TE, 30899 and 30899TE) ..............A–6 Optional Operator Cab Electrical Schematic - Groundsmaster 4500-D/4700-D .....................A–7 Main Wire Harness - Groundsmaster 4500-D/4700-D ........A–8 Main Wire Harness - Groundsmaster 4500-D/4700-D ........A–9 Seat and Console Wire Harness - Groundsmaster 4500-D/4700-D ....A–10 Seat and Console Wire Harness - Groundsmaster 4500-D/4700-D .....A–11 Power Center Wire Harness - Groundsmaster 4500-D/4700-D ....A–12...
Page 9 Chapter 1 Safety Table of Contents Safety Instructions ..........................1–2 Before Operating the Machine ......................1–3 While Operating the Machine ......................1–4 Maintenance and Service........................1–5 Jacking Instructions ........................... 1–7 Safety and Instructional Decals ......................1–9 Groundsmaster ® 4500-D/4700-D Page 1–1 Safety 19245SL Rev A...
Page 10: Safety Instructions
Safety Instructions The Groundsmaster 4500-D and 4700-D are tested and certified by Toro for compliance with existing safety standards and specifications. Although hazard control and accident prevention partially are dependent upon the design and configuration of the machine, these factors are also dependent upon the awareness, concern and proper training of the personnel involved in the operation, transport, maintenance and storage of the machine.
Page 11: Before Operating The Machine
Become familiar with the controls and know how to stop the machine and engine quickly. Additional copies of the Operator’s Manuals are available at www.toro.com. • Never allow children to operate the machine. Never allow adults to operate the machine without proper instructions.
Page 12: While Operating The Machine
C. Apply the parking brake. D. Stop engine and remove key from switch. 7. Toro recommends that anytime the machine is parked (short or long term), the cutting decks should be lowered to the ground. This relieves hydraulic pressure from the deck lift circuit and eliminates the risk of the cutting decks unexpectedly lowering to the ground.
Page 13: Maintenance And Service
16. At the time of manufacture, the machine conformed to the safety standards for riding mowers. To assure optimum performance and continued safety certification of the machine, use genuine Toro replacement parts and accessories. Replacement parts and accessories made by other manufacturers may result in non-conformance with the safety standards and the warranty may be voided.
Page 14 Maintenance and Service (continued) 18. When welding on machine, disconnect all battery cables to prevent damage to machine electronic equipment. Disconnect negative battery cable first and positive cable last. Also, disconnect wire harness connector from both of the TEC controllers, disconnect and remove the engine ECM and disconnect the terminal connector from the alternator.
Page 15: Jacking Instructions
Jacking Instructions CAUTION When changing attachments, tires or performing other service, use correct jacks and supports. Make sure machine is parked on a solid, level surface such as a concrete floor. Prior to raising machine, remove any attachments that may interfere with the safe and proper raising of the machine.
Page 16 Jacking the Rear End g036671 Figure 2 1. Apply parking brake and chock both front tires to prevent the machine from moving. 2. Place jack securely under the center of rear axle. 3. Jack rear of machine off the ground. 4.
Page 17: Safety And Instructional Decals
Numerous safety and instruction decals are affixed to the traction unit and cutting units of your Groundsmaster. If any decal becomes illegible or damaged, install a new decal. Decal part numbers are listed in your Parts Catalog. Order replacement decals from Authorized Toro Distributor. Groundsmaster ®...
Page 18 Safety: Safety and Instructional Decals Page 1–10 Groundsmaster ® 4500-D/4700-D 19245SL Rev A...
Page 19 Chapter 2 Specifications and Maintenance Table of Contents Specifications ............................2–2 Overall Dimensions..........................2–2 Engine (Models 30893, 30893TE, 30899 and 30899TE)..............2–3 Engine (Models 30885 and 30887) ....................2–4 Hydraulic System ..........................2–5 Axles, Planetaries and Brakes ......................2–6 Cutting Decks............................. 2–7 Torque Specifications ...........................
Page 20: Specifications
Specifications Overall Dimensions g307587 Figure 3 Specifications and Maintenance: Specifications Page 2–2 Groundsmaster ® 4500-D/4700-D 19245SL Rev A...
Page 21: Engine (Models 30893, 30893Te, 30899 And 30899Te)
Engine (Models 30893, 30893TE, 30899 and 30899TE) Item Description Make / Designation Yanmar Model 4TNV84T−ZMTR: 4−Cycle, 4 Cylinder, Water Cooled, Turbocharged, Tier 4i Diesel Engine Bore 84 mm (3.307 in) Stroke 90 mm (3.543 in) Total Displacement 1995 cc (121.7 in³) Firing Order 1 (closest to flywheel end) −...
Page 22: Engine (Models 30885 And 30887)
Engine (Models 30885 and 30887) Item Description Make / Designation Yanmar Model 4TNV86CT−DTR: 4−Cycle, 4 Cylinder, Water Cooled, Turbocharged, Tier 4 Diesel Engine Bore 86 mm (3.386 in) Stroke 90 mm (3.543 in) Total Displacement 2090 cc (127.5 in³) Firing Order 1 (closest to flywheel end) −...
Page 23: Hydraulic System
Hydraulic System Item Description Piston (Traction) Pump Sauer−Danfoss Variable Displacement Axial Piston Pump Maximum Displacement (per revolution) 45 cc (2.75 in³) System Relief Pressure: Forward 350 bar (5075 PSI) System Relief Pressure: Reverse 360 bar (5225 PSI) Charge Pressure 17 bar (250 PSI) Front Wheel Motors Danfoss Variable Displacement Axial Piston Motors Displacement (per revolution)
Page 24: Axles, Planetaries And Brakes
Axles, Planetaries and Brakes Item Description Tire pressure (front and rear) 138 kPa (20 PSI) Rear wheel toe−in 3 mm (0.125 in) Wheel lug nut torque (front and 116 to 135 N·m (85 to 100 ft−lb), front and rear rear) in a crossing pattern Steering cylinder castle nut torque 136 to 169 N·m (100 to 125 ft−lb)
Page 25: Cutting Decks
Cutting Decks MOUNTING: All cutting decks are supported by independent lift arms and are interchangeable to any cutting deck positions. The Groundsmaster 4500-D uses five (5) cutting decks. The Groundsmaster 4700-D uses seven (7) cutting decks. CONSTRUCTION: Deck chamber and frame are welded steel construction reinforced with channels and plates.
Page 26: Torque Specifications
Torque Specifications The recommended fastener torque values are listed in the following tables. For critical applications, as determined by Toro, either the recommended torque or a torque that is unique to the application is clearly identified and specified in this Service Manual.
Page 27: Calculating The Torque Values When Using A Drive-Adapter Wrench
Calculating the Torque Values When Using a Drive-Adapter Wrench g205924 Figure 4 Torque Conversion Factor = A / B Torque wrench A (effective length of torque wrench) Drive-adapter wrench (crowsfoot) B (effective length of torque wrench and drive-adapter wrench) Using a drive-adapter wrench (e.g., crowfoot wrench) in any position other than 90°...
Page 28: Identifying The Fastener
Toro recommends replacing fasteners with a locking feature once they have been removed because the effectiveness of the locking feature diminishes with each reuse. If it is necessary to reuse a fastener with a locking feature; apply a thread locking compound (Loctite for example) to the fastener during installation.
Page 29: Standard Torque For Dry, Zinc Plated, And Steel Fasteners (Inch Series)
Standard Torque for Dry, Zinc Plated, and Steel Fasteners (Inch Series) Thread Size Grade 1, 5 SAE Grade 1 Bolts, Screws, SAE Grade 5 Bolts, Screws, SAE Grade 8 Bolts, Screws, and 8 with Studs, and Sems with Studs, and Sems with Studs, and Sems with Thin Height Regular Height Nuts...
Page 30: Standard Torque For Dry, Zinc Plated, And Steel Fasteners (Metric Fasteners)
Standard Torque for Dry, Zinc Plated, and Steel Fasteners (Metric Fasteners) Class 8.8 Bolts, Screws, and Class 10.9 Bolts, Screws, and Thread Size Studs with Regular Height Nuts Studs with Regular Height Nuts (Class 8 or Stronger Nuts) (Class 10 or Stronger Nuts) M5 X 0.8 57 ±...
Page 31: Other Torque Specifications
Other Torque Specifications SAE Grade 8 Steel Set Screws Recommended Torque Thread Size Square Head Hex Socket 1/4 - 20 UNC 140 ± 20 in-lb 73 ± 12 in-lb 5/16 - 18 UNC 215 ± 35 in-lb 145 ± 20 in-lb 3/8 - 16 UNC 35 ±...
Page 32: Shop Supplies
Shop Supplies The procedures found in this Service Manual may recommend the use of commonly used shop supplies (lubricants, sealants and adhesives). A symbol denoting the use of a shop supply may appear in figures that support a procedure. Always refer to the written procedure for specific information regarding the type and the application of a shop supply.
Page 33 GASKET COMPOUND Used to create a seal between mating parts. Gasket compounds may be used with or without the presence of a pre-formed gasket. Gasket compounds may be solvent or silicone based, and cure when exposed to air or designed to cure in an air-less environment (anaerobic). Most gasket compounds are designed to be applied to clean surfaces free of oil, chemical residue and previously used gaskets or gasket compounds.
Page 34: Special Tools
Special Tools You can order these special tools from your Toro Distributor. Some tools may also be available from a local tool supplier. Hydraulic Pressure Testing Kit K Line Part No. TOR47009 Use this kit to take various pressure readings for diagnostic tests. Quick...
Page 35 1. Diagnostic fitting rear traction circuit relief valve): 2. Straight fitting Diagnostic Fitting 59-7410 3. 90º fitting Toro Part Numbers (reverse traction relief pressure): 4. Diagnostic fitting Straight Fitting: 340-2 90º Fitting: 340-159 Diagnostic Fitting: 86-5480 Groundsmaster ®...
Page 36 Hydraulic O-Ring Kit Toro Part No. 117-2727 This kit includes O-rings in a variety of sizes for the face seal and port seal hydraulic connections. To help prevent a hydraulic leak, replace the O-rings when you open the hydraulic connection.
Page 37 Hydraulic Test Fitting Kit K Line Part No. TOR4079 This kit includes a variety of O-ring face seal fittings to let you connect the test gauges into the system. K LINE FITTING TYPE SIZE PART NUMBER 4 ORFS (9/16–18) TOR4079–3 6 ORFS (11/16–16) TOR4079–12 8 ORFS (13–16–16)
Page 38 High Flow Hydraulic Filter Kit K Line Part Number: TOR6011 The high flow hydraulic filter kit is designed with large flow (150 LPM or 40 GPM) and high pressure (34,500 kPa or 5,000 psi) capabilities. This kit provides for bidirectional filtration which prevents filtered unwanted material from entering into the circuit regardless of the flow direction.
Page 39 Remote Starter Switch (purchased) switch connector for circuit protection. 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 connectors. Connecting the...
Page 40 Dielectric Gel Toro Part No. 107-0342 Use the dielectric gel to prevent corrosion of unsealed connection terminals. To ensure complete coating of the terminals, liberally apply the gel to the component and wire harness connector, plug the connector into the component,...
Page 41 Chapter 3 Troubleshooting Table of Contents GEARS – The Systematic Approach to Defining, Diagnosing and Solving Problems ......3–2 Gather Information ..........................3–2 Evaluate Potential Causes ......................... 3–2 Assess Performance.......................... 3–2 Repair ..............................3–2 Solution Confirmation......................... 3–2 General Hydraulic System Problems ..................... 3–3 Traction Circuit Problems ........................
Page 42: Gears - The Systematic Approach To Defining, Diagnosing And Solving Problems
GEARS – The Systematic Approach to Defining, Diagnosing and Solving Problems Gather Information • Information reported by the customer • Information observed by you • Establish the what, where and when of the issue Evaluate Potential Causes • Consider possible causes of the problem to develop a hypothesis •...
Page 43: General Hydraulic System Problems
General Hydraulic System Problems The charts that follow contain suggestions that can be used to assist in diagnosing hydraulic system performance issues. The suggestions are not all−inclusive. Also, consider that there may be more than one cause for a machine problem. Review the hydraulic schematic and information on hydraulic system operation in the Hydraulic Flow Diagrams section of this Chapter.
Page 44: Traction Circuit Problems
Traction Circuit Problems Note: When troubleshooting traction circuit problems, if a problem exists in both low (mow) and auto speeds, consider a faulty component that affects the entire traction circuit (e.g. charge circuit, traction circuit relief valves, piston pump). If the problem exists in LOW speed (mow) but not in Auto speed, consider a problem that only exists in mow (e.g.
Page 45: Mow Circuit Problems
Mow Circuit Problems Problem Possible Cause None of the cutting decks will operate. Cutting decks are not fully lowered to ground. Note: To engage the mow circuit, the seat PTO switch is not in engaged position. must be occupied, the cutting deck(s) must Operator seat is unoccupied.
Page 46 Problem Possible Cause All cutting decks operate slowly. Engine RPM is low. All deck motors are worn or damaged. First and second gear pump sections are worn or damaged. Cutting deck stops under load. Relief valve in deck control manifold is bypassing.
Page 47: Steering Circuit Problems
Steering Circuit Problems Problem Possible Cause Steering inoperative or sluggish. Steering components (e.g. tie rods, steering cylinder ends) are worn or binding. Steering cylinder is binding. Oil level in hydraulic reservoir is low (Note: Other hydraulic systems are affected as well). Steering relief valve in steering control valve is stuck or damaged.
Page 48: Lift Circuit Problems
Lift Circuit Problems Problem Possible Cause Engine RPM is too low. Cutting decks will not raise. Note: Seat must be occupied in order to raise Hydraulic oil level in reservoir is low (NOTE: the cutting decks. Other hydraulic systems are affected as well). Electrical problem exists (see Chapter 6: Electrical System (page...
Page 49: Engine Cooling Fan Circuit Problems
Engine Cooling Fan Circuit Problems Problem Possible Cause Cooling fan runs only in forward direction (fan Fan control manifold solenoid cartridge valve does not run in reverse direction). (S1) is faulty. Electrical problem exists that prevents fan control manifold solenoid valve (S1) operation (see Chapter 6: Electrical System (page 6–1)).
Page 50: Operator Advisories
Operator Advisories CAUTION Remove all jewelry, especially rings and watches, before doing any electrical troubleshooting or testing. Also, disconnect the battery cables unless the test requires battery voltage. For effective troubleshooting and repairs, you must have a good understanding of the electrical circuits and components used on this machine (see Chapter 6: Electrical System (page 6–1)).
Page 51 Advisory Advisory Name Cause InfoCenter Message | Corrective Action Required B2409 DECK LOWER DENIED Out of seat To lower deck | Operator must be seated B2507 PTO DENIED Engine too hot To engage PTO | Let engine cool B2509 PTO DENIED Out of seat To engage PTO | Operator must be seated...
Page 52: Machine Fault Codes
(+) source. This short could be Swap the T1: Primary controller with a to battery voltage known-good unit (contact an Authorized or to another signal Toro Distributor for assistance). that is in a high state. C1014 ETR/RTR/OK Overcurrent Test the output circuit for a short.
Page 53 TEC (P74, pin 10). Swap the T1: Primary controller with a known-good unit (contact an Authorized Toro Distributor for assistance). C1124 Fan Direction - Overcurrent Test the output circuit for a short. Short to Ground...
Page 54 Test for proper resistance in the component S1 output. connected to the auxiliary TEC (P75, pin Swap the T2: Auxiliary controller with a known-good unit (contact an Authorized Toro Distributor for assistance). C1423 Solenoid 2 - Low current Test the output circuit for a short.
Page 55 (+) source. This Swap the T2: Auxiliary controller with a short could be to known-good unit (contact an Authorized battery voltage or Toro Distributor for assistance). to another signal that is in a high state. C1444 Solenoid 4 - Overcurrent Test the output circuit for a short.
Page 56 Swap the T1: Primary controller with a (+) source. This known-good unit (contact an Authorized short could be to Toro Distributor for assistance). battery voltage or to another signal that is in a high state.
Page 57 (+) source. This Swap the T2: Auxiliary controller with a short could be to known-good unit (contact an Authorized battery voltage or Toro Distributor for assistance). to another signal that is in a high state. C1484 Solenoid 8 - Overcurrent Test the output circuit for a short.
Page 58 (+) source. Swap the T1: Primary controller with a This short could be known-good unit (contact an Authorized to battery voltage Toro Distributor for assistance). or to another signal that is in a high state. C14B4 Transport Overcurrent Test the output circuit for a short.
Page 59 TEC (P75, pin indicating a short 42). to ground. Swap the T2: Auxiliary controller with a known-good unit (contact an Authorized Toro Distributor for assistance). C14E5 PTO 3 - Open Open circuit Test the output circuit for an open. Circuit...
Page 60 Test the engine start output circuit wiring start output. between the TEC and the engine ECU. Swap the T1: Primary controller with a known-good unit (contact an Authorized Toro Distributor for assistance). P0616 Start Output - Overcurrent Check the circuit wiring (P74, pin 8).
Page 61 (P74, pin 17). Test the traction coil wiring. Test the traction coil. Swap the T1: Primary controller with a known-good unit (contact an Authorized Toro Distributor for assistance). P110C Traction Coil 1 A current monitor Traction is Use the InfoCenter to verify the traction...
Page 62 This ensures the Swap the T1: Primary controller with a voltage across the known-good unit (contact an Authorized coil is approaching Toro Distributor for assistance). 0 when required. The second check to verify that the PWM duty cycle across the coil is...
Page 63 Swap the T1: Primary controller with a of current to the known-good unit (contact an Authorized traction coil. Toro Distributor for assistance). It is expected that the actual level of coil current will track the desired level of...
Page 64 Contro- Fault Condition Fault Additional Fault Title ller(s) / Circuit Service Actions Notes Affected Description P1165 Swashplate 1 Open circuit PTO is Check for open connector (P74, pin 28). - Signal Open detected on swash disabled Circuit plate sensor signal. traction speed is reduced by...
Page 65 Contro- Fault Condition Fault Additional Fault Title ller(s) / Circuit Service Actions Notes Affected Description P2504 Alternator - Test the alternator using the Yanmar TNV Charging system Charging Too (alternator) is (Tier 4) Service Manual. High producing a Check and clean the battery connections. voltage that the TEC has Test and charge the battery.
Page 66 Toro Distributor for assistance). Model Number Model number not Disable U110C Reprogram system software (contact your Unknown recognized. engine. Authorized Toro Distributor for assistance). U110D Serial Number Serial number not Disable Reprogram system software (contact your Unknown recognized. engine. Authorized Toro Distributor for assistance).
Page 67: Starting Problems
Starting Problems Note: Check InfoCenter Display for possible operator advisories or faults whenever diagnosing machine electrical problems. Problem Possible Cause No electrical power to machine. The battery is discharged. The battery cables are loose or corroded. Fuse F−B5 (2 Amp) is faulty. Ground connection on the machine is loose or corroded.
Page 68: General Run And Transport Problems
General Run and Transport Problems Note: Check InfoCenter Display for possible operator advisories or faults whenever diagnosing machine electrical problems. Problem Possible Cause Engine continues to run, but should not, when The ignition switch or circuit wiring is faulty. the ignition switch is turned off. The engine or fuel system is malfunctioning (see Yanmar Service Manual).
Page 69: Cutting Deck Operating Problems
Cutting Deck Operating Problems Note: Check InfoCenter Display for possible operator advisories or faults whenever diagnosing machine electrical problems. Note: To engage the mow circuit, the operator must be in the operator seat, the traction speed must be in the LOW speed (mow) position, the PTO switch must be ON and the cutting deck(s) must be fully lowered and in float.
Page 70: Cutting Deck Lift/Lower Problems
Cutting Deck Lift/Lower Problems Note: Check InfoCenter Display for possible operator advisories or faults whenever diagnosing machine electrical problems. Note: To lower a cutting deck, the operator must be in the operator seat and the traction speed must be in the LOW speed (mow) position. To raise a cutting deck, the operator must be in the operator seat.
Page 71 Problem Possible Cause On Groundsmaster 4700−D, center cutting The center deck lift switch or circuit wiring is decks will not raise or lower, but both wing faulty. cutting decks will raise and lower. Fuse(s) for TEC controller are faulty (fuse C−1).
Page 72: Aftercut Appearance
Aftercut Appearance There are a number of factors that can contribute to unsatisfactory quality of cut, some of which may be turf conditions. Turf conditions such as excessive thatch, uneven ground conditions, “sponginess” or attempting to cut off too much grass height may not always be overcome by adjusting the machine.
Page 73 Chapter 4 Yanmar Diesel Engine Table of Contents General Information ..........................4–2 Operator’s Manual ..........................4–2 Yanmar Service and Troubleshooting Manuals .................. 4–2 Stopping the Engine........................... 4–2 Engine Electronic Control Unit (ECU) ....................4–3 Yanmar Engine: Models 30893, 30893TE, 30899 and 30899TE............4–5 Yanmar Engine: Models 30885 and 30887 ..................
Page 74: General Information
Service and repair parts for Yanmar engines are supplied through your Authorized Toro Distributor. If no parts list is available, be prepared to provide your distributor with the Toro model and serial number of your machine.
Page 75: Engine Electronic Control Unit (Ecu)
Engine Electronic Control Unit (ECU) g307583 Figure 7 (Tier 4i) Electronic control unit (30893 / 30893TE / 30899 / 30899TE) Engine ECU The Yanmar engine that powers your Groundsmaster uses an electronic control unit (ECU) for engine management and also to communicate with the machine TEC controllers and the operator Info Center display on the machine.
Page 76 The Yanmar electronic tool and troubleshooting manual should be used to provide assistance in identifying the cause of the problem and the repairs that are necessary. Contact your Toro distributor for assistance in Yanmar engine troubleshooting.
Page 77: Yanmar Engine: Models 30893, 30893Te, 30899 And 30899Te
Yanmar Engine: Models 30893, 30893TE, 30899 and 30899TE g307585 Figure 9 The engine used on Groundsmaster models 30893, 30893TE, 30899 and 30899TE is a Yanmar TNV Series, turbocharged, diesel engine that complies with EPA interim Tier 4 emission regulations. The T4i engine features include an electronic control unit (ECU) controlled direct fuel injection and electronic governor.
Page 78: Yanmar Engine: Models 30885 And 30887
During the operation of the engine, if conditions warrant, the engine ECU may generate an engine fault. Use the machine InfoCenter to identify the engine fault; refer to the Yanmar Troubleshooting Manual, or contact an Authorized Toro Distributor for assistance. Yanmar Diesel Engine: General Information Page 4–6 Groundsmaster ®...
Page 79: Diesel Particulate Filter
Diesel Particulate Filter The diesel particulate filter (DPF) used on Yanmar Tier 4 compliant engines is designed to breakdown the hazardous elements in the exhaust and prevent the discharge of unburnt fuel or oil known as particulate matter or soot. The DPF includes a Diesel Oxidation Catalyst (DOC), a Soot Filter (SF), 2 temperature sensors, and a pressure differential sensor.
Page 80 Regeneration (continued) Types of regeneration that are performed manually (while the machine is stationary) Type Conditions Description Parked Occurs when exhaust back pressure in the DPF increases due to continued soot buildup. The InfoCenter displays the stationary regeneration icon. May occur because the InfoCenter was set to inhibit reset regeneration and machine Manually initiate a parked regeneration as soon operation continued, adding more soot to...
Page 81: Service And Repairs
Service and Repairs Air Cleaner System 1.4 to 1.6 N·m (12 to 15 in-lb) VACUATOR DIRECTION MODELS MODELS 30885 and 30893, 30893TE, 30887 30899 and 30899TE g307625 Figure 11 Air cleaner assembly Flat washer (2 used) Air cleaner inlet hose Air cleaner mount Lock nut (2 used) Hose clamp...
Page 82 Removal (Figure 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 11 as a guide. Installation (Figure g307626...
Page 83 Installation (Figure 11) (continued) g307627 Figure 13 Air cleaner assembly Groove Service indicator Filter element Adapter B. Orientate vacuator valve on air cleaner cover toward ground. C. Make sure that air cleaner outlet hose (item 17 or 18 in Figure 11) does not contact any engine or machine components.
Page 84: Fuel System
Fuel System g307694 Figure 14 Fuel suction tube Cap screw (2 used) Flange nut (2 used) Fuel gauge Clamp (2 used) Fuel/water separator Fuel hose (supply) Flange nut (2 used) Elbow fitting Fuel pump Return fitting Flat washer (2 used) Hose clamp Fuel hose (return) Grommet...
Page 85 DANGER Because diesel fuel is flammable, use caution when storing or handling it. Do not smoke while filling the fuel tank. Do not fill fuel tank while engine is running, hot or when machine is in an enclosed area. Always fill fuel tank outside and wipe up any spilled diesel fuel before starting the engine.
Page 86 Fuel Tank Removal (Figure 14) (continued) g307695 Figure 15 Fuel tank cap Fuel supply hose Fuel gauge Fuel return hose 4. Disconnect wire harness connections from the fuel pump (item 13). 5. Remove fuel tank using Figure 14 as a guide. Fuel Tank Installation (Figure 1.
Page 87: Radiator And Oil Cooler Assembly
Radiator and Oil Cooler Assembly g307729 Figure 16 Radiator/oil cooler assembly Flange head screw (4 used) Coolant reservoir Cap screw (4 used) Hydraulic tube R−clamp (2 used) Hydraulic tube Bushing Washer (4 used) Hydraulic tube Elbow fitting Plenum assembly Hose Flange nut (4 used) Lower radiator hose Cap screw (6 used)
Page 88 Removal (Figure 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 (page 8–26)). CAUTION Do not open radiator cap or drain coolant if the radiator or engine is hot.
Page 89 Removal (Figure 16) (continued) g307730 Figure 17 Radiator/oil cooler Bulkhead nut Hydraulic tube Spacer Hydraulic tube O−ring Hydraulic hose 10. Disconnect hydraulic hoses from radiator/oil cooler (Figure 17). Put caps or plugs on open hydraulic hoses and fittings to prevent system contamination. Label the hydraulic hoses to show their correct position on the oil cooler for assembly purposes.
Page 90 Removal (Figure 16) (continued) g307731 Figure 18 Radiator cap Radiator/oil cooler O−ring Plug 90º fitting (2 used) Draincock O−ring Hydraulic plug 14. If necessary, remove draincock (item 7 in Figure 18), plug (item 6 in Figure 18) and hydraulic plug (item 8 in Figure 18) from radiator/oil cooler.
Page 91 Installation (Figure 16) (continued) 6. Position lower radiator shroud to radiator/oil cooler. Install fasteners to secure lower shroud to radiator. Do not fully tighten fasteners until after engine cooling fan motor, fan and upper shroud are installed. 7. Install engine cooling fan motor and bracket assembly, cooling fan and upper radiator shroud to machine (see Engine Cooling Fan Motor (page 5–147)).
Page 92: Engine
Engine g307774 Figure 19 LH front engine mount bracket Flange nut (13 used) Engine RH front engine mount bracket Rebound washer (4 used) Negative battery cable LH rear engine mount bracket Lock washer Tailpipe RH rear engine mount bracket Cap screw (3 used) Flange nut (4 used) Lock washer (16 used) Cap screw...
Page 93 Engine Removal (Figure 19) (continued) CAUTION Do not open radiator cap or drain coolant if the radiator or engine is hot. Allow the engine and exhaust system to cool before working on the engine. Pressurized, hot coolant can escape and cause burns. Ethylene−glycol antifreeze is poisonous.
Page 94 Engine Removal (Figure 19) (continued) g307776 Figure 21 (Models 30893, 30893TE, 30899 and 30899TE) Engine Fuel return hose Hose clamp Fuel supply hose 7. Disconnect fuel supply and return hoses from injection pump (Figure Figure 21). Cap fuel hoses and injector pump fittings to prevent contamination.
Page 95 Engine Removal (Figure 19) (continued) IMPORTANT Make sure to not damage the engine, fuel lines, hydraulic lines, electrical harness or other parts while removing the engine. 14. Carefully move engine away from the hydraulic pump assembly to disengage the pump input shaft from the coupler on the engine flywheel. Once the engine has cleared the hydraulic pump, carefully lift engine from the machine.
Page 96 Engine Installation (Figure 19) (continued) 9. Connect the following engine electrical components: A. The engine wire harness to the machine wire harness. B. The positive battery cable and fusible link harness to the engine starter motor. C. The negative battery cable, engine ground cable and main wire harness ground wires to the right side of the engine below the starter motor with external lock washer and cap screw.
Page 97: Pump Adaptor Plate
Pump Adaptor Plate g307828 Figure 22 Flywheel plate Cap screw (8 used) Engine assembly Hardened washer (8 used) Cap screw with patchlock (8 used) Spring coupler Hardened washer (8 used) Coupler Removal (Figure Note: The hydraulic pump assembly needs to be removed from engine before coupler can be removed.
Page 98 Coupler Installation (Figure g307829 Figure 23 Coupler Engine flywheel Coupler hub 1. Position spring coupler to engine flywheel and align mounting holes. Make sure that coupling hub is away from engine flywheel (Figure 23). 2. Secure coupler to flywheel with eight (8) cap screws and hardened washers. Torque cap screws in a crossing pattern from 40 to 44 N·m (29 to 33 ft−lb).
Page 99: Exhaust System (Models 30885 And 30887)
Exhaust System (Models 30885 and 30887) g307830 Figure 24 Gasket Bolt (20 used) Hose clip (2 used) Exhaust assembly stay DPF lifter Hose Exhaust assembly stay DPF stiffener (5 used) Bolt (3 used) Exhaust assembly stay DPF stiffener Hose clip (2 used) Exhaust assembly stay DPF stiffener Pressure sensor...
Page 100 Once the DPF has gone through the reconditioning process, it can be re−installed in the exhaust system. Contact your Toro Distributor for information on reconditioning the DPF. The diesel oxidation catalyst (DOC) has a service life expectancy and requires replacement at recommended intervals.
Page 101 Removal (continued) CAUTION The muffler and exhaust pipe may be hot. To avoid possible burns, allow the engine and exhaust system to cool before working on the exhaust system. 1. Raise and support hood to gain access to exhaust system. Allow engine and exhaust to cool before doing any disassembly of exhaust system components.
Page 102 Yanmar Diesel Engine: Service and Repairs Page 4–30 Groundsmaster ® 4500-D/4700-D 19245SL Rev A...
Page 103 Chapter 5 Hydraulic System Table of Contents General Information ..........................5–3 Operator’s Manual ..........................5–3 Check Hydraulic Fluid ........................5–3 Towing Traction Unit........................... 5–3 Relieving Hydraulic System Pressure ....................5–4 Traction Circuit Component Failure....................5–5 Hydraulic Hoses..........................5–6 Installing Hydraulic Hoses and Tubes (O-Ring Face Seal) ..............5–7 Installing the Hydraulic Fittings (SAE Straight Thread O-Ring Fittings)..........
Page 104 Charge Hydraulic System ........................ 5–95 Gear Pump............................5–97 Gear Pump Service ........................5–100 Piston (Traction) Pump ........................5–103 Piston (Traction) Pump Service...................... 5–107 Rear Traction Control Manifold ...................... 5–108 Rear Traction Manifold Service ...................... 5–110 Control Manifold Cartridge Valve Service..................5–111 Two Speed Shift Manifold ......................
Page 105: General Information
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 g307854 Figure 26 Hydraulic reservoir Reservoir cap The Groundsmaster hydraulic system is designed to operate on anti−wear hydraulic fluid.
Page 106: Relieving Hydraulic System Pressure
(traction) pump, and on the port located in−between ports M8 and P2 on the rear traction manifold which is located behind the front tire. Use Toro part numbers 95−8843 (hydraulic hose), 95−0985 (quantity 2) (coupler fitting) and 340−77 (quantity 2) (hydraulic fitting).
Page 107: Traction Circuit Component Failure
Once the Toro high flow hydraulic filter kit has been placed in the circuit, raise and support the machine with all wheels off the ground. Then, operate the traction circuit to allow oil flow throughout the circuit.
Page 108: Hydraulic Hoses
Note: If the hose has an elbow at one end, tighten the swivel nut on the elbow end before you tighten the nut on the straight end of the hose. For more hydraulic hose information, refer to the Toro Basics Series Training Book Hydraulic Hose Servicing (Part No. 94813SL).
Page 109: Installing Hydraulic Hoses And Tubes (O-Ring Face Seal)
Installing Hydraulic Hoses and Tubes (O-Ring Face Seal) g212099 Figure 28 Tube or hose Swivel nut O-ring Fitting body 1. Ensure that all the threads, the sealing surfaces of the hose/tube, and the fitting are free of burrs, nicks, scratches, or unwanted material. 2.
Page 110 Installing Hydraulic Hoses and Tubes (O-Ring Face Seal) (continued) Hose/Tube Installation Torque Table Fitting Dash Size Hose/Tube Side Thread Size Installation Torque (inch)—threads per inch) 9/16—18 25 to 29 N∙m (18 to 22 ft-lb) 11/16—16 37 to 44 N∙m (27 to 33 ft-lb) 13/16—16 51 to 63 N∙m (37 to 47 ft-lb) 1—14...
Page 111: Installing The Hydraulic Fittings (Sae Straight Thread O-Ring Fittings)
Installing the Hydraulic Fittings (SAE Straight Thread O-Ring Fittings) Installing a Non-Adjustable Fitting g212226 Figure 30 Fitting O-ring 1. Ensure that all the threads, the sealing surfaces of fitting, and the component port are free of burrs, nicks, scratches, or unwanted material. 2.
Page 112 Installing an Adjustable Fitting g212224 Figure 31 Locknut Back-up washer O-ring g212225 Figure 32 Step 1: clearance the lock nut Step 3: align the fitting Step 2: seat the back-up washer Step 4: tighten the lock nut 1. Ensure that all the threads, the sealing surfaces of fitting, and the component port are free of burrs, nicks, scratches, or unwanted material.
Page 113 Installing an Adjustable Fitting (continued) 7. Tighten the fitting lock nut (Step 4 in Figure 32): A. Hold the fitting in the correct alignment with a wrench and use a torque wrench and tighten the lock nut to the recommended torque value within the specified range of torque values;...
Page 114: Hydraulic Schematic
Hydraulic Schematic g307891 Figure 33 Groundsmaster 4500-D Hydraulic System: Hydraulic Schematic Page 5–12 Groundsmaster ® 4500-D/4700-D 19245SL Rev A...
Page 115 g307892 Figure 34 Groundsmaster 4700-D Groundsmaster ® 4500-D/4700-D Page 5–13 Hydraulic System: Hydraulic Schematic 19245SL Rev A...
Page 116: Hydraulic Flow Diagrams
Hydraulic Flow Diagrams g307904 Figure 35 Hydraulic System: Hydraulic Flow Diagrams Page 5–14 Groundsmaster ® 4500-D/4700-D 19245SL Rev A...
Page 117: Traction Circuit: Low Mode
Traction Circuit: LOW Mode The traction circuit piston pump is a variable displacement pump that is directly coupled to the engine flywheel. This pump utilizes an integral electro−hydraulic servo piston assembly that controls the rate and direction of hydraulic flow. Pressing the traction pedal rotates a potentiometer that provides an input to the machine TEC controller.
Page 118 Forward Direction (continued) When in LOW mode position with the traction pedal pushed in the forward direction, oil from the piston pump is directed to the front wheel motors and rear axle motor through a parallel system. Oil flow to the front wheel motors drives the motors in the forward direction and then returns to the piston pump.
Page 119: Traction Circuit: Auto Mode
Traction Circuit: Auto Mode g307905 Figure 36 Groundsmaster ® 4500-D/4700-D Page 5–17 Hydraulic System: Hydraulic Flow Diagrams 19245SL Rev A...
Page 120 The traction circuit piston pump is a variable displacement pump that is directly coupled to the engine flywheel. This pump utilizes an integral electro-hydraulic servo piston assembly that controls the rate and direction of hydraulic flow. Pressing the traction pedal rotates a potentiometer that provides an input to the machine TEC controller.
Page 121 Forward Direction (continued) When going down a hill, the tractor becomes an over-running load that drives the front wheel and rear axle motors. In this condition, the rear axle motor could lock up as the oil pumped from the motor increases pressure as it returns to the piston pump.
Page 122: Lower Cutting Decks: Groundsmaster 4500-D
Lower Cutting Decks: Groundsmaster 4500-D g308025 Figure 37 Hydraulic System: Hydraulic Flow Diagrams Page 5–20 Groundsmaster ® 4500-D/4700-D 19245SL Rev A...
Page 123 A four section gear pump is coupled to the piston (traction) pump. The third gear pump section supplies hydraulic flow to both the lift control manifold and the steering control valve. Hydraulic flow from this pump section is delivered to the circuits through a proportional flow divider located in the fan control manifold.
Page 124 Cutting Deck Lower To lower the five (5) cutting decks on a Groundsmaster 4500-D, the front of the lift switch is depressed. The switch acts as an input to the TEC controller (T1) which then provides an electrical output to solenoid valve S6 in the lift control manifold.
Page 125: Lower Cutting Decks: Groundsmaster 4700-D
Lower Cutting Decks: Groundsmaster 4700-D g308026 Figure 40 Groundsmaster ® 4500-D/4700-D Page 5–23 Hydraulic System: Hydraulic Flow Diagrams 19245SL Rev A...
Page 126 A four section gear pump is coupled to the piston (traction) pump. The third gear pump section supplies hydraulic flow to both the lift control manifold and the steering control valve. Hydraulic flow from this pump section is delivered to the circuits through a proportional flow divider located in the fan control manifold.
Page 127 Cutting Deck Lower (continued) flow from the rod ends of the center five (5) deck lift cylinders. The weight of the cutting decks cause the lift cylinders to extend and the center decks to lower. An orifice in the lift control manifold restricts oil flow from the lift cylinders to control deck drop speed.
Page 128: Raise Cutting Decks: Groundsmaster 4500-D
Raise Cutting Decks: Groundsmaster 4500-D g308073 Figure 43 Hydraulic System: Hydraulic Flow Diagrams Page 5–26 Groundsmaster ® 4500-D/4700-D 19245SL Rev A...
Page 129 A four section gear pump is coupled to the piston (traction) pump. The third gear pump section supplies hydraulic flow to both the lift control manifold and the steering control valve. Hydraulic flow from this pump section is delivered to the circuits through a proportional flow divider located in the fan control manifold.
Page 130 Cutting Deck Raise To raise the five (5) cutting decks on a Groundsmaster 4500-D, the rear of the lift switch is depressed. The switch acts as an input to the TEC controller (T1) which then provides an electrical output to solenoid valve S5 in the lift control manifold. Energized solenoid valve S5 shifts to allow a passage for oil flow to the rod ends of the five (5) deck lift cylinders.
Page 131: Raise Cutting Decks: Groundsmaster 4700-D
Raise Cutting Decks: Groundsmaster 4700-D g308074 Figure 46 Groundsmaster ® 4500-D/4700-D Page 5–29 Hydraulic System: Hydraulic Flow Diagrams 19245SL Rev A...
Page 132 A four section gear pump is coupled to the piston (traction) pump. The third gear pump section supplies hydraulic flow to both the lift control manifold and the steering control valve. Hydraulic flow from this pump section is delivered to the circuits through a proportional flow divider located in the fan control manifold.
Page 133 Cutting Deck Raise To raise the center five (5) cutting decks on the Groundsmaster 4700-D, the rear of the center console switch is depressed. The switch acts as an input to the TEC controller (T1) which then provides an electrical output to solenoid valves S1 and S5 in the lift control manifold.
Page 134: Mow Circuit
Mow Circuit g308129 Figure 49 Hydraulic System: Hydraulic Flow Diagrams Page 5–32 Groundsmaster ® 4500-D/4700-D 19245SL Rev A...
Page 135 Hydraulic flow for the mow circuit is supplied by the first two (2) sections of the gear pump. The first gear pump section P1 supplies hydraulic flow to decks 5, 3 and 2 (also deck 7 on the GM 4700-D), while the second gear pump section supplies decks 1 and 4 (also deck 6 on the GM 4700-D).
Page 136 PTO Disengaged (continued) g308182 Figure 51 DECK CONTROL MANIFOLD (GM4700-D) PTO Engaged When the PTO switch is turned ON with the decks lowered, the solenoid valves (PRV1 and PRV2) are energized with outputs from the TEC controller (T1). The energized valves shift to direct pump flow toward the deck motors. As circuit pressure to the deck motors increases, the brake relief cartridge (RV) opens which allows an oil flow through the manifold orifice positioned before the logic cartridge (LC).
Page 137: Cutting Deck Blade Braking
Cutting Deck Blade Braking DECK CONTROL MANIFOLD FROM 1500 GEAR PRV2 3500 1.16 PUMP FRONT CENTER RV09 1.16 FRONT LEFT TO OIL COOLER ORIFICE g308183 Figure 52 DECK CONTROL MANIFOLD FROM 1500 GEAR PUMP PRV2 3500 1.16 FRONT CENTER RV09 1.16 FRONT LEFT...
Page 138 Cutting Deck Blade Braking (continued) shift. The shifted relief valve removes the flow path from the orifice at the logic cartridge, causing the logic cartridge to shift and block the return oil path from the deck motors (Figure 52). The inertia of the rotating cutting blades, however, effectively turns the deck motors into pumps causing an increase in pressure as the flow from the motors comes up against the closed logic cartridge (LC).
Page 139: Steering Circuit
Steering Circuit g308197 Figure 55 Groundsmaster ® 4500-D/4700-D Page 5–37 Hydraulic System: Hydraulic Flow Diagrams 19245SL Rev A...
Page 140 A four section gear pump is coupled to the piston (traction) pump. The third gear pump section supplies hydraulic flow to the steering control valve and the lift/lower control valve. Pump hydraulic flow is delivered to the two circuits through a proportional flow divider located in the fan control manifold. Steering circuit pressure is limited to 72 bar (1050 PSI) by a relief valve located in the steering control valve.
Page 141 Left Turn (continued) Pressure retracts the lift cylinder for a left turn. The rotary meter ensures that the oil flow to the cylinder is proportional to the amount of the turning on the steering wheel. Fluid leaving the cylinder flows back through the spool valve then through the T port and to the hydraulic reservoir.
Page 142: Engine Cooling Fan Circuit
Engine Cooling Fan Circuit g308199 Figure 57 Hydraulic System: Hydraulic Flow Diagrams Page 5–40 Groundsmaster ® 4500-D/4700-D 19245SL Rev A...
Page 143 A four section gear pump is coupled to the piston (traction) pump. The final gear pump section (farthest from the piston pump) supplies hydraulic flow for the hydraulic engine cooling fan motor. The fan control manifold controls the operation of the hydraulic motor that drives the engine cooling fan in addition to including the flow divider for the steering and lift circuits.
Page 144 Forward Direction Fan Operation (continued) TO RESERVOIR TO STEERING CIRCUIT 50/50 FLOW DIVIDER TO LIFT/LOWER CIRCUIT FAN CONTROL MANIFOLD FROM GEAR TO OIL FROM GEAR PUMP SECTION COOLER PUMP SECTION g308210 Figure 58 Reverse Direction Fan Operation (Figure The TEC controller (T1) can reverse the cooling fan to clean debris from the rear intake screen.
Page 145: Testing
Testing The most effective method for isolating problems in the hydraulic system is by using hydraulic test equipment such as pressure gauges and flow meters in the circuits during various operational checks (see the Special Tools (page 2–16)). IMPORTANT All obvious areas such as hydraulic oil supply, oil filters, binding components, loose fasteners or improper adjustments must be checked before assuming that a hydraulic component is the source of the problem.
Page 146: Which Hydraulic Tests Are Necessary
Precautions for Hydraulic Testing (continued) 4. Put metal caps or plugs on any hydraulic lines left open or exposed during testing or removal of components. 5. The engine must be in good operating condition. Use a phototac to determine engine speed when performing a hydraulic test. Engine speed will affect the accuracy of the tester readings.
Page 147 Which Hydraulic Tests Are Necessary? (continued) 5. If a engine cooling fan circuit problem exists, consider performing one or more of the following tests: Engine Cooling Fan Circuit and/or Gear Pump Flow Tests. Groundsmaster ® 4500-D/4700-D Page 5–45 Hydraulic System: Testing 19245SL Rev A...
Page 148: Traction Circuit Charge Pressure (Using Pressure Gauge)
Traction Circuit Charge Pressure (Using Pressure Gauge) g308253 Figure 59 Hydraulic System: Testing Page 5–46 Groundsmaster ® 4500-D/4700-D 19245SL Rev A...
Page 149 Note: The traction charge circuit is designed to replace loss of hydraulic fluid from the closed loop traction circuit. Procedure for Traction Circuit Charge Pressure Test CAUTION Prevent personal injury and/or damage to equipment. Read all WARNINGS, CAUTIONS and Precautions for Hydraulic Testing at the beginning of this section.
Page 150 Procedure for Traction Circuit Charge Pressure Test (continued) Note: Steering and lift/lower circuits would also be affected if the third gear pump section is worn or damaged. 9. Next, with the pressure gauge still connected to the diagnostic test fitting, monitor the gauge reading while operating the machine in forward and reverse.
Page 151: Traction Circuit Relief Pressure (Using Pressure Gauge)
Traction Circuit Relief Pressure (Using Pressure Gauge) g308280 Figure 61 FORWARD DIRECTION TEST SHOWN Groundsmaster ® 4500-D/4700-D Page 5–49 Hydraulic System: Testing 19245SL Rev A...
Page 152 Procedure for Traction Circuit Relief Pressure Test CAUTION Prevent personal injury and/or damage to equipment. Read all WARNINGS, CAUTIONS and Precautions for Hydraulic Testing at the beginning of this section. 1. Make sure hydraulic oil is at normal operating temperature by operating the machine for approximately ten (10) minutes.
Page 153 Procedure for Traction Circuit Relief Pressure Test (continued) g308279 Figure 63 Forward relief valve Straight fitting Reverse relief valve 90º fitting Piston (traction) pump Diagnostic test fitting Reverse traction port 3. Locate traction circuit test fitting for function to be checked (forward or reverse): A.
Page 154 Procedure for Traction Circuit Relief Pressure Test (continued) 9. When testing is completed, disconnect pressure gauge from diagnostic test fitting. If reverse traction circuit was tested, remove test fitting, 90º fitting and straight fitting from piston (traction) pump. Install plug into piston pump port and torque plug to 43 N·m (32 ft-lb).
Page 155: Reverse Traction Circuit Reducing Valve (Pr) Pressure (Using Pressure Gauge)
Reverse Traction Circuit Reducing Valve (PR) Pressure (Using Pressure Gauge) g308371 Figure 64 Groundsmaster ® 4500-D/4700-D Page 5–53 Hydraulic System: Testing 19245SL Rev A...
Page 156 (Figure 65). Remove #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 70 bar (1000 PSI) pressure gauge with hydraulic hose attached to installed diagnostic fitting.
Page 157 Procedure for Reverse Traction Circuit Reducing Valve (PR) Pressure Test (continued) 7. Release traction pedal to neutral, stop engine and record test results. g308370 Figure 66 Rear traction manifold Relief (RV) valve #6 zero leak plug Reducing (PR) valve 8. The pressure reducing valve (PR) is located on the bottom of the rear traction manifold (Figure 66).
Page 158: Rear Traction Circuit Relief (Rv) Pressure (Using Pressure Gauge)
Rear Traction Circuit Relief (RV) Pressure (Using Pressure Gauge) g308371 Figure 67 Hydraulic System: Testing Page 5–56 Groundsmaster ® 4500-D/4700-D 19245SL Rev A...
Page 159 (Figure 68). Remove #6 zero leak plug on inside of rear traction manifold and install diagnostic fitting (Toro part number 59-7410) into manifold port. 4. Connect a 70 bar (1000 PSI) pressure gauge with hydraulic hose attached to installed diagnostic fitting.
Page 160 Procedure for Rear Traction Circuit Relief Valve (RV) Pressure Test (continued) 5. Start engine and increase engine speed to high idle speed. Make sure that Auto/LOW mode switch is in the LOW (mow) position and release the parking brake. 6. Measure and record reverse traction circuit reducing valve (PR) pressure (see Reverse Traction Circuit Reducing Valve (PR) Pressure (Using Pressure Gauge) (page...
Page 161: Piston (Traction) Pump Flow (Using Tester With Pressure Gauge & Flow Meter)
Piston (Traction) Pump Flow (Using Tester with Pressure Gauge & Flow Meter) g308373 Figure 70 Groundsmaster ® 4500-D/4700-D Page 5–59 Hydraulic System: Testing 19245SL Rev A...
Page 162 Procedure for Piston (Traction) Pump Flow Test This test measures piston (traction) pump output (flow). During this test, pump load is created at the flow meter using the adjustable load valve on the tester. Note: Before performing piston pump flow test, make sure that traction speed is set to 100% using the InfoCenter settings menu.
Page 163 Procedure for Piston (Traction) Pump Flow Test (continued) 3. Thoroughly clean junction of hydraulic hose and right side fitting on bottom of piston pump (forward port) (Figure 71). Disconnect hose from right side pump fitting. 4. Install tester with pressure gauge and flow meter in series between piston pump fitting and disconnected hose to allow flow from traction pump to tester.
Page 164: Cutting Deck Circuit Pressure (Using Pressure Gauge)
Cutting Deck Circuit Pressure (Using Pressure Gauge) g308387 Figure 72 TEST FOR GM4500-D DECKS 1 AND 4 SHOWN Hydraulic System: Testing Page 5–62 Groundsmaster ® 4500-D/4700-D 19245SL Rev A...
Page 165 Procedure for Cutting Deck Circuit Pressure Test CAUTION Prevent personal injury and/or damage to equipment. Read all WARNINGS, CAUTIONS and Precautions for Hydraulic Testing at the beginning of this section. 1. Make sure hydraulic oil is at normal operating temperature by operating the machine for approximately ten (10) minutes.
Page 166 Procedure for Cutting Deck Circuit Pressure Test (continued) 5. After installing pressure gauge, start engine and run at low idle speed. Check for hydraulic leakage and correct before proceeding with test. CAUTION Keep away from decks during test to prevent personal injury from the cutting blades.
Page 167: Cutting Deck Circuit Relief Pressure (Using Tester With Pressure Gauge & Flow Meter)
Cutting Deck Circuit Relief Pressure (Using Tester with Pressure Gauge & Flow Meter) g308392 Figure 76 TEST FOR GM4500-D SECOND PUMP SECTION SHOWN Groundsmaster ® 4500-D/4700-D Page 5–65 Hydraulic System: Testing 19245SL Rev A...
Page 168 Procedure for Cutting Deck Circuit Relief Pressure Test CAUTION Prevent personal injury and/or damage to equipment. Read all WARNINGS, CAUTIONS and Precautions for Hydraulic Testing at the beginning of this section. 1. Make sure hydraulic oil is at normal operating temperature by operating the machine for approximately ten (10) minutes.
Page 169 Procedure for Cutting Deck Circuit Relief Pressure Test (continued) B. For second gear pump section (decks #1, #4 and #6), cutting deck circuit relief (PRV1) is tested at the inlet to the deck #1 motor (Figure 77). 4. Thoroughly clean junction of appropriate hydraulic inlet hose and deck motor fitting (Figure 78).
Page 170: Deck Motor Case Drain Leakage (Using Tester With Pressure Gauge & Flow Meter)
Deck Motor Case Drain Leakage (Using Tester with Pressure Gauge & Flow Meter) TO HYDRAULIC TANK STEEL CAP MEASURING CONTAINER g308472 Figure 79 TEST FOR GM4500-D DECK MOTOR #1 SHOWN Hydraulic System: Testing Page 5–68 Groundsmaster ® 4500-D/4700-D 19245SL Rev A...
Page 171 Procedure for Deck Motor Case Drain Leakage Test Note: Over a period of time, a deck motor can wear internally. A worn motor may bypass oil to its case drain causing the motor to be less efficient. Eventually, enough oil loss will cause the deck motor to stall under heavy cutting conditions. Continued operation with a worn, inefficient motor can generate excessive heat, cause damage to seals and other components in the hydraulic system and affect quality of cut.
Page 172 Procedure for Deck Motor Case Drain Leakage Test (continued) g308391 Figure 81 Flow IN Case drain Flow OUT 3. Disconnect pressure return hose from the motor to be tested (Figure 81). Install tester with pressure gauge and flow meter in series with the motor and the disconnected return hose.
Page 173: Steering Circuit Relief Pressure (Using Pressure Gauge)
Steering Circuit Relief Pressure (Using Pressure Gauge) g308484 Figure 82 TEST FOR GM4500-D SHOWN (STEERING WHEEL TURNED FOR RIGHT TURN) Groundsmaster ® 4500-D/4700-D Page 5–71 Hydraulic System: Testing 19245SL Rev A...
Page 174 Procedure for Steering Circuit Relief Pressure Test The steering circuit relief pressure test should be performed to make sure that the steering circuit relief pressure is correct. CAUTION Prevent personal injury and/or damage to equipment. Read all WARNINGS, CAUTIONS and Precautions for Hydraulic Testing at the beginning of this section.
Page 175 Procedure for Steering Circuit Relief Pressure Test (continued) stabilize briefly and then may continue to increase. The steering circuit relief pressure is the gauge reading when pressure stabilizes. GAUGE READING TO BE 80 to 103 bar (1150 TO 1500 PSI). 8.
Page 176: Steering Cylinder Internal Leakage
Steering Cylinder Internal Leakage STEERING 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 g308509 Figure 84 The steering cylinder internal leakage test should be performed if a steering problem is identified.
Page 177 Procedure for Steering Cylinder Internal Leakage Test (continued) CAUTION Prevent personal injury and/or damage to equipment. Read all WARNINGS, CAUTIONS and Precautions for Hydraulic Testing at the beginning of this section. 1. Park machine on a level surface with the cutting decks lowered and off. Make sure hydraulic oil is at normal operating temperature, engine is off and the parking brake is applied.
Page 178: Lift/Lower Circuit Relief Pressure (Using Pressure Gauge)
Lift/Lower Circuit Relief Pressure (Using Pressure Gauge) g308513 Figure 85 GM4500-D SHOWN Hydraulic System: Testing Page 5–76 Groundsmaster ® 4500-D/4700-D 19245SL Rev A...
Page 179 Procedure for Lift/Lower Circuit Relief Pressure Test The lift/lower circuit relief pressure test should be performed to make sure that the cutting unit lift and lower circuit relief pressure is correct. CAUTION Prevent personal injury and/or damage to equipment. Read all WARNINGS, CAUTIONS and Precautions for Hydraulic Testing at the beginning of this section.
Page 180 Procedure for Lift/Lower Circuit Relief Pressure Test (continued) 6. While remaining on the seat, depress rear of lift switch (raise) to allow lift/lower circuit pressure to increase. Momentarily hold the switch with the lift cylinders fully retracted while looking at the pressure gauge as the lift/lower relief valve opens.
Page 181: Engine Cooling Fan Circuit (Using Pressure Gauge And Phototac)
Engine Cooling Fan Circuit (Using Pressure Gauge and Phototac) g308528 Figure 88 GM4500-D SHOWN Groundsmaster ® 4500-D/4700-D Page 5–79 Hydraulic System: Testing 19245SL Rev A...
Page 182 Procedure for Engine Cooling Fan Circuit Test The engine cooling fan circuit test should be performed to make sure that the engine cooling fan circuit has the correct system pressure and fan speed. CAUTION Prevent personal injury and/or damage to equipment. Read all WARNINGS, CAUTIONS and Precautions for Hydraulic Testing at the beginning of this section.
Page 183 Procedure for Engine Cooling Fan Circuit Test (continued) Note: If pressure and fan speed are both low and the final gear pump section flow proves to be correct (see Gear Pump Flow (Using Tester with Pressure Gauge & Flow Meter) (page 5–82)), suspect that seals in fan control manifold are leaking or faulty (see Fan Control Manifold Service (page...
Page 184: Gear Pump Flow (Using Tester With Pressure Gauge & Flow Meter)
Gear Pump Flow (Using Tester with Pressure Gauge & Flow Meter) g308641 Figure 90 GM4500-D and SECOND GEAR PUMP SECTION FLOW TEST SHOWN Hydraulic System: Testing Page 5–82 Groundsmaster ® 4500-D/4700-D 19245SL Rev A...
Page 185: Procedure For Gear Pump Flow Test
Gear Pump Flow (Using Tester with Pressure Gauge & Flow Meter) (continued) The gear pump flow test should be performed to make sure that the mow, steering, lift/lower, cooling fan and traction charge circuits have adequate hydraulic flow. Gear pump sections are illustrated in Figure 91.
Page 186 Procedure for Gear Pump Flow Test (continued) #4 Deck #1 Deck #5 Deck #7 Deck #6 Deck Deck Deck (GM4700) (GM4700) g308386 Figure 92 CUTTING DECK LOCATIONS 4. Determine which gear pump section is to be tested. Disconnect hydraulic hose from fitting in gear pump section that is to be tested (Figure 91).
Page 187 Procedure for Gear Pump Flow Test (continued) intake line. If line is not restricted, consider that the tested gear pump section is worn or damaged. 12. After testing is completed, disconnect flow tester from hydraulic hose and fitting in gear pump section. Reconnect hose to the pump fitting. 13.
Page 188: Adjustments
Adjustments Adjust Control Manifold Relief Valves g275100 Figure 93 Relief valve cap Adjustment socket Several of the hydraulic control manifolds on your Groundsmaster include adjustable relief valves. The following procedure can be used to adjust these relief valves. Refer to the Testing (page 5–43) section of this chapter for information on testing relief pressure.
Page 189: Service And Repairs
Service and Repairs General Precautions for Removing and Installing Hydraulic System Components Before Repair or Replacement of Components 1. Before removing any parts from the hydraulic system, park machine on a level surface, apply parking brake, lower cutting decks or attachments and stop engine.
Page 190 After Repair or Replacement of Components (continued) oil before starting engine. This will ensure that internal components have adequate lubrication during initial operation. 7. After disconnecting or replacing any hydraulic components, operate machine functions slowly until air is out of system (see Charge Hydraulic System (page 5–95)).
Page 191: Check Hydraulic Lines And Hoses
Check Hydraulic Lines and Hoses WARNING Keep body and hands away from pin hole leaks or nozzles that eject hydraulic fluid under high pressure. Use paper or cardboard, not hands, to search for leaks. Hydraulic fluid escaping under pressure can have sufficient force to penetrate the skin and cause serious injury.
Page 192: Priming Hydraulic Pumps
Priming Hydraulic Pumps Whenever the hydraulic system is flushed, the hydraulic system is charged or hydraulic components are installed, it is important to properly prime the hydraulic pumps. Hydraulic pump priming ensures that the gear pump and piston (traction) pump have adequate oil during initial start−up and running. The pumps can be primed by using a remote starter switch (see Special Tools (page 2–16)) to crank...
Page 193: Flush Hydraulic System
Flush Hydraulic System IMPORTANT Flush the hydraulic system any time there is a severe component failure or the system is contaminated. Contaminated oil may appear milky or black or may contain metal particles. IMPORTANT Flush hydraulic system when changing from petroleum base hydraulic fluid to a biodegradable fluid.
Page 194 Flush Hydraulic System (continued) 6. Connect all hydraulic hoses, lines and components that were disconnected while draining system. IMPORTANT When filling hydraulic reservoir, use only hydraulic fluids specified in Operator’s Manual. Other fluids could cause system damage. 7. Fill hydraulic reservoir with new hydraulic fluid. 8.
Page 195: Filtering Closed−Loop Traction Circuit
To effectively remove contamination from closed−loop traction circuit, use of the Toro high flow hydraulic filter and hydraulic hose kits are recommended (see Special Tools (page 2–16)).
Page 196 (5) minutes. IMPORTANT If using a filter that is not the bi−directional Toro high flow filter, do not press the traction pedal in the reverse direction. If flow is reversed when using a filter that is not bi−directional, debris from the filter will re−enter the traction circuit.
Page 197: Charge Hydraulic System
Charge Hydraulic System Note: When initially starting the hydraulic system with new or rebuilt components such as motors, pumps or lift cylinders, it is important that the hydraulic system be charged properly. Air must be purged from the system to reduce the chance of component damage.
Page 198 Charge Hydraulic System (continued) C. Faulty charge relief valve. D. Faulty gear pump. 9. Once the lift cylinder does move in ten (10) to fifteen (15) seconds, proceed to step 10. 10. Operate the traction pedal in the forward and reverse directions. The wheels should rotate in the proper direction.
Page 199: Gear Pump
Gear Pump g308679 Figure 96 Piston pump assembly Hydraulic tee fitting O-ring Flat washer (4 used) 90º hydraulic fitting 45º hydraulic fitting (2 used) Gear pump assembly 45º hydraulic fitting O-ring 90º hydraulic fitting (2 used) Straight fitting O-ring 90º hydraulic fitting (2 used) O-ring Hydraulic adapter 90º...
Page 200 Removal (Figure 96) (continued) 5. Read the General Precautions for Removing and Installing Hydraulic System Components (page 5–87). 6. For assembly purposes, label all hydraulic lines connected to gear pump fittings. 7. Disconnect hydraulic lines from gear pump and put caps or plugs on open hydraulic lines and fittings.
Page 201 Installation (Figure 96) (continued) IMPORTANT Position gear pump to the piston (traction)pump so that the gear pump inlet (suction) ports are facing down. IMPORTANT A case drain exists in the piston (traction) pump and a suction port is near the input shaft of the gear pump (Figure 97).
Page 202: Gear Pump Service
Gear Pump Service g308692 Figure 99 Dust seal Seal (8 used) Body (2 pump section) Retaining ring Idler gear Body (3 pump section) Flange washer Drive gear Drive shaft Shaft seal Back-up gasket Idler gear Front cover Pressure seal Rear body (4 pump section) Dowel pin (16 used) Front body (first pump section)
Page 203 Disassembly (Figure 99) (continued) DIAGONAL LINE g275425 Figure 100 2. Use a marker to make a diagonal line across the gear pump for assembly purposes (Figure 100). IMPORTANT Use caution when clamping gear pump in a vise to avoid distorting any pump components.
Page 204 Assembly (Figure 1. Apply clean hydraulic oil to all pump parts before assembling. Note: Pressure seals and back-up gaskets fit in grooves machined into thrust plates. Body seals fit in grooves machined in body faces. 2. Assemble pump sections starting at front cover end. Apply grease or petroleum jelly to new section seals to hold them in position during gear pump assembly.
Page 205: Piston (Traction) Pump
Piston (Traction) Pump g308679 Figure 101 Piston pump assembly Hydraulic tee fitting O-ring Flat washer (4 used) 90º hydraulic fitting 45º hydraulic fitting (2 used) Gear pump assembly 45º hydraulic fitting O-ring 90º hydraulic fitting (2 used) Straight fitting O-ring 90º...
Page 206 Removal (Figure 101) (continued) g308694 Figure 102 Piston pump Solenoid coil (forward) Solenoid coil (reverse) 3. Label wire harness connectors that attach to the two (2) solenoid coils on left side of piston pump (Figure 102). Disconnect harness connectors from solenoid coils on piston pump.
Page 207 Removal (Figure 101) (continued) Note: A case drain exists in the piston (traction) pump and a suction port is near the input shaft of the gear pump (Figure 103). When the gear pump is removed from the piston pump, plug piston pump case drain hole to prevent draining the piston pump.
Page 208 Installation (Figure 101) (continued) 6. Using labels placed during pump removal, connect wire harness connectors to the two (2) solenoid coils on left side of piston (traction) pump. g308681 Figure 104 Piston pump case drain Gear pump Piston pump 7. Fill piston (traction) pump housing with new hydraulic oil through the case drain (90º...
Page 209: Piston (Traction) Pump Service
Piston (Traction) Pump Service g278631 Figure 105 Control kit (12 volt) O-ring Plug asm Coil kit Screw O-ring Charge relief kit Plug asm O-ring Nut-seal Plug Shaft Screw Plug Bearing-ball Gasket-control Plug-thread, straight Ring-retaining Ring-locking Screw Ring-retaining Screen Pin-slotted Seal-lip Screw Valve-relief, high pressure (345 bar) Valve plate...
Page 210: Rear Traction Control Manifold
Rear Traction Control Manifold g308695 Figure 106 Rear traction control manifold O-ring O-ring Cap screw (2 used) Hydraulic tube Hydraulic hose Flange nut (2 used) O-ring Hydraulic tube Two speed shift manifold Hydraulic straight fitting O-ring Lift circuit junction manifold O-ring Hydraulic tee fitting Hydraulic tube...
Page 211 Removal (Figure 106) Note: The ports on the rear traction control manifold are marked for easy identification of components. Refer to the Appendix A (page A–1). 1. Read the General Precautions for Removing and Installing Hydraulic System Components (page 5–87). 2.
Page 212: Rear Traction Manifold Service
Rear Traction Manifold Service 34 N·m 67 N·m (25 ft−lb) (50 ft−lb) 27 N·m (20 ft−lb) 156 N·m (115 ft−lb) 34 N·m (25 ft−lb) g275437 Figure 107 Rear traction manifold body #4 zero leak plug with O−ring Orifice (0.050) (port OR1) Relief valve (port RV) #6 zero leak plug with O−ring Pressure reducing valve (port PR)
Page 213: Control Manifold Cartridge Valve Service
Control Manifold Cartridge Valve Service 1. Make sure the control manifold is clean before removing the cartridge valve from the control manifold. 2. If cartridge valve is solenoid operated, remove nut securing solenoid coil to the cartridge valve. Carefully slide coil off the valve. IMPORTANT Use care when handling the cartridge valve.
Page 214 Control Manifold Cartridge Valve Service (continued) D. Torque cartridge valve using a deep socket wrench to value identified in control manifold illustration. 8. If cartridge valve is solenoid operated, carefully install solenoid coil to the cartridge valve. Secure coil to valve with nut and torque nut to 6.8 N·m (60 in−lb).
Page 215: Two Speed Shift Manifold
Two Speed Shift Manifold g308769 Figure 108 Hydraulic tube Two speed shift manifold O-ring Cap screw (2 used) O-ring O-ring Hydraulic tube Hydraulic tube Flange nut (2 used) Rear traction control manifold O-ring Lift circuit junction manifold Hydraulic tube Note: The ports on the two speed shift manifold are marked for easy identification of components.
Page 216 Removal (Figure 108) (continued) 4. Disconnect hydraulic lines from manifold and put caps or plugs on open hydraulic lines and fittings. 5. Remove two speed shift manifold from the frame using Figure 108 as guide. 6. If hydraulic fittings are to be removed from control manifold, mark fitting orientation to allow correct assembly.
Page 217 Manifold Service (continued) Note: The check valve adapter used in the two speed shift manifold allows free flow toward the manifold and prevents flow away from the manifold (Figure 110). Installation (Figure 108) 1. If fittings were removed from control manifold, lubricate and place new O-rings onto fittings.
Page 218: Rear Axle Motor
Rear Axle Motor g308773 Figure 111 Rear axle motor O-ring O-ring O-ring 90º hydraulic fitting O-ring Pinion gear Cap screw (2 used) 90º hydraulic fitting External snap ring (2 used) Flat washer (2 used) O-ring O-ring O-ring Temperature sender with O-ring Hydraulic fitting 90º...
Page 219 Removal (Figure 111) (continued) IMPORTANT Support axle motor to prevent motor from falling during removal. 6. Remove motor using Figure 111 as a guide. 7. If hydraulic fittings are to be removed from axle motor, mark fitting orientation to allow correct assembly. Remove fittings from motor and discard O-rings. Installation (Figure 111)
Page 220: Front Wheel Motors
Front Wheel Motors g308859 Figure 112 Flange head screw (6 per planetary) 7. Spring plate Piston wheel motor (2 used) Splined brake shaft Compression spring Flat washer (2 per motor) Planetary assembly Jam nut Cap screw (2 per motor) Wheel assembly Brake assembly (LH shown) O-ring Lug nut (8 per wheel)
Page 221 Removal (Figure 112) (continued) 4. To prevent contamination of hydraulic system during wheel motor removal, thoroughly clean exterior of motor. 5. Disconnect hydraulic lines from wheel motor. Put caps or plugs on lines and fittings to prevent contamination. Label the hydraulic lines to show their correct position on the wheel motor for assembly purposes.
Page 222 Removal (Figure 112) (continued) g308861 Figure 114 RIGHT WHEEL O-ring O-ring Tee fitting O-ring O-ring Straight fitting O-ring O-ring Straight fitting 7. Remove and discard O-ring (item 16) from flange of wheel motor. 8. If hydraulic fittings are to be removed from wheel motor, mark fitting orientation to allow correct assembly (Figure 113 Figure...
Page 223: Rear Axle And Front Wheel Motor Service
Rear Axle and Front Wheel Motor Service g275434 Figure 115 Plug with O−ring Dowel pin Bearing Minimum angle stop Bearing Retaining ring Bias spring Gasket Retaining ring (2 used) Servo piston Valve plate Seal O−ring Cylinder block kit Support washer O−ring Swashplate Plug with O−ring (3 used)
Page 224 Rear Axle and Front Wheel Motor Service (continued) REAR AXLE MOTOR FLUSHING VALVE g275435 Figure 116 Plug Plug O−ring O−ring Centering spring Centering spring Spring retaining washer Orifice poppet Shift spool Endcap Note: The front wheel motors on your Groundsmaster are identical (Figure 115).
Page 225: Cutting Deck Motor
Cutting Deck Motor g308862 Figure 117 Socket head screw Hydraulic 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.
Page 226 Removal (continued) 7. Place cover on deck spindle opening to prevent contamination. 8. If hydraulic fittings are to be removed from deck motor, mark fitting orientation to allow correct assembly. Remove fittings from motor and discard O-rings. Installation 1. If fittings were removed from deck motor, lubricate and place new O-rings onto fittings.
Page 227: Cutting Deck Motor Service
Cutting Deck Motor Service g308863 Figure 119 Dust seal (2 used) Front wear plate Rear cover Retaining ring Drive gear Anti-cavitation valve Flange washer Dowel pin (4 used) Relief valve Shaft seal Idler gear Cap screw (4 used) Front flange O-ring Washer (4 used) Pressure seal...
Page 228 Disassembly (Figure 119) (continued) IMPORTANT Prevent damage when clamping the motor into a vise; clamp on the front flange only. Also, use a vise with soft jaws. 3. Clamp front flange of motor in a vise with soft jaws with the shaft end down. 4.
Page 229 Disassembly (Figure 119) (continued) IMPORTANT Make sure to not damage the front flange counter bore when removing the seals from the front flange. 11. Carefully remove dust seals, retaining ring, flange washer and shaft seal from the front flange (Figure 121).
Page 230 Assembly (Figure 119) Note: When assembling the motor, check the marker line on each part to make sure the parts are properly aligned during assembly. 1. Lubricate O-rings, pressure seals, back-up gaskets and wear plate grooves with a thin coat of petroleum jelly. Lubricate all other internal parts freely with clean hydraulic oil.
Page 231 Assembly (Figure 119) (continued) 15. Install the four (4) cap screws with washers and hand tighten screws. IMPORTANT Prevent damage when clamping the motor into a vise; clamp on the front flange only. Also, use a vise with soft jaws. 16.
Page 232: Deck Control Manifold
Deck Control Manifold g308889 Figure 123 GROUNDSMASTER 4500-D SHOWN Deck control manifold Hydraulic oil filter assembly Lift control manifold Filter mount bracket Valve mount bracket Flange head screw (2 used) Flange head screw (2 used) Flange head screw (2 used) Fan drive manifold Note: The deck control manifolds used on Groundsmaster 4500-D and 4700-D are different but they mount to the machine in the same location.
Page 233 Removal (Figure 123) (continued) 2. Read the General Precautions for Removing and Installing Hydraulic System Components (page 5–87). 3. Unlatch and raise hood. g308890 Figure 124 GM4500-D Deck manifold O-ring O-ring O-ring Straight fitting (8 used) 45º fitting O-ring O-ring O-ring Straight fitting Straight fitting...
Page 234 Removal (Figure 123) (continued) g308891 Figure 125 GM4700-D Deck manifold O-ring O-ring O-ring Test fitting Straight fitting Dust cap O-ring O-ring O-ring Straight fitting O-ring O-ring 90º fitting O-ring 45º fitting Straight fitting (8 used) 4. To prevent contamination of hydraulic system during manifold removal, thoroughly clean exterior of manifold.
Page 235 Installation (Figure 123) (continued) 3. Remove caps and plugs from fittings and hydraulic lines. Properly connect hydraulic lines to manifold (see Installing Hydraulic Hoses and Tubes (O-Ring Face Seal) (page 5–7)). 4. Connect wire harness electrical connectors to the solenoid valve coils. 5.
Page 236: Deck Control Manifold Service (Gm4500-D)
Deck Control Manifold Service (GM4500-D) g308893 Figure 126 Manifold body Relief valve (RV8 & RV9) Proportional relief (PRV1 & PRV2) Logic valve (LC1 & LC2) Zero leak plug (#6) Solenoid coil Pilot piston Zero leak plug (#8) Note: The ports on the deck control manifold are marked for easy identification of components (e.g.
Page 237 Deck Control Manifold Service (GM4500-D) (continued) g308894 Figure 127 Manifold body Zero leak plug (#6) Zero leak plug (#4) Note: The deck control manifold uses several zero leak plugs. These plugs have a tapered sealing surface on the plug head that is designed to resist vibration induced plug loosening.
Page 238: Deck Control Manifold Service (Gm4700-D)
Deck Control Manifold Service (GM4700-D) g308897 Figure 128 Manifold body Zero leak plug (#4) Logic valve (LC1, LC2, LC3 & LC4) Nut (4 used) Proportional relief (PRV2 & PRV2) 10. Solenoid coil (4 used) Zero leak plug (#6) Relief valve (RV8, RV9, RV10 & Pilot piston (4 used) RV11) Zero leak plug (#8)
Page 239 Deck Control Manifold Service (GM4700-D) (continued) g308898 Figure 129 Manifold body Zero leak plug (#4) Zero leak plug (#6) Note: The deck control manifold uses several zero leak plugs. These plugs have a tapered sealing surface on the plug head that is designed to resist vibration induced plug loosening.
Page 240: Steering Control Valve
Steering Control Valve g308910 Figure 130 Steering wheel cover Flange head screw (4 used) Tinnerman nut (4 used) Lock nut Steering column Column brace Steering wheel Steering control valve O-ring Flat washer Socket head screw (4 used) Straight fitting (5 used) Socket head screw (4 used) Flange nut (4 used) O-ring...
Page 241 Removal (Figure 130) (continued) g308911 Figure 131 Roller support Headlight assembly Screw (2 used) Flange nut (2 used) Carriage screw (2 used) Platform shroud g308912 Figure 132 4. Slide rubber bellows up from bottom of steering column. Support steering column to prevent it from falling. 5.
Page 242 Removal (Figure 130) (continued) 9. Put caps or plugs on disconnected lines and fittings to prevent contamination. 10. Loosen and remove four (4) socket head screws and flange nuts that secure steering column to machine. 11. Remove steering column assembly with steering control valve attached from machine.
Page 243: Steering Control Valve Service
Steering Control Valve Service g278299 Figure 133 Pin bolt Distributor plate Shaft seal Bolt (4 each) Cardan shaft Thrust washer (2 each) Washer (5 each) Plug Bearing End cover Plug Ring Tube (2 each) Spring Spring set Inner gearwheel Relief valve Spool Dust sealing ring O-ring (3 each)
Page 244: Steering Cylinder
Steering Cylinder g308934 Figure 134 Steering cylinder 90º hydraulic fitting Slotted hex nut Ball joint O-ring Cotter pin Ball joint Hydraulic hose O-ring Retaining ring Drive axle assembly Hydraulic hose Grease fitting Ball joint spacer Grease fitting Axle washer Removal (Figure 134) 1.
Page 245 Removal (Figure 134) (continued) 6. Remove cotter pins, slotted hex nuts, axle washer and ball joint spacer from the threaded ends of ball joints. Remove steering cylinder with ball joints from machine. 7. If necessary, remove ball joints from steering cylinder. 8.
Page 246: Steering Cylinder Service
Steering Cylinder Service g308935 Figure 135 Tube assembly Piston Wiper Lock nut O-ring Retaining ring Seal Back-up seal Rod assembly O-ring Seal Head O-ring Disassembly (Figure 135) 1. Remove oil from steering cylinder into a drain pan by slowly pumping the cylinder shaft.
Page 247 Disassembly (Figure 135) (continued) 2. Mount steering cylinder securely in a vise by clamping on the clevis end of the barrel. Use of a vise with soft jaws is recommended. 3. Loosen head from barrel: A. Use a spanner wrench to rotate head clockwise until the edge of the retaining ring appears in the barrel opening.
Page 248 Assembly (Figure 135) (continued) IMPORTANT Prevent damage when clamping the cylinder’s barrel into a vise; clamp on the clevis only. Do not close vise enough to distort the barrel. 5. Mount steering cylinder in a vise with soft jaws. Secure head in barrel: A.
Page 249: Engine Cooling Fan Motor
Engine Cooling Fan Motor g308936 Figure 136 Cap screw (4 used) Radiator/oil cooler assembly Hydraulic tube Air intake hose Hydraulic tube Flange head screw (4 used) Washer (4 used) O-ring Flange nut (4 used) Flange nut (6 used) O-ring Fan motor and bracket assembly Cap screw (6 used) Bulkhead nut Flange head screw (8 used)
Page 250 Removal (Figure 136) (continued) 2. Read the General Precautions for Removing and Installing Hydraulic System Components (page 5–87). 3. Unlatch and raise hood. 4. Remove four (4) cap screws and washers used to secure fan (item 2) to fan hub. Remove fan. CAUTION The radiator and engine may be hot.
Page 251 Removal (Figure 136) (continued) g308937 Figure 137 Hydraulic tube Lock nut (2 used) Hydraulic tube Fan motor Hydraulic tube Fan motor bracket Hex nut O-ring Flat washer Hydraulic fitting Fan hub O-ring Woodruff key O-ring Cap screw (2 used) Hydraulic fitting Flat washer (2 used) O-ring 7.
Page 252 Installation (Figure 136) (continued) C. Position fan hub onto motor shaft and secure with washer (item 5) and hex nut (item 4). Torque nut from 37 to 44 N·m (27 to 33 ft-lb). D. Connect hydraulic tubes (items 1, 2 and 3) to fan motor fittings. Use support shim (item 14 in Figure 136) to help orientate tubes during...
Page 253: Engine Cooling Fan Motor Service
Engine Cooling Fan Motor Service g275454 Figure 138 Thrust plate Ring Thrust plate Washer Anti-extrusion Body Washer Front cover Seal Flange Drive gear Standard seal Driven gear Square seal Support Ball bearing Shaft seal Dowel pin Ring Screw The engine cooling fan motor has similar construction as the cutting deck motors. The body of the cooling fan motor (item 3 in Figure 138) includes the rear cover...
Page 254: Fan Control Manifold
Fan Control Manifold g308970 Figure 139 Deck manifold (GM4500-D shown) 11. Hydraulic tube Fan control manifold Hydraulic hose Hydraulic tube Support bracket Flange head screw (2 used) Hydraulic hose Hydraulic tube Battery support Hydraulic tube Air cleaner mount Hydraulic tube Removal (Figure 139)
Page 255 Removal (Figure 139) (continued) g308971 Figure 140 O-ring Dust cap Straight fitting (7 used) Test fitting O-ring O-ring 7. Remove hydraulic manifold from the frame using Figure 139 as guide. 8. If hydraulic fittings are to be removed from fan control manifold, mark fitting orientation to allow correct assembly (Figure 140).
Page 256: Fan Control Manifold Service
Fan Control Manifold Service g308983 Figure 141 Manifold body Flow divider cartridge (port FD) Proportional relief cartridge (port Zero leak plug (#6) (3 used) Solenoid coil (2 used) Zero leak plug (#4) (2 used) Check valve (port CV) Solenoid valve (port S1) Note: The ports on the fan control manifold are marked for easy identification of components (e.g.
Page 257: Lift Control Manifold
Lift Control Manifold g308985 Figure 142 GROUNDSMASTER 4500-D SHOWN Deck control manifold Hydraulic oil filter assembly Lift control manifold Filter mount bracket Valve mount bracket Flange head screw (2 used) Flange head screw (2 used) Flange head screw (2 used) Fan drive manifold Note: The lift control manifolds used on Groundsmaster 4500-D and 4700-D machines are different but they mount to the machine in the same location.
Page 258 Removal (Figure 142) 1. Park machine on a level surface, lower cutting decks, stop engine, apply parking brake and remove key from the ignition switch. IMPORTANT To prevent unexpected deck lowering, make sure that cutting decks are fully lowered before loosening hydraulic lines from lift manifold. 2.
Page 259 Removal (Figure 142) (continued) g308987 Figure 144 GROUNDSMASTER 4700-D Lift manifold (GM4700-D) Straight fitting (2 used) Dust cap O-ring Test fitting (2 used) O-ring O-ring Straight fitting (2 used) O-ring O-ring 7. Remove hydraulic manifold from the frame using Figure 142 as guide.
Page 260: Lift Control Manifold Service (Gm4500-D)
Lift Control Manifold Service (GM4500-D) g308991 Figure 145 Manifold body Zero leak plug (#4) Relief valve (port RV) Proportional relief valve (port TS) Solenoid coil Solenoid valve (port S6) Straight fitting Solenoid coil (2 used) O-ring Solenoid valve (port S5) Check valve (port CV) Orifice (0.080) O–ring...
Page 261 Lift Control Manifold Service (GM4500-D) (continued) WARNING If lift manifold is attached to machine, make sure that cutting decks are fully lowered before loosening hydraulic lines, cartridge valves or plugs from lift manifold. If decks are raised as components are loosened, decks may drop unexpectedly.
Page 262: Lift Control Manifold Service (Gm4700-D)
Lift Control Manifold Service (GM4700-D) g308993 Figure 146 Manifold body Proportional relief valve (port TS) Solenoid valve (port S5) Solenoid valve (ports S2, S3, S7, Solenoid coil (5 used) Zero leak plug (#4) Solenoid valve (port S1) Solenoid coil (5 used) Relief valve (port R1) Solenoid valve (ports S4, S6, S9) Note: The ports on the lift control manifold are marked for easy identification of...
Page 263 Lift Control Manifold Service (GM4700-D) (continued) WARNING If lift manifold is attached to machine, make sure that cutting decks are fully lowered before loosening hydraulic lines, cartridge valves or plugs from lift manifold. If decks are raised as components are loosened, decks may drop unexpectedly.
Page 264 Lift Control Manifold Service (GM4700-D) (continued) IMPORTANT A flow control orifice is placed beneath several of the hydraulic fittings on the lift control manifold (Figure 147). The lift manifold uses two (2) different orifice sizes. If a fitting is removed from the lift control manifold and an orifice is in the manifold port, make sure to remove orifice and label its position for assembly purposes.
Page 265: Lift Circuit Junction Manifold
Lift Circuit Junction Manifold g309017 Figure 148 Lift circuit junction manifold Two speed shift manifold Flange head screw (2 used) Rear traction control manifold Removal (Figure 148) 1. Park machine on a level surface, lower cutting decks, stop engine, engage parking brake and remove key from the ignition switch.
Page 266 Removal (Figure 148) (continued) g309018 Figure 149 Manifold body Straight fitting (3 used) Orifice (0.055) Zero leak plug Orifice (0.030) g309019 Figure 150 Manifold body O-ring O-ring 90º hydraulic fitting Straight fitting (3 used) 5. Remove hydraulic manifold from the frame using Figure 148 as guide.
Page 267 Removal (Figure 148) (continued) 6. If necessary, remove fittings from manifold and discard O-rings (Figure 149 Figure 150). Installation (Figure 148) IMPORTANT When installing orifice in manifold, make sure that orifice is flat in the base of the manifold port. Manifold damage is possible if the orifice is cocked in the cavity.
Page 268: Lift Cylinders: Decks #1, #4 And #5
Lift Cylinders: Decks #1, #4 and #5 g309020 Figure 151 Lift arm (deck #4) Flange head screw Lift arm (deck #5) Flange nut O-ring Lift cylinder (decks #4 and #5) Lift arm (deck #1) 90º hydraulic fitting (2 per cylinder) 11. Lift cylinder (deck #1) Cylinder pin (3 used) O-ring...
Page 269 Removal (Figure 151) (continued) 4. Disconnect hydraulic hoses from lift cylinder. Put caps or plugs on open hoses and fittings to prevent system contamination. Label disconnected hydraulic hoses for proper assembly. 5. Remove flange nut and flange head screw that secure the cylinder pin (item 4) to the lift arm.
Page 270: Lift Cylinders: Decks #2 And #3
Lift Cylinders: Decks #2 and #3 g309037 Figure 153 Flange head screw Cylinder pin O-ring Flange nut Lift arm (deck #2) 90º hydraulic fitting Cylinder pin Lift arm (deck #3) Grease fitting Lift cylinder O-ring Retaining ring Hydraulic fitting Removal (Figure 153) 1.
Page 271 Removal (Figure 153) (continued) 4. Disconnect hydraulic hoses from lift cylinder. Put caps or plugs on open hydraulic hoses and fittings to prevent system contamination. Label the hydraulic hoses to show their correct position on the lift cylinder for assembly purposes.
Page 272: Lift Cylinders: Decks #6 And #7 (Gm4700-D)
Lift Cylinders: Decks #6 and #7 (GM4700-D) g309038 Figure 155 Lift cylinder Retaining ring Lift arm assembly (deck #6 shown) Lock nut (2 used per side) Cylinder pin Grease fitting Rear link 90º hydraulic fitting Lift link Link assembly O-ring Plastic roller O-ring Removal...
Page 273 Removal (Figure 155) (continued) 4. Disconnect hydraulic hoses from lift cylinder. Put caps or plugs on open hydraulic hoses and fittings to prevent system contamination. Label the hydraulic hoses to show their correct position on the lift cylinder for assembly purposes.
Page 274 Installation (Figure 155) (continued) 6. Lubricate lift cylinder grease fittings. 7. After assembly is completed, operate lift cylinder to verify that lift cylinder, hydraulic hoses and fittings do not contact any machine components during operation. Hydraulic System: Service and Repairs Page 5–172 Groundsmaster ®...
Page 275: Lift Cylinder Service
Lift Cylinder Service g309069 Figure 157 Tube assembly O–ring Head Lock nut O–ring Wiper Wear ring Back–up ring Rod assembly Seal Seal Grease fitting (2 used) Piston Retaining ring Note: The lift cylinders used on the Groundsmaster are all very similar regardless of the location on the machine.
Page 276 Disassembly (Figure 157) (continued) IMPORTANT Prevent damage when clamping the cylinder in a vise; clamp on the clevis only. Do not close vise enough to distort the barrel. 2. Mount lift cylinder securely in a vise by clamping on the clevis end of the barrel.
Page 277 Assembly (Figure 157) (continued) A. If rod diameter is 16 mm (0.630 in), torque lock nut from 41 to 47 N·m (30 to 35 ft-lb). B. If rod diameter is 19 mm (0.750 in), torque lock nut from 82 to 94 N·m (60 to 70 ft-lb).
Page 278: Hydraulic Reservoir
Hydraulic Reservoir g309070 Figure 158 Plug O-ring Bumper O-ring Straight hydraulic fitting Flat washer Dipstick O-ring O-ring Breather Cap screw (2 used) Hydraulic hose Screen filter Flat washer (2 used) Hose clamp Hydraulic reservoir Clamp (2 used) Suction hose Reservoir strainer Flange nut (3 used) Hydraulic hose O-ring...
Page 279 Removal (Figure 158) (continued) 2. Read the General Precautions for Removing and Installing Hydraulic System Components (page 5–87). 3. To prevent contamination of hydraulic system during hydraulic reservoir removal, thoroughly clean exterior of reservoir. 4. To allow draining of hydraulic reservoir, disconnect the hydraulic hose (item 23) from the fitting in the bottom of the reservoir.
Page 280: Radiator And Oil Cooler Assembly
Radiator and Oil Cooler Assembly g309081 Figure 159 Hydraulic System: Service and Repairs Page 5–178 Groundsmaster ® 4500-D/4700-D 19245SL Rev A...
Page 281 Radiator and Oil Cooler Assembly (continued) Figure 159 (continued) Radiator/oil cooler assembly Flange head screw (4 used) Coolant reservoir Cap screw (4 used) Hydraulic tube R-clamp (2 used) Washer (4 used) Hydraulic tube Bushing Hydraulic tube Elbow fitting Plenum assembly Flange nut (4 used) Hose Cap screw (6 used)
Page 282 Radiator and Oil Cooler Assembly (continued) g309083 Figure 161 Radiator/oil cooler Radiator cap O-ring Plug 90º fitting (2 used) Draincock Plug O-ring Note: The hydraulic oil cooler on your Groundsmaster is combined with the radiator. See Radiator and Oil Cooler Assembly (page 4–15).
Page 283 Electrical System Table of Contents General Information ..........................6–2 Operator's Manual..........................6–2 Electrical Drawings ..........................6–2 Toro Electronic Controllers (TEC)....................... 6–3 Engine Electronic Control Unit (ECU) ....................6–5 Yanmar Engine Electrical Components....................6–7 CAN−bus Communications........................ 6–7 Electrical Drawings ..........................6–7 InfoCenter Display ..........................
Page 284: General Information
General Information Operator's Manual The Operator’s Manual provides information regarding the operation, general maintenance, and maintenance intervals for your Greensmaster machine. Refer to the Operator’s Manual for additional information when servicing the machine. Electrical Drawings The electrical schematic and wire harness drawings for Groundsmaster 4500-D and 4700-D machines are located in Appendix A (page A–1).
Page 285: Toro Electronic Controllers (Tec)
Operator platform TEC-5004 (T2) (GM4700-D only) TEC-5004 (T1) The Groundsmaster 4500-D machines use a single Toro Electronic Controller (TEC-5004) to manage machine electrical functions. Groundsmaster 4700-D machines uses two (2) TEC controllers (TEC-5004) for machine operations. The TEC controllers are microprocessor controlled that sense the condition of various switches and sensors (inputs).
Page 286 Toro Electronic Controllers (TEC) (continued) g321413 Figure 163 TEC controller Socket head screw Machine harness connector The TEC controllers are attached to the machine under the operator seat. Note: To prevent machine electrical system damage while welding on the machine, disconnect the battery cables from the batteries, disconnect the wire...
Page 287: Engine Electronic Control Unit (Ecu)
Engine Electronic Control Unit (ECU) g307583 Figure 164 Engine (models 30893, 30893TE, 30899 Engine ECU and 30899TE) g307584 Figure 165 Engine (models 30885 and 30887) Engine ECU The Yanmar engine that powers the Groundsmaster 4500−D and 4700−D uses an electronic control unit (ECU) for engine management and also to communicate with the TEC controllers and the InfoCenter Display on the machine.
Page 288 Engine Electronic Control Unit (ECU) (continued) any reason, make sure that the ignition switch is in the OFF position with the key removed before disconnecting the engine ECU. See Engine Electronic Control Unit (ECU) (page 4–3). IMPORTANT Do not plug or unplug the engine ECU for a period of thirty (30) seconds after the machine ignition switch is turned OFF.
Page 289: Yanmar Engine Electrical Components
CAN−bus Communications The Toro TEC controller(s), the Yanmar Engine Controller and the InfoCenter Display used on the Groundsmaster 4500−D and 4700−D communicate with each other on a CAN−bus system. Using this system allows the traction unit to fully integrate all the different electrical components of the traction unit and bring them together as one.
Page 290: Infocenter Display
InfoCenter Display g309292 Figure 166 InfoCenter display Console arm The InfoCenter Display used on your Groundsmaster is a LCD device that is located on the console. The InfoCenter provides information for the machine operator during machine operation, provides electrical system diagnostic assistance for technicians and allows inputs for adjustable machine settings.
Page 291 KEY SWITCHED 13.2V 95.2 AFTER SECONDS Service due in 155 hours 13.2V AFTER SECONDS MAIN INFORMATION SCREEN Service due in 155 Hours 13.2V 1250 g309293 Figure 167 Groundsmaster ® 4500-D/4700-D Page 6–9 Electrical System: General Information 19245SL Rev A...
Page 292 Splash Screen 13.2V 95.2 g309302 Figure 168 Battery voltage Down button Hour meter Menu/back button Right button Service due in 155 hours 13.2V g309303 Figure 169 Battery voltage Right button Hydraulic oil temperature Down button Time to next service Menu/back button Engine RPM The two (2) InfoCenter splash screens (Figure 168...
Page 293 Main Information Screens g309300 Figure 170 Parking brake applied Right button Traction speed Down button Coolant temperature Menu/back button Fault indicator Service due in 155 Hours 13.2V 1250 g309301 Figure 171 Battery voltage Engine RPM Hydraulic oil temperature Right button Fault indicator Down button Time to next service...
Page 294 Main Information Screens (continued) The main information screens will display arrows whenever the cutting decks are either raising (up arrows) or lowering (down arrows). If controls are not selected properly to allow certain machine operations, an advisory will be displayed on the InfoCenter Display. Typically, an advisory can be eliminated with a change in controls by the operator.
Page 295 Faults Screen Faults C1134 −57.3 Ago Clear System Faults g316092 Figure 173 Fault menu Choose menu item Fault items Back button Move to menu items The faults screen (Figure 173) will list all machine electrical faults that have occurred since the faults were last cleared from the InfoCenter. The faults will be identified by a fault number and when the fault occurred.
Page 296 Service Screen Key On: 95.2 Hours Machine Run: 72.3 Hours PTO On: 63.7 Hours g309317 Figure 174 Service menu Choose menu item Service items Back button Move to menu items The service screen (Figure 174) contains machine operational information including hours and counts. Values listed for these service menu items cannot be changed.
Page 297 Service Screen (continued) • DPF Regeneration provides the necessary procedure for stationary regeneration for the exhaust system DPF (diesel particulate filter) on machines with a Tier 4 engine (models 30885 and 30887). If the engine ECU identifies that a stationary DPF regeneration is necessary, an advisory will occur on the InfoCenter and the necessary steps will be listed in the service screen menu.
Page 298 Diagnostics Screen (continued) include the low range speed, seat switch and parking brake position. Identified outputs consist of master, lower, raise and float solenoids. • Center Deck identifies machine requirements to allow the center deck to raise and lower. Inputs indicate the state of the center deck lift/lower switch.
Page 299 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 hidden so they cannot be changed unless the PIN is entered.
Page 300 Settings Screen (continued) Smart Power allows the user to enable or disable the Smart Power feature. Counter Balance allows counterbalance pressure applied by the cutting decks to be adjusted. Options for counterbalance are low, medium and high. Turnaround allows the user to set ON/OFF. The ON feature allows the decks to be raised in turnaround position.
Page 301: Adjustments
Adjustments Traction Pedal Adjustment g309420 Figure 179 Traction pedal Rod end bearing Pedal position sensor Spring shaft Hex nut Spring shaft hex The traction pedal includes a neutral assembly that is used to adjust the traction neutral position (Figure 179). 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 302 Traction Pedal Adjustment (continued) A. Voltage in full reverse should be from 0.5 to 1.75V (approximate). B. Voltage in full forward should be from 3.5 to 4.5V (approximate). 5. If voltage range from full reverse to full forward is incorrect, adjustment of the spring shaft and rod end bearing is necessary (Figure 179).
Page 303: Traction Pedal Position Sensor Calibration
Traction Pedal Position Sensor Calibration g309423 Figure 182 Traction pedal Pedal position sensor IMPORTANT A properly installed and calibrated traction pedal position sensor is critical to accurate traction system response and for reliable sensor life. Use care when removing, installing and calibrating the traction pedal position sensor.
Page 304 Traction Pedal Position Sensor Calibration (continued) ADVISORY #B216A Calibrate Teach Is Engaged g309424 Figure 183 ADVISORY #B216A Calibrate. Exit Good g309425 Figure 184 4. Use the InfoCenter Display Service menu (see InfoCenter Display (page 6–8)) to obtain and select the Traction Pedal menu item. The InfoCenter display should indicate that the traction pedal calibration process is engaged (Figure 183).
Page 305: Electrical System Quick Checks
Electrical System Quick Checks Battery Test (Open Circuit) Use a multimeter to measure the voltage between the battery terminals. Set multimeter to the DC volts setting. The battery should be at a temperature of 16 to 38 ºC (60 to 100 ºF). The ignition key should be off and all accessories turned off.
Page 306: Check Operation Of Interlock Switches
Interlock switch operation is described in the Traction Unit Operator’s Manual. Your Groundsmaster is equipped with one (1) (Groundsmaster 4500-D) or two (2) (Groundsmaster 4700-D) Toro Electronic Controllers (TEC) which monitor interlock switch operation. Testing of individual interlock switches and relays is included in the Component Testing section of this Chapter.
Page 307: Component Testing
Component Testing For accurate resistance and/or continuity checks, electrically disconnect the component being tested from the circuit (e.g. unplug the ignition switch connector before checking continuity on the switch terminals). For engine component testing information, see the Yanmar Workshop Manual and Yanmar Troubleshooting Manual.
Page 308: Ignition Switch
Ignition Switch ON/PREHEAT START REAR VIEW FRONT VIEW g309438 Figure 185 The ignition (key) switch on the console arm has three (3) positions (OFF, ON/PREHEAT and START). Testing Note: Before disconnecting the ignition switch for testing, the switch and its circuit wiring should be tested as a TEC electrical input using the InfoCenter Display (see InfoCenter Display (page...
Page 309: Fuses
Fuses g010255 Figure 186 Fuses g309470 Figure 187 The fuse block is located in the right storage box back of the operator seat (Figure 186). In addition to the fuses in the fuse block, a 60 Amp fuse is included in the storage box to protect the power circuit for the operator cab (if equipped).
Page 310 Fuse Identification and Function (continued) Fuse A−5 (10 Amp) protects power supply to the engine control unit (ECU). Fuse B−1 (7.5 Amp) protects TEC controller 1 output power supply for the two (2) PTO solenoids (PRV1 and PRV2), the cooling fan speed solenoid (TS) and counterbalance solenoid valve (TS).
Page 311 Fuse Testing (continued) IMPORTANT If fuse replacement is necessary, ensure that replacement fuse has the correct Amp rating. 6. Close and secure power center cover. Groundsmaster ® 4500-D/4700-D Page 6–29 Electrical System: Component Testing 19245SL Rev A...
Page 312: Fusible Link Harness
Fusible Link Harness g275996 Figure 188 Starter motor Fusible link harness TO MAIN HARNESS STARTER B+ FUSIBLE LINK (14 GAUGE) FUSIBLE LINK (16 GAUGE) g275997 Figure 189 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 (Figure 188).
Page 313: Pto Switch
PTO Switch g309580 Figure 190 Console arm PTO switch The two position PTO switch is located on the console arm (Figure 190). The PTO switch is pulled up to engage the PTO and pushed in to disengage the PTO. Note: To engage the PTO, the seat has to be occupied, traction speed has to be in low range (mow) and the cutting decks have to be fully lowered.
Page 314 Testing (continued) Verify continuity between switch terminals. Replace switch if testing identifies that switch is faulty. SWITCH POSITION CLOSED CIRCUITS OPEN CIRCUITS OFF (DOWN) COM B + NC B COM B + NO B COM C + NC C COM C + NO C ON (UP) COM B + NO B COM B + NC B...
Page 315: Auto/Low Mode, Engine Speed Request And Cutting Deck Lift Switches
Auto/Low Mode, Engine Speed Request and Cutting Deck Lift Switches g309581 Figure 192 Console arm Lift switch (GM4700 #7) Auto/Low mode switch Lift switch (GM4700 #6) Lift switch (#1 to #5) The Auto/Low mode and cutting deck lift switches are all identical. These switches are located on the console arm (Figure 192).
Page 316 Testing (continued) 4. The switch terminals are marked as shown in Figure 193. The circuit logic of the switch is shown in the chart below. With the use of a multimeter (ohms setting), the switch functions may be tested to determine whether continuity exists between the various terminals for each position.
Page 317: Headlight Switch
Headlight Switch g309584 Figure 194 Console arm Headlight switch The headlight switch is located on the operator side of the console arm (Figure 194). This two (2) position rocker switch allows the headlights to be turned on and off. Testing 1.
Page 318: Cruise Control Switch
Cruise Control Switch g028454 Figure 196 Power-point switch Cruise control switch The cruise control switch is used as an input for the TEC controller to maintain ground speed when engaged. The cruise control function is enabled when the switch is in the ON (center) position. Pressing the front of the switch to the momentary position sets the desired ground speed.
Page 319 Testing (continued) SWITCH POSITION CLOSED CIRCUITS OPEN CIRCUITS CRUISE DISENGAGE NONE CRUISE ON (CENTER) 2 + 3 5 + 6 SPEED SET (MOMENTARY) 2 + 3 NONE 5 + 6 6. If switch tests correctly and circuit problem still exists, check wire harness (see Appendix A (page A–1)).
Page 320: Seat Switch
Seat Switch g309585 Figure 198 Wire harness connector Seat switch connector The seat switch is normally open and closes when the operator is on the seat. The seat switch and its electrical connector are located in the seat assembly. If the traction system or PTO switch is engaged when the operator raises out of the seat, an operator advisory will be displayed on the InfoCenter.
Page 321: Parking Brake Switch
Parking Brake Switch g309633 Figure 199 RH brake pedal Lock nut Brake detent Brake pivot pin LH brake pedal Carriage screw Switch plate Switch Brake switch The parking brake switch is a normally open proximity switch. The parking brake switch is attached to the bottom of the RH brake pedal (Figure 199).
Page 322 Switch Testing (continued) g321233 Figure 200 6. Replace parking brake switch if testing determines that it is faulty. 7. After testing is complete, connect wire harness electrical connector to the brake switch. Electrical System: Component Testing Page 6–40 Groundsmaster ® 4500-D/4700-D 19245SL Rev A...
Page 323: Cutting Deck Position Switches
Cutting Deck Position Switches g309635 Figure 201 Position switch Lift arm (#5 shown) Switch connector The cutting deck position switches are normally open proximity switches that are located on the traction unit frame (Figure 201). The sensing plate is located on the cutting deck lift arm.
Page 324 Switch Testing (continued) Note: Before disconnecting the deck position switch for testing, the switch and its circuit wiring should be tested as a TEC electrical input using the InfoCenter Display (see InfoCenter Display (page 6–8)). If input testing verifies that the deck position switch and circuit wiring are functioning correctly, no further position switch testing is necessary.
Page 325: Relays With Four (4) Terminals
Relays with Four (4) Terminals g309686 Figure 203 TEC 1 power relay Cab power relay TEC 2 power relay g309687 Figure 204 Air cleaner mount Screw Engine ECU mount Tinnerman nut 4 terminal relay Your Groundsmaster uses a number of electrical relays that have four (4) terminals.
Page 326 The air heater relay is used on models 30893, 30893TE, 30899 and 30899TE to provide current for the engine air heater used for starting a cold engine. When necessary, the air heater relay is energized by the engine ECU. The glow relay is used on models 30885 and 30887 to provide current to the engine glow plugs when energized by the engine ECU.
Page 327: Relays With Five (5) Terminals
Relays with Five (5) Terminals g309695 Figure 206 Air cleaner mount Cap screw Flange nut Engine ECU mount 5 terminal relay Your Groundsmaster uses a number of electrical relays that have five (5) terminals. A tag near the wire harness relay connector can be used to identify each relay.
Page 328 Testing g276024 Figure 207 Coil terminal Normally closed terminal Common terminal Normally open terminal 1. Park machine on a level surface, lower cutting decks, stop engine, engage parking brake and remove key from the ignition switch. 2. To make sure that machine operation does not occur unexpectedly, disconnect negative (−) cable from battery and then disconnect positive (+) cable from battery (see Battery Service (page...
Page 329: Traction Pedal Position Sensor
Traction Pedal Position Sensor g309423 Figure 208 Traction pedal Pedal position sensor The traction pedal position sensor is connected to the traction pedal assembly (Figure 208). This position sensor determines the neutral band for the traction pedal, the direction of travel desired by the operator and the traction speed. The position sensor is a single analog, dual digital signal electronic device.
Page 330: Toro Electronic Controllers (Tec)
Operator platform TEC-5004 (TEC 2) (GM4700-D only) TEC-5004 (TEC 1) Groundsmaster 4500−D and 4700−D machines use a Toro Electronic Controller (TEC−5004) to control electrical system operation. Groundsmaster 4700−D machines use an additional TEC−5004 controller for electrical control of the rear cutting decks (PTO and lift/ lower functions).
Page 331 Toro Electronic Controllers (TEC) (continued) g309762 Figure 210 TEC 1 Controller The TEC 1 controller monitors the states of the following components as inputs: ignition switch, traction pedal position sensor, parking brake switch, automatic switch, seat switch, swash plate sensor, cruise control switch, PTO switch, center cutting deck lift switch, cutting deck position switches (decks 1 and 2), hydraulic temperature sender and hydraulic pressure transducer.
Page 332 Toro Electronic Controllers (TEC) (continued) g309763 Figure 211 TEC 2 Controller The connection terminal functions for the TEC controllers are shown in Figure Figure 211. Note that electrical power for controller outputs is provided through 4 (4) connector terminals (PWR 2, PWR 3, PWR 4 and PWR 5) each protected with a 7.5 amp fuse.
Page 333 Toro Electronic Controllers (TEC) (continued) IMPORTANT When testing for wire harness continuity at the connector for the TEC controller, take care to not damage the connector pins with multimeter test leads. If connector pins are enlarged or damaged during testing, connector repair will be necessary for proper machine operation.
Page 334: Hydraulic Solenoid Valve Coils
Hydraulic Solenoid Valve Coils g309817 Figure 214 GROUNDSMASTER 4500−D SHOWN Deck control manifold Fan control manifold Lift control manifold Two speed shift manifold Numerous hydraulic solenoid valve coils are used on the hydraulic control manifolds of Groundsmaster 4500−D and 4700−D machines. When energized by the TEC controller, these coils provide hydraulic circuit control.
Page 335 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 (Figure 214). 3. Disconnect wire harness connector from solenoid valve coil. Note: Prior to taking small resistance readings with a digital multimeter, short the meter test leads together.
Page 336: Piston (Traction) Pump Control Solenoid Coils
Piston (Traction) Pump Control Solenoid Coils g309820 Figure 216 Piston pump Reverse solenoid coil Forward solenoid coil The piston (traction) pump uses an electronic control assembly for swash plate rotation. Electrical outputs from the machine TEC controller are provided to two (2) solenoid coils for pump control.
Page 337 Solenoid Coil Testing (continued) g276033 Figure 217 Solenoid coil Coil nut O−ring 3. Using a multimeter (ohms setting), measure resistance between the two (2) connector terminals on the solenoid coil. Solenoid coil resistance should be 3.66 ohms. Note: Solenoid coil resistance should be measured with solenoid at approximately 20 ºC (68 ºF).
Page 338: Hydraulic Oil Temperature Sender
Hydraulic Oil Temperature Sender g309836 Figure 218 Rear axle motor Oil temperature sender A temperature sender is used as an input for the TEC controller to identify if the hydraulic oil temperature has reached an excessive level. The hydraulic oil temperature sender is attached to the rear axle motor at the rear of the machine (Figure 218).
Page 339 Testing (continued) 4. Put sensing end of sender in a container of oil with a thermometer and slowly heat the oil (Figure 219). CAUTION Handle the hot oil with extreme care to prevent personal injury or fire. Note: Prior to taking resistance readings with a digital multimeter, short the meter test leads together.
Page 340: Fuel Pump (Models 30893, 30893Te, 30899 And 30899Te)
Fuel Pump (Models 30893, 30893TE, 30899 and 30899TE) g309899 Figure 220 Fuel pump Fuel water separator Fuel supply hose Engine Hose clamp The fuel pump is attached to the air cleaner mount below the fuel water separator (Figure 220). Operational Test 1.
Page 341 Operational Test (continued) IMPORTANT If fuel pump is replaced, make sure that replacement pump is the correct pump for your Groundsmaster by using your Parts Catalog. If incorrect pump is used, fuel system components can be damaged. 8. Install fuel supply hose to the fuel injection pump fitting on the engine and secure with hose clamp.
Page 342: Fuel Pump (Models 30885 And 30887)
Fuel Pump (Models 30885 and 30887) g309900 Figure 221 Fuel pump Fuel water separator Pump discharge hose Engine Hose clamp The fuel pump is attached to the air cleaner mount below the fuel water separator (Figure 221). Operational Test 1. Park machine on a level surface, lower cutting decks, stop engine and apply parking brake.
Page 343 Operational Test (continued) IMPORTANT If fuel pump is replaced, make sure that replacement pump is the correct pump for your Groundsmaster by using your Parts Catalog. If incorrect pump is used, fuel system components can be damaged. 8. Install fuel pump discharge hose to the fuel filter fitting on the engine and secure with hose clamp.
Page 344: Can−Bus Termination Resistor
CAN−bus Termination Resistor Termination Resistor g276034 Figure 222 System communication between electrical components on Groundsmaster 4500−D and 4700−D machines is accomplished on a CAN−bus communication system. Two (2) specially designed, twisted cables form the bus for the network used on the machine. These wires provide the data pathways between machine components.
Page 345: Diode Assemblies
Diode Assemblies g276035 Figure 223 Diode assembly Female terminal Male terminal End of diode body The Groundsmaster engine wire harness contains a diode assembly that is used for circuit protection from voltage spikes when the engine starter solenoid is de− energized.
Page 346: Resistor Assembly
Appendix A (page A–1)). 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). The resistance across the resistor terminals should be 1.6K ohms.
Page 347: Fan Speed Switch (Machines With Two−Post Rops Extension Operator Fan Kit)
Fan Speed Switch (Machines with Two−Post ROPS Extension Operator Fan Kit) g276047 Figure 225 Fan speed switch Control panel Control knob The fan speed switch is attached to the overhead control panel (Figure 225). The switch is used to select the fan speed (off, low, medium, or high). Testing 1.
Page 348 Testing (continued) 4. The switch terminals are identified in (Figure 226). With the use of a multimeter (ohms setting), test the switch functions to determine if continuity exists between only the terminals listed for each switch position. Check the continuity between the switch terminals. Switch Position Closed Circuits B+C+L...
Page 349: Resistor Module (Machines With Two−Post Rops Extension Operator Fan Kit)
Resistor Module (Machines with Two−Post ROPS Extension Operator Fan Kit) g276049 Figure 227 Operator’s fan Resistor module Fan mount bracket The resistor module is attached to the rear of the fan mounting bracket (Figure 227). The resistor module is used for operation of the operator’s fan. Testing 1.
Page 350 Testing (continued) g276050 Figure 228 Pin 1 (Violet wire) Pin 4 (Not used) Pin 2 (Brown wire) Motor pin Pin 3 (Orange wire) Resistor module 4. Use a multimeter to check that the resistance values of the resistor module as below (Figure 228).
Page 351: Service And Repairs
(−) cable first. Clean clamps and terminals separately. Reconnect cables with positive (+) cable first. Coat battery posts and cable connectors with battery terminal protector (Toro Part No. 107−0392) or petroleum jelly to prevent corrosion. 5. If the battery electrolyte is accessible, check electrolyte level every 25 operating hours and every 30 days if machine is in storage.
Page 352: Battery Storage
Battery Storage If the machine will be stored for more than 30 days: 1. Remove the battery and charge it fully (see Battery Service (page 6–71)). 2. Either store battery on a shelf or on the machine. 3. Leave battery cables disconnected if the battery is stored on the machine. 4.
Page 353: 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 caution to avoid splashing or spilling electrolyte.
Page 354 Battery Removal and Installation (Figure 229) (continued) 6. Make sure that rubber boot is properly placed over positive cable end and positive battery post. 7. Lower and secure operator’s console panel. Battery Inspection and Maintenance 1. Replace battery if case is cracked or leaking. 2.
Page 355 Battery Testing (continued) H. Using the table in the column to the right, determine the minimum voltage for the battery temperature reading. If the test voltage is below the minimum voltage for the battery temperature, replace the battery. If the test voltage is at or above the minimum, return the battery to service.
Page 356 Battery Charging To minimize possible damage to the battery and allow the battery to be fully charged, the slow charging method is presented here. This charging method can be accomplished with a constant current battery charger which is readily available. CAUTION Follow the manufacturer’s instructions when using a battery charger.
Page 357 Battery Charging (continued) 3. Following the battery charger manufacturer’s instructions, connect the charger cables to the battery. Make sure a good connection is made. 4. Charge the battery following the battery charger manufacturer’s instructions. 5. While charging, occasionally check the battery. If the electrolyte is violently gassing or spewing or if the battery case feels hot to the touch, the charging rate must be lowered or temporarily stopped.
Page 358 Electrical System: Service and Repairs Page 6–76 Groundsmaster ® 4500-D/4700-D 19245SL Rev A...
Page 359 Chapter 7 Axles, Planetaries and Brakes Table of Contents General Information ..........................7–2 Operator’s Manual ..........................7–2 Adjustments............................7–3 Planetary Drive Assembly Endplay ....................7–3 Service and Repairs ..........................7–4 Brake Assembly ..........................7–4 Brake Inspection and Repair......................7–7 Planetary Drive Assembly ........................7–8 VA02 Series Planetary Drive Service ....................
Page 360: General Information
General Information Operator’s Manual The Operator’s Manual provides information regarding the operation, adjustment procedures, and general maintenance for your Greensmaster machine. Refer to the Operator’s Manual for additional information when servicing the machine. Axles, Planetaries and Brakes: General Information Page 7–2 Groundsmaster ®...
Page 361: Adjustments
Adjustments Planetary Drive Assembly Endplay A front planetary drive assembly that is properly operating should have no endplay. Any endplay in a planetary assembly indicates that there are potential problems with the planetary. Check planetary endplay at intervals specified in your Operator’s Manual.
Page 362: Service And Repairs
Service and Repairs Brake Assembly g310077 Figure 231 Flange head screw (6 per planetary) 7. Spring plate Piston motor (2 used) Splined brake shaft Compression spring Flat washer (2 per motor) Planetary assembly (2 used) Jam nut Cap screw (2 per motor) Front wheel assembly (2 used) Brake assembly (LH shown) Brake cable (LH shown)
Page 363 Brake Assembly Removal (Figure 231) (continued) 4. Remove front wheel assembly. 5. Remove hydraulic wheel motor (see Front Wheel Motors (page 5–118)). 6. Disconnect brake cable from pull rod on brake (Figure 233). Note: Be careful to not drop splined brake shaft as brake assembly is removed.
Page 364 Brake Assembly Installation (Figure 231) (continued) 1. Install splined brake shaft into brake assembly. Make sure that splines engage rotating discs in brake assembly. 2. Apply gasket sealant (Loctite #2 or equivalent) to sealing surfaces of new gasket (item 12). Align gasket and secure brake assembly to planetary with screws (item 11).
Page 365: Brake Inspection And Repair
Brake Inspection and Repair g276542 Figure 234 Brake housing (LH shown) Hitch pin (2 used) Rotating actuator Seal Stationary disc (4 used) Extension spring (3 used) Pull rod Rotating disc (3 used) Ball (3 used) Retaining ring Plug Clevis pin (2 used) Link (2 used) Gasket O−ring...
Page 366: Planetary Drive Assembly
Planetary Drive Assembly g310077 Figure 235 Flange head screw (6 per planetary) 7. Spring plate Piston motor (2 used) Splined brake shaft Compression spring Flat washer (2 per motor) Planetary assembly (2 used) Jam nut Cap screw (2 per motor) Front wheel assembly (2 used) Brake assembly (LH shown) Brake cable (LH shown)
Page 367 Removal (Figure 235) (continued) CAUTION When removing front wheel, use correct jacks and supports. Make sure machine is parked on a solid, level surface such as a concrete floor. Prior to raising machine, remove any attachments that may interfere with the safe and proper raising of the machine. Always chock or block wheels.
Page 368 Installation (Figure 235) (continued) 7. Lower machine from jack stands. Tighten lug nuts from 115 to 135 N·m (85 to 100 ft−lb) in a crossing pattern. Axles, Planetaries and Brakes: Service and Repairs Page 7–10 Groundsmaster ® 4500-D/4700-D 19245SL Rev A...
Page 369: Va02 Series Planetary Drive Service
VA02 Series Planetary Drive Service 37 N·m (27 ft-lb) VA02 series planetary g276546 Figure 236 Spindle O−ring End cap Boot seal Spacer Thrust plate Lip seal Locking washer O−Ring Inner bearing cup (2) Lock nut Retaining ring (2) Inner bearing cone (2) Ring gear Primary gear Wheel stud (8)
Page 370 19, 20 17, 18 g276499 Figure 237 Spindle Ring gear Boot seal Retaining ring Lip seal Plug Inner bearing cup (2) O−ring Inner bearing cone (2) Plug (2) Wheel stud (8) O−Ring (2) Socket head screw (8) End cap Lock washer (8) Thrust plate Housing O−Ring...
Page 371 Disassembly (continued) 7. Remove primary carrier and secondary carrier from ring gear. 8. Bend the locking washer tab away from the lock nut. Use a TMFS12 spanner socket to remove the 55 x 1.5 mm lock nut. Remove the locking washer and spacer.
Page 372 Assembly (continued) 10. Align key on spacer and install spacer onto spindle shaft. 11. Align key on locking washer and install locking washer onto spindle shaft. IMPORTANT Perform the following steps without interruption. Once the thread locking compound is applied, you have only a few minutes before the curing process will influence the bearing lock nut torque.
Page 373 Assembly (continued) at certain points, gears are not rolling freely and the planetary should be examined for improper assembly or damaged components. 20. Install front wheel assembly. 21. Fill planetary drive with gear lube; refer to traction unit Operator’s Manual. A portion of the gear lube will pass into the brake assembly automatically.
Page 374: Rear Axle Assembly
Rear Axle Assembly g310214 Figure 238 Rear axle motor 90o hydraulic fitting Lug nut (5 used per wheel) O−ring O−ring Rear axle assembly Pinion gear Temperature sender with O−ring Steering cylinder assembly External snap ring (2 used) Gear Cotter pin (2 used) O−ring External snap ring (2 used) Slotted hex nut (2 used)
Page 375 g310215 Figure 239 Outside plug (2 used) Center axle drain plug g276502 Figure 240 Gearbox drain plug Gearbox fill plug Remove Rear Axle (Figure 238) 1. Park machine on a level surface, lower cutting decks, stop engine, engage parking brake and remove key from the ignition switch. 2.
Page 376 Remove Rear Axle (Figure 238) (continued) 9. If needed for further axle disassembly, remove steering cylinder from axle (see Steering Cylinder (page 5–142)). 10. If required, remove tie rod ends from steering arms on rear axle (Figure 241). Remove the cotter pins and castle nuts from the tie rod ball joints. Use a ball joint fork and remove the tie rod ends from the axle steering arms.
Page 377 Install Rear Axle (Figure 238) (continued) WARNING Failure to maintain proper wheel lug nut torque could result in failure or loss of wheel and may result in personal injury. 8. Install wheel assemblies to rear axle. Lower machine to ground. Torque wheel lug nuts from 116 to 135 N·m (85 to 100 ft−lb).
Page 378: Rear Axle Service
Rear Axle Service g276507 Figure 244 Axles, Planetaries and Brakes: Service and Repairs Page 7–20 Groundsmaster ® 4500-D/4700-D 19245SL Rev A...
Page 379 Rear Axle Service (continued) Figure 244 (continued) LH axle support RH axle support Bevel gear shaft Flange bushing (2 used) Input shaft assembly Axle case (LH shown) Axle vent Bolt (8 used) Ball bearing Filter O−ring Bevel gear (29 tooth) Vent extension Differential shaft (LH shown) Shim set...
Page 380: Bevel Gear Case And Axle Case
Bevel Gear Case and Axle Case The following procedures assume the rear axle assembly has been removed from the machine. Removal 47 to 56 N·m (35 to 41 ft-lb) 47 to 56 N·m (35 to 41 ft-lb) g276508 Figure 245 Cap screw (4 used) Axle support Lock nut (2 used)
Page 381 Removal (continued) Threadlocking Compound 77 to 91 N·m (57 to 67 ft-lb) g276511 Figure 247 Axle case Screw (2 used) Axle case support Support shim 4. Remove the axle case support mounting screws, the axle case support and the support shims (Figure 247).
Page 382 Removal (continued) 5. Remove the knuckle pin mounting screws and the knuckle pin. Remove the gasket and any remaining gasket material from either mating surface (Figure 248). 6. While holding the bevel gear case, tap the upper end of the bevel gear shaft out of the upper bearing and upper bevel gear.
Page 383 Installation g276514 Figure 250 Axle case Shaft seal Bevel gear case 1. Coat new shaft seal with grease and install in axle case as shown (Figure 250). g276515 Figure 251 Axle case cover Upper bevel gear Lower bevel gear Collar Bevel gear shaft Upper bearing Lower bearing...
Page 384 Installation (continued) 4. Install the knuckle pin. Use medium strength threadlocking compound and tighten the knuckle pin mounting screws from 23 to 27 N·m (17 to 20 ft-lb). 77 to 91 N·m (57 to 67 ft-lb) VERTICAL ENDPLAY g276516 Figure 252 Axle case support Dial indicator Axle case...
Page 385 Installation (continued) g276517 Figure 253 Axle support Dial indicator Upper bevel gear Axle bearing shims Differential shaft gear 7. Temporarily install the bevel gear case/axle case assembly on the axle support. Position a dial indicator at the tooths center. Prevent the axle from turning and measure the upper bevel gear to differential shaft gear backlash (Figure 253).
Page 386 Installation (continued) Position a dial indicator at the tooths center. Prevent the axle from turning and measure the lower bevel gear to axle gear backlash (Figure 254). LOWER BEVEL GEAR BACKLASH: 0.10 to 0.40 mm (0.004 to 0.016 in) 10. Adjust backlash by increasing or reducing axle bearing shim thickness (see Axle Shafts (page 7–31)).
Page 387: Differential Shafts
Differential Shafts 47 to 56 N·m (35 to 41 ft-lb) 47 to 56 N·m (35 to 41 ft-lb) g276519 Figure 255 Cap screw (4 used) Bevel gear/axle case assembly Lock nut (2 used) O-ring Lock washer (2 used) Stud (2 used) Axle support The following procedures assume the rear axle assembly has been removed from the machine.
Page 388 Removal (continued) 5. Inspect all gears, shafts, bearings and cases for damage and wear. Replace components as necessary. Installation 1. Press bearings onto differential shaft. Place correct combination of bearing shims in axle support and drive differential shaft and bearing assembly into axle support.
Page 389: Axle Shafts
Axle Shafts 23 to 27 N·m (17 to 20 ft-lb) g276522 Figure 257 Axle case Screw (6 used) Axle cover assembly O-ring g276523 Figure 258 Bearing Spacer Bevel gear Retaining ring Shims The following procedures assume the rear axle assembly has been removed from the machine.
Page 390 Installation g276524 Figure 259 Axle shaft seal Bearing Axle cover Axle shaft 1. Coat new axle shaft seal with grease and install in axle cover as shown (Figure 259). 2. Press the axle cover and bearing assembly onto the axle shaft. Press only on the inner race of the cover bearing (Figure 259).
Page 391: Input Shaft/Pinion Gear
Input Shaft/Pinion Gear 47 to 56 N·m (35 to 41 ft-lb) 47 to 56 N·m (35 to 41 ft-lb) g276525 Figure 260 Nut (2 used) Bearing Cover plate Lock washer (2 used) O-ring Dowel pin (2 used) Stud (2 used) Input shaft/pinion gear Lock washer (6 used) Lock nut...
Page 392 Installation (Figure 260) Note: When installing bearing cones onto the input shaft/pinion gear, press only on the inner race of the bearing cone. 1. If the inner bearing cone was removed, press a new bearing cone all the way onto the input shaft/pinion gear. 2.
Page 393 Installation (Figure 260) (continued) Design Cone Center Distance g276527 Figure 262 Input shaft/pinion gear Bearing case 8. Use a depth gauge to measure the distance from the end face of the input shaft/pinion gear to the mating surface of the bearing case. Subtract the “Design Cone Center Distance”...
Page 394 Installation (Figure 260) (continued) 13. Place the correct combination of shims on the gear case. Tighten mounting nuts and screws from 47 to 56 N·m (35 to 41 ft-lb). 14. Install retaining rings and driven gear on input shaft/ pinion gear. 15.
Page 395: Differential Gear
Differential Gear g276529 Figure 264 Gear case Case screw (8 used) Pinion gear Differential gear Axle support (left) O-ring Axle support (right) The following procedures assume the rear axle assembly has been removed from the machine. Removal 1. Remove bevel gear case/axle case assemblies (see Bevel Gear Case and Axle Case (page 7–22)).
Page 396 Removal (continued) g276530 Figure 265 Differential case Spring pin 6. Drive the spring pin from the differential case with a punch and hammer. Discard the spring pin (Figure 265). Note: Mark and arrange all components so they can be reassembled in their original position.
Page 397 Inspection g276533 Figure 267 Side gear Differential case 1. Measure the differential side gear O.D. and the differential case I.D. to determine the side gear to case clearance (Figure 267). Replace components as necessary. SIDE GEAR TO CASE CLEARANCE: 0.05 to 0.30 mm (0.002 to 0.012 in) SIDE GEAR O.D.
Page 398 Inspection (continued) g276534 Figure 268 Pinion shaft Pinion gear 2. Measure the differential pinion shaft O.D. and the pinion gear I.D. to determine the pinion shaft to pinion gear clearance (Figure 268). Replace components as necessary. PINION SHAFT TO PINION GEAR CLEARANCE: 0.03 to 0.25 mm (0.001 to 0.010 in) PINION SHAFT O.D.
Page 399 Installation (continued) g276535 Figure 269 Vise Dial indicator Differential gear case 5. Secure the differential case in a soft jawed vise. Position a dial indicator on a tooth of the differential pinion gear. Press the pinion and side gear against the differential case and measure the pinion gear to side gear backlash (Figure 269).
Page 400 Installation (continued) 13. Coat a new O-ring with grease and install left side axle support half. Tighten axle support case screws from 47 to 56 N·m (35 to 41 ft-lb). 14. Install input shaft/pinion gear assembly (see Input Shaft/Pinion Gear (page 7–33)).
Page 401: Pinion Gear To Ring Gear Engagement
Pinion Gear to Ring Gear Engagement PROFILE TOP LAND LENGTHWISE BEARING HEEL ROOT g276537 Figure 271 The final position of the pinion gear is verified by using the gear contact pattern method as described in the following procedure. GEAR TOOTH DEFINITIONS (Figure 271): Toe −...
Page 402 Pinion Gear to Ring Gear Engagement (continued) g276539 Figure 273 Input shaft/pinion gear Differential gear case Bearing case shims Differential bearing shims 3. While applying a light load to the ring gear, rotate the pinion gear in the direction of forward travel until the ring gear has made one complete revolution.
Page 403: Gear Pattern Movement Summary
Gear Pattern Movement Summary Heel Contact Base Contact g276540 Figure 274 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 (Figure 274): A.
Page 404 Axles, Planetaries and Brakes: Service and Repairs Page 7–46 Groundsmaster ® 4500-D/4700-D 19245SL Rev A...
Page 405 Chapter 8 Chassis Table of Contents General Information ..........................8–2 Operator’s Manual ..........................8–2 Cutting Deck Identification ......................... 8–2 Service and Repairs ..........................8–3 Steering Column ..........................8–3 Traction Pedal ............................ 8–7 Console Arm ............................ 8–10 Lift Arms for Cutting Decks #1, #4 and #5 ..................8–12 Lift Arms for Cutting Decks #2 and #3 ....................
Page 406: General Information
General Information Operator’s Manual The Operator’s Manual provides information regarding the operation, adjustment procedures, and general maintenance for your Greensmaster machine. Refer to the Operator’s Manual for additional information when servicing the machine. Cutting Deck Identification #4 Deck #1 Deck #5 Deck #7 Deck #6 Deck...
Page 407: Service And Repairs
Service and Repairs Steering Column g308910 Figure 277 Steering wheel cover Flange head screw (4 used) Tinnerman nut (4 used) Lock nut Steering column Column brace Steering wheel Steering control valve O-ring Flat washer Socket head screw (4 used) Straight fitting (5 used) Socket head screw (4 used) Flange nut (4 used) O-ring...
Page 408 Removal (Figure 277) (continued) g308911 Figure 278 Roller support Headlight assembly Screw (2 used) Flange nut (2 used) Carriage screw (2 used) Platform shroud 3. Remove cover from steering wheel by carefully prying up on one of the cover spokes. 4.
Page 409 Removal (Figure 277) (continued) g310401 Figure 279 Steering tower Pedal block Lock washer (2 each) Pedal Release pin Spring Universal joint Cylinder shaft Jam nut Cylinder Pedal cover Bolt (2 each) Installation (Figure 277) 1. Assemble steering column using Figure 277 as a guide.
Page 410 Installation (Figure 277) (continued) 11. Install and secure platform shroud to machine (Figure 278). Chassis: Service and Repairs Page 8–6 Groundsmaster ® 4500-D/4700-D 19245SL Rev A...
Page 411: Traction Pedal
Traction Pedal g310428 Figure 280 Washer head screw (2 used) Cap screw (4 used) Spring retainer Reverse pedal pad Flange bearing mount Compression spring Pedal assembly Flange nut (2 used) Flat washer Spring pin Washer head screw (2 used) Sensor cover plate Forward pedal pad Standoff spacer (2 used) Traction pivot shaft...
Page 412 IMPORTANT A properly assembled and calibrated traction pedal position sensor is critical to accurate traction system response and for reliable sensor life. Use care when removing, assembling and calibrating the traction pedal position sensor. g310429 Figure 281 Pivot shaft Pivot hub Position sensor Screw (2 used) Spacer (2 used)
Page 413 Assembly (Figure 280) 1. Assemble traction pedal using Figure 280, Figure 281 Figure 282 guides noting the following items: A. Apply grease to both the OD and ID of the spring retainer (item 23 in Figure 280) before installation. Take care to not get grease on threads of spring shaft (19) or jam nut (9).
Page 414: Console Arm
Console Arm g310461 Figure 283 Headlight switch Console arm frame Flange nut (2 used) LH cover Flange head screw (2 used) Screw (2 used) RH cover Bag holder Flange nut (2 used) Washer head screw (10 used) Ignition switch Clip (2 used) Phillips head screw Hex nut Power point...
Page 415 Disassembly (Figure 283) 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 416: Lift Arms For Cutting Decks #1, #4 And #5
Lift Arms for Cutting Decks #1, #4 and #5 g310462 Figure 285 Flat washer Slotted roll pin Deck position switch Flange nut Lift cylinder pin Switch plate Lift arm (#1 deck) Flange nut Lock nut Lift cylinder pin Washer head screw Bumper support bracket Flange head screw Skid plate...
Page 417 Removal (Figure 285) (continued) #4 Deck #1 Deck #5 Deck #7 Deck #6 Deck Deck Deck (GM4700) (GM4700) g308386 Figure 286 CUTTING DECK LOCATIONS 3. If lift arm for either deck #4 or #5 (Figure 286) is to be removed, clean, label and remove hydraulic hoses from the deck motor (Figure 287).
Page 418 Installation (Figure 285) (continued) g310463 Figure 287 Supply hose Case drain hose Return hose Hose retaining loop 6. If lift arm for either deck #4 or #5 was removed, slide hydraulic hoses through the hose retaining loop on the lift arm. Remove caps and plugs from hydraulic hoses and fittings and install hoses to the deck motor (Figure 287).
Page 419: Lift Arms For Cutting Decks #2 And #3
Lift Arms for Cutting Decks #2 and #3 g310535 Figure 288 Grease fitting Pivot pin Flange nut Set screw (2 used per stop) Bumper Thrust washer Rotation stop Thrust washer Cap screw Flange head screw Lift cylinder pin Lift cylinder Lock nut Lock nut Deck pivot shaft...
Page 420 Removal (Figure 288) (continued) #4 Deck #1 Deck #5 Deck #7 Deck #6 Deck Deck Deck (GM4700) (GM4700) g308386 Figure 289 CUTTING DECK LOCATIONS 3. Remove lift cylinder pin (item 10) that secures lift cylinder to lift arm. 4. Loosen and remove lock nut (item 17) from pivot pin. 5.
Page 421: Lift Arms For Cutting Decks #6 And #7 (Groundsmaster 4700-D)
Lift Arms for Cutting Decks #6 and #7 (Groundsmaster 4700-D) g310552 Figure 290 Retaining ring Thrust washer Slotted roll pin Flat washer (4 used per support Cap screw Support arm (deck #6 shown) arm) Cap screw (4 used per support arm) 17. Lock nut Flange nut Flange bushing...
Page 422 Removal (Figure 290) 1. Park machine on a level surface, lower cutting decks, stop engine, engage parking brake and remove key from the ignition switch. 2. Remove cutting deck from lift arm (see Cutting Deck Operator’s Manual). #4 Deck #1 Deck #5 Deck #7 Deck #6 Deck...
Page 423: Operator Seat
Operator Seat g310565 Figure 292 Seat frame Hair pin Arm support Seat plate Seat pivot shaft Support bracket Torsion spring Screw (2 used) Manual tube Seat plate latch Flat washer (2 used) Spacer Clevis pin Flange head screw (4 used) Cap screw Flat washer Flange nut (4 used)
Page 424 Removal (Figure 292) 1. Park machine on a level surface, lower cutting decks, stop engine, apply parking brake and remove key from the ignition switch. 2. Disconnect seat electrical connector from machine wire harness. 3. Support console arm assembly to prevent it from shifting. 4.
Page 425 Installation (Figure 292) (continued) IMPORTANT Make sure to not damage the electrical harness or other parts while moving the console arm assembly. 3. Position and secure console arm assembly to seat. Install all fasteners before fully tightening them. A. Secure support bracket (item 24) and support channel (item 22) with flange nut (item 29) and carriage screw (item 28).
Page 426: Operator Seat Service
Operator Seat Service g276885 Figure 294 Backrest cushion Washer Torx screw (5 used) Seat cushion Cap screw (2 used) RH adjustment rail Armrest cover Seat Rail stop LH armrest Torx screw Bushing (2 used) Spring (2 used) Torx screw (3 used) Backrest Magnet Washer (3 used)
Page 427: Operator Seat Suspension
Operator Seat Suspension g276887 Figure 295 Cover Washer (2 used) Clamp (2 used) Tether Hose nipple Cover Level control Rivet (2 used) Screw Air control valve Washer (4 used) Handle Shock absorber C−clip (4 used) Bumper Air spring Pin (2 used) Air tube assembly Rivet (2 used) Plastic plug (23 used)
Page 428 Disassembly (Figure 295) 1. Park machine on a level surface, lower cutting decks, stop engine, apply parking brake and remove key from the ignition switch. 2. Remove operator seat from seat suspension (see Operator Seat (page 8–19)). 3. Disconnect seat suspension electrical connector from machine wire harness. g310578 Figure 296 Seat frame...
Page 429 Assembly (Figure 295) (continued) 4. Make sure that seat electrical connectors are secured to machine wire harness. Groundsmaster ® 4500-D/4700-D Page 8–25 Chassis: Service and Repairs 19245SL Rev A...
Page 430: Hood
Hood g310579 Figure 297 Screen Washer (2 used) LH hood frame tube Latch keeper Rubber bumper (2 used) RH hood frame tube Pop rivet (2 used) Flange nut (2 used) LH hood frame tube Hood Pop rivet (4 used) Hood frame tube Plastic plug (20 used) Flex draw latch (2 used) Flange head screw (25 used)
Page 431 Removal (Figure 297) 1. Park machine on a level surface, lower cutting decks, stop engine, engage parking brake and remove key from the ignition switch. 2. Release hood latches and raise hood. 3. Remove hair pins and washers from pivot pins on radiator frame. 4.
Page 432 Chassis: Service and Repairs Page 8–28 Groundsmaster ® 4500-D/4700-D 19245SL Rev A...
Page 433 Chapter 9 Cutting Decks Table of Contents General Information ..........................9–2 Operator’s Manual ..........................9–2 Adjustments ............................9–3 Blade Stopping Time.......................... 9–3 Service and Repairs ..........................9–4 Blade Spindle Assembly ........................9–4 Blade Spindle Service ........................9–7 Rear Roller............................9–11 Rear Roller Service ..........................
Page 434: General Information
General Information CAUTION Never install or work on the cutting decks or lift arms with the engine running. Always stop engine and remove key from ignition switch first. Operator’s Manual The Operator’s Manual provides information regarding the operation, adjustment procedures, and general maintenance for your Greensmaster machine. Refer to the Operator’s Manual for additional information when servicing the machine.
Page 435: Adjustments
Adjustments CAUTION Never install or work on the cutting decks or lift arms with the engine running. Always stop engine and remove key from ignition switch first. See the Cutting Deck Operator’s Manual for adjustment procedures for cutting decks on the Groundsmaster 4500-D and Groundsmaster 4700-D. Blade Stopping Time The blades of the cutting decks are to come to a complete stop in approximately five (5) seconds after the PTO is disengaged.
Page 436: Service And Repairs
Service and Repairs CAUTION Never install or work on the cutting decks or lift arms with the engine running. Always stop engine and remove key from ignition switch first. Blade Spindle Assembly g310580 Figure 298 Flange nut (6 used) O-ring Anti-scalp cup Hydraulic deck motor Spindle assembly...
Page 437 g310581 Figure 299 Socket head screw Hydraulic motor Removal (Figure 298) 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 washers that secure hydraulic motor to the cutting deck (Figure 299).
Page 438 Installation (Figure 298) (continued) 6. Position O-ring to top of spindle housing. Secure hydraulic motor to the cutting deck with two (2) socket head screws and flat washers. 7. After assembly, raise and lower the cutting deck to verify that hydraulic hoses and fittings do not contact anything.
Page 439: Blade Spindle Service
Blade Spindle Service g310606 Figure 300 Spindle housing Grease fitting Spindle plug Bearing Spindle shaft Spacer ring Oil seal Spacer set (2 piece) Shaft spacer Bearing Spindle nut Large snap ring Disassembly (Figure 300) 1. Remove blade spindle from cutting deck (see Blade Spindle Assembly (page 9–4)).
Page 440 Disassembly (Figure 300) (continued) g277084 Figure 301 Bearing Inner bearing spacer Spacer ring Outer bearing spacer Large snap ring Assembly (Figure 300) Note: A replacement spindle bearing set contains two (2) bearings, a spacer ring and a large snap ring (items 1, 2 and 3 in Figure 301).
Page 441 Assembly (Figure 300) (continued) g277085 Figure 302 Bearing cups Arbor press Large snap ring Support Outer bearing spacer Arbor press base 3. Using an arbor press, push the bearing cups into the top and bottom of the spindle housing. The top bearing cup must contact the outer bearing spacer previously installed, and the bottom bearing cup must contact the large snap ring.
Page 442 Assembly (Figure 300) (continued) 6. Slide spacer ring and inner bearing spacer into spindle housing, then install upper bearing cone and greased oil seal into top of housing. NOTE: The upper seal must have the lip facing out (up) (Figure 303).
Page 443: Rear Roller
Rear Roller g310607 Figure 304 Deck frame Roller shaft screw Skid bracket Rear roller assembly Roller mount Cap screw Grease fitting Flange head screw Removal (Figure 304) 1. Park machine on a level surface, lower cutting decks, stop engine, engage parking brake and remove key from the ignition switch.
Page 444 Removal (Figure 304) (continued) g310608 Figure 305 Grease fitting Cap screw Roller shaft screw Roller scraper Roller mount Scraper plate 3. Remove four (4) flange head screws securing roller mounts to rear of deck frame. Remove roller mounts and rear roller assembly from deck frame. 4.
Page 445: Rear Roller Service
Rear Roller Service g310671 Figure 306 Roller tube Outer seal Roller shaft Bearing lock nut Inner seal Set screw Bearing Disassembly (Figure 306) 1. Remove bearing lock nut from each end of roller 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 446 Assembly (Figure 306) g310672 Figure 307 Roller tube Inner seal tool Inner seal 1. Install inner seals into roller tube making sure that seal lip (and garter spring) faces end of tube. Use inner seal tool (see Special Tools (page 2–16)) and soft face hammer to fully seat seals against roller shoulder (Figure...
Page 447 Assembly (Figure 306) (continued) g310674 Figure 309 Roller tube Outer seal Inner seal Bearing/outer seal tool Bearing C. Install first outer seal into roller tube making sure that seal lip (and garter spring) faces end of tube. Use bearing/outer seal tool (see Special Tools (page 2–16)) and soft face hammer to lightly seat seal against...
Page 448 Assembly (Figure 306) (continued) g310676 Figure 311 Roller tube Bearing Roller shaft Outer seal Inner seal Bearing/outer seal tool D. Carefully install first outer seal into roller tube making sure that seal lip (and garter spring) faces end of tube. Use bearing/outer seal tool (see Special Tools (page 2–16)) and soft face hammer to lightly seat seal (Figure...
Page 449: Front Roller Service
Front Roller Service g310677 Figure 312 Mounting bolt Bearing spacer Bearing Front roller Disassembly (Figure 312) 1. Remove roller mounting bolt. 2. Remove roller assembly from carrier frame. 3. To remove bearings and bearing spacer: A. Insert punch through end of roller and drive opposite bearing out by alternating taps to opposite side of inner bearing race.
Page 450 Assembly (Figure 312) (continued) 3. Verify that there is no more than a 1.5 mm (0.060 inch) gap between roller assembly and the roller mount brackets of the deck frame. If this gap is larger than 1.5 mm (0.060 inch), shim excess clearance with 5/8” washers. 4.
Page 451: Cutting Deck Carrier Frame
Cutting Deck Carrier Frame g310863 Figure 313 Carrier frame Hardened washer (2 used per deck) 13. Lock nut Lynch pin Cap screw (2 used per deck) Flat washer Thrust washer Cap screw Compression spring Rebound washer Pivot shaft Pivot shaft Lift arm (#4 shown) Pivot shaft Lift arm (#6 shown)
Page 452 Removal and Installation (Figure 313) #4 Deck #1 Deck #5 Deck #7 Deck #6 Deck Deck Deck (GM4700) (GM4700) g308386 Figure 314 CUTTING DECK LOCATIONS Each cutting deck is suspended from a carrier frame. The cutting deck carrier frame is attached to the lift arm and allows the cutting deck to pivot on the lift arm pivot shaft.
Page 453 Appendix A Foldout Drawings Table of Contents Electrical Drawing Designations......................A–2 Hydraulic Schematic - Groundsmaster 4500-D ..................A–3 Hydraulic Schematic - Groundsmaster 4700-D ..................A–4 Electric Schematic - Groundsmaster 4500-D/4700-D (Models 30885 and 30887) ......A–5 Electric Schematic - Groundsmaster 4500-D/4700-D (Models 30893, 30893TE, 30899 and 30899TE) .........................A–6 Optional Operator Cab Electrical Schematic - Groundsmaster 4500-D/4700-D........A–7 Main Wire Harness - Groundsmaster 4500-D/4700-D ...............A–8...
Page 454: Electrical Drawing Designations
Y or YE YELLOW Numerous harness wires used on the Toro machines include a line with an alternate color. These wires are identified with the wire color and line color with either a / or _ separating the color abbreviations listed above (e.g., R/BK is a red wire with a black line, OR_BK is an orange wire with a black line).
Page 455: Hydraulic Schematic - Groundsmaster 4500-D
Hydraulic Schematic - Groundsmaster 4500-D g310870 Groundsmaster 4500-D, Drawing 136-3244 Rev A, Sheet 1 19245SL Rev A Page A–3...
Page 456: Hydraulic Schematic - Groundsmaster 4700-D
Hydraulic Schematic - Groundsmaster 4700-D g310871 Page A–4 19245SL Rev A Groundsmaster 4700-D, Drawing 136-3245 Rev A, Sheet 1...
Page 457: Electric Schematic - Groundsmaster 4500-D/4700-D (Models 30885 And 30887
Electric Schematic - Groundsmaster 4500-D/4700-D (Models 30885 and 30887) g310872 Groundsmaster 4500-D/4700-D (Models 30885 and 30887), Drawing 122-1265 Rev B, Sheet 1 19245SL Rev A Page A–5...
Page 458: Electric Schematic - Groundsmaster 4500-D/4700-D
Electric Schematic - Groundsmaster 4500-D/4700-D (Models 30893, 30893TE, 30899 and 30899TE) g310873 Page A–6 19245SL Rev A Groundsmaster 4500-D/4700-D (Models 30893, 30893TE, 30899 and 30899TE), Drawing 122-1265 Rev B, Sheet 1...
Page 459: Optional Operator Cab Electrical Schematic - Groundsmaster 4500-D/4700-D
Optional Operator Cab Electrical Schematic - Groundsmaster 4500-D/4700-D g310875 Groundsmaster 4500-D/4700-D , Drawing 122-0705 Rev A, Sheet 1 19245SL Rev A Page A–7...
Page 460: Main Wire Harness - Groundsmaster 4500-D/4700-D
Main Wire Harness - Groundsmaster 4500-D/4700-D g310950 Page A–8 19245SL Rev A Groundsmaster 4500-D/4700-D, Drawing 122-1263 Rev B, Sheet 1 of 2...
Page 461 Main Wire Harness - Groundsmaster 4500-D/4700-D g310951 Groundsmaster 4500-D/4700-D, Drawing 122-1263 Rev B, Sheet 2 of 2 19245SL Rev A Page A–9...
Page 462: Seat And Console Wire Harness - Groundsmaster 4500-D/4700-D
Seat and Console Wire Harness - Groundsmaster 4500-D/4700-D g310972 Page A–10 19245SL Rev A Groundsmaster 4500-D/4700-D, Drawing 122-1264 Rev A, Sheet 1 of 2...
Page 463 Seat and Console Wire Harness - Groundsmaster 4500-D/4700-D g310973 Groundsmaster 4500-D/4700-D, Drawing 122-1264 Rev A, Sheet 2 of 2 19245SL Rev A Page A–11...
Page 464: Power Center Wire Harness - Groundsmaster 4500-D/4700-D
Power Center Wire Harness - Groundsmaster 4500-D/4700-D g310974 Page A–12 19245SL Rev A Groundsmaster 4500-D/4700-D, Drawing 122-1262 Rev B, Sheet 1 of 2...
Page 465 Power Center Wire Harness - Groundsmaster 4500-D/4700-D g310975 Groundsmaster 4500-D/4700-D, Drawing 122-1262 Rev B, Sheet 2 of 2 19245SL Rev A Page A–13...
Page 466: Deck 6 And 7 Wire Harness - Groundsmaster 4700-D
Deck 6 and 7 Wire Harness - Groundsmaster 4700-D g310991 Page A–14 19245SL Rev A Groundsmaster 4700-D, Drawing 122-1273 Rev A, Sheet 1 of 2...
Page 467 Deck 6 and 7 Wire Harness - Groundsmaster 4700-D g310992 Groundsmaster 4700-D, Drawing 122-1273 Rev A, Sheet 2 of 2 19245SL Rev A Page A–15...
Page 468: Engine Wire Harness Drawing - Groundsmaster 4500−D/4700−D
Engine Wire Harness Drawing - Groundsmaster 4500−D/4700−D (Models 30885 and 30887) g311045 Page A–16 19245SL Rev A Groundsmaster 4500-D/4700-D (Models 30885 and 30887), Drawing 122-1671 Rev B, Sheet 1 of 2...
Page 469 Engine Wire Harness Drawing - Groundsmaster 4500−D/4700−D (Models 30885 and 30887) g311046 Groundsmaster 4500-D/4700-D (Models 30885 and 30887), Drawing 122-1671 Rev B, Sheet 2 of 2 19245SL Rev A Page A–17...
Page 470: Engine Wire Harness Drawing - Groundsmaster 4500−D/4700−D
Engine Wire Harness Drawing - Groundsmaster 4500−D/4700−D (Models 30893, 30893TE, 30899 and 30899TE) g311126 Page A–18 19245SL Rev A Groundsmaster 4500-D/4700-D (Models 30893, 30893TE, 30899 and 30899TE), Drawing 121-8853 Rev C, Sheet 1 of 2...
Page 471: Engine Wire Harness Drawing - Groundsmaster 4500−D/4700−D
Engine Wire Harness Drawing - Groundsmaster 4500−D/4700−D (Models 30893, 30893TE, 30899 and 30899TE) g311127 Groundsmaster 4500-D/4700-D (Models 30893, 30893TE, 30899 and 30899TE), Drawing 121-8853 Rev C, Sheet 2 of 2 19245SL Rev A Page A–19...
Page 472: Wire Harness Diagram - Two−Post Rops Extension
Wire Harness Diagram - Two−Post ROPS Extension g277230 Page A–20 19245SL Rev A Groundsmaster 4500-D/4700-D, Drawing 122-0892 Rev B, Sheet 1 of 2...
Page 473 Wire Harness Diagram - Two−Post ROPS Extension g277231 Groundsmaster 4500-D/4700-D, Drawing 122-0892 Rev B, Sheet 2 of 2 19245SL Rev A Page A–21...

This manual is also suitable for:

Groundsmaster 4700-d series

Toro Groundsmaster 4500-D Series Service Manual

Table of Contents

Chapter 1 :Safety

Table of Contents

Chapter 2 :Specificationsandmaintenance

Table of Contents

Chapter 3 :Troubleshooting

General Information/Service and Repairs

Chapter 4 :Yanmardieselengine

Table of Contents

Chapter 5 :Hydraulicsystem

Table of Contents

Chapter 6 :Electricalsystem

Table of Contents

Chapter 7 :Axles,Planetariesandbrakes

General Information/Service and Repairs

Chapter 8 :Chassis

Chapter 9 :Cuttingdecks

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Summary of Contents for Toro Groundsmaster 4500-D Series