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1. GND SOLI SOLI RAMP UP MODULE 5012 5012 PWR P23 INTERCONNECT TO MAIN pe DIODE Groundsmaster 4500 D 4700 D Serial Number Above 260000600 Console Wire Harness 30 STANDARD CONTROL MODULE 1 HOUR METER P29 ru STANDARD CONTROL MODULE 28 RAMP UP MODULE CZ C Ce C8 23 INTERCONNECT TO MAIN FLOW PL 2WD 4WD SWITCH 5 SW 1 22 POWER POINT P3 GLOW CONTROLLER
2. ALTERNATOR RUN SOLENOID HOLD P4 B PUY RABE 2 k ww LOTTE M PULL Ge BK BK R 4 CY TEMP SENDER P23 C9 PK P4 D ENGINE OIL PRESSURE 4 P4 C o 7o t ENGINE OVER TEMP 119 6 14 6 W OR g R BK 2 FUEL PUMP g g E E amp 8 GLOW PLUGS 4 PS A S 16 9 OR 5 MOO d 8 BN L 4 LZ dJ R BK je s R ee P s P23 82 CIO FL 23 10 pu FUSIBLE LINK UO d t Start e q 23 1 BK RONE ENGINE GROUND R BU P23 87 KUBOTA GLOW PLUG 9 CONTROLER L BU W start 4 THERMO P4 E FRAME GROUND VIO BATTERY 5 BN m 5 5 R BK 25 2 P23 c1 23 3 2 05 4 PTO SWITCH 2WD 4WD 1 1 2 L 2 1 Df MD F7 4 25 5 2 START 12v O s lt 2262 oA 25 86 2 8 HIGH TEM
3. GLOW CONTROLLER 2WD 4WD SWITCH K6 HIGH TEMP K7 PARKING BRAKE PTO SWITCH P2 J1 P3 P4 P14 P15 P5 p 123 4 5 6 i 23 45 67 8 123 4 5 2 3 4 5 123 4 5 6 7 8 x x zz t fi 5 E 99 E BLACK 3 BLACK au gt BLACK SOLI a gt gt 9 YELLOW 3 SOLI 30 d WHITE 1 soi P28 RAMP UP MODULE 85 2 5 GREEN 012 P7 8IN 3 z ORANGE E PWR 81 4 L m SHIELDED CABLE 8615 BLACK VIOLET Ls a ES VIOLET PI x BLUE BLUE 2 BLACK Al 4 A2 5 BLACK BLACK 5 BI ORANGE 82 2 TAN 8 3 ORANGE 4 GREEN 85 5 BLACK BLUEMHITE 87 SES GREEN 88 lj YELLOW 571 5 YELLOW lt 1 a 2 ORANGE DRANGE P23 INTERCONNECT TO MAIN HARNESS VIOLET VIOLET 2 WHITE YELLOW PINK WHITE 2m 5 BLACK VIOLET 5 GRAY 3 a m 9 02 sal WHITE z GREEN n 9 04 d z 05 9 gt E lt u o PT RED 2 E 3 SP8 P12 RED 5 6 1 2 t P6 DIODE PACK YELLO
4. Page 4 7 9 G104INVW 1081N02 393VH ONY 2 WU P 9 154 081 H i T ww 1 m i a E Bu 102 mH 1 154 S 2 L 2 j 2 4 3 eme 7 lt 1 245 1 It a zn 154 E T d E 0005 4 154 8 MOTH 0006 YC T 05 05 4 OAY M304 5 9 gt 19 X bd ot L M X 4 mH 1 1 1m t a i dolo Ey 11075 mm 5 T 92 gt 4 ZAS d 3 Pe PRIORITY FLOW 1 1081N02 230 5 i JAIA 1081NO2 83315 wl 8 DNI M f co
5. Page 9 6 Rev B R BK Way 2 5 HN HR L PULL E BK BK R GY TEMP SENDER Y GN ENGINE OIL PRESSURE GN ENGINE OVER TEMP m 110 C 5 BU W OR 9 qr R BK 5 FUEL PUMP 5 2 5 5 GLOW PLUGS 4 9 18 OR lt 1 tr sb 15 BN d zii E gig L 1 lo z R BK 4 318 4 Y R FL 8 FUSIBLE LINK Staff SP p K ENGINE LZ ENGINE GROUND R BK R BU 8 CONTROLLER GLOW PLUG e ITE vio THERMO LAMP GLOW OR BN 12 e GND Y BK BK D2 Ki BK 2 WD 4 WD IN AWD BK BK 4 PARKING BRAKE GN ON 2 Wb START RELAY 5 dm PTO SWITCH tac TT i GN K Ta e DECK UP 01 Ble 1 s PK Lot CENTER POSITION w Ww 3 BU 13007 14 IN LEFT PTO OR eerily SEAT SWITCH GN 1 ET DECK 6 Cyc SEAT SWITCH ff d LEFTDCK o VIO SEAT VACANT ER ON LEFT PTO KI DECK RAISED R OETIQNAL FUSE BLOCK DECK UP
6. 1081403 15155 NOIL2VUL ONY NMOO 33M0d Q104INV 1081N02 ONY 7 4 LW 9 1 i e i ES iu iram 16 i E dd 1 1d A Elka E n 2d i 9 1 X o Ol 6 154 4 1N084 0005 um m eem 5 ayaa J rg S 5 SETA 5 MOT 1 JAN 9006 X NOI 1 E t 05 0S z 5 id j EM M04 E ox i DG L ESTEE 154 2 4 p 05 cT RE J a t 1031N03 OMZ OMY 1 Lye E Is CA E v Ul C1 oo x 1 OI04INYW 1081N02 9230 E 1 9 E D 5 A 1 JAA 1041402 8331 1 s 52 n 4 gt 1 is E UL 22 taa T dd 9 AWA 108102 4 83 07 1311 Page 4 18 Groundsmaster 4500 D 4700 D Hydraulic Sy
7. MEASURING CONTAINER Milliliters in 15 sec Ounces in 15 sec 95 3 2 189 6 4 284 9 6 12 8 16 0 19 2 83 Working Pressure Low Pressure 25 6 Return or Suction gt lala 2 28 8 32 0 Hydraulic System Rev Page 4 36 Groundsmaster 4500 D 4700 D Procedure for Cutting Deck Motor Case Drain Leakage Test NOTE period of time a deck motor can wear in ternally A worn motor may by pass 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 hy draulic system and affect quality of cut NOTE One method to find a failing or malfunctioning deck motor is to have another person observe the ma chine while mowing in dense turf A bad motor will run slower produce fewer clippings and may cause a differ ent appearance on the turf 1 Make sure hydraulic oil is at normal operating tem perature by operating the machine for approximately 10 minutes Make sure the hydraulic tank is full 2 Park machine on a level surface with t
8. TEMP SENDER i GN F Ensine OIL PRESSURE BU W ENGINE OVER TEMP C w 5 OR i 3 FUEL PUMP lt GLOW PLUGS 4 rey S 15 3 o 8 i C C NOTE The wire harness and relays of the GM 4500 D and 4700 D 41 i 51 BN i 3 are the same The drawing on this page uses the GM 4500 D Schematic 1 o t 4 R BK Serial Number Below 220999999 to show the operational circuits 4 319 Y FUSIBLE LINK SP D i ENGINE BK R BK CONTROLLER GLOW PLUG KUBOTA RUM GROUND BATTERY VI START 4 1 HERMO LAMP GLOW OR BN Y 120 GND BK BK BK ww ww lt 2 WD 4 WD B BK IN 4WD PARK ING GN OFF START RELAY K5 mE PA A miaz GN K BU i 1 80777 1 1 se YY P W W ui i vr NOTE Refer to Cutting Deck Position Switch and Cutting Deck Lift Lower Switch in 11 1 SEEMS BER Chapte
9. Figure 15 4 Engine wire harness 5 Fusible link harness 1 Battery cable 2 Battery cable 3 Engine to frame ground Figure 16 1 Electric starter 3 Oil pressure switch 2 Fusible link connection Figure 17 4 Cable jam nut 5 Cable washer lock nut 1 Engine run solenoid 2 3 Throttle cable Groundsmaster 4500 D 4700 D One person should operate lift or hoist while the other person guides the engine into the machine IMPORTANT Make sure not to damage the engine fuel lines hydraulic lines electrical harness or oth er parts while installing the engine 4 Slowly lower engine into the machine 5 Align engine mounts to the rubber engine supports Secure engine with cap screws rebound washers and flange head nuts 6 Secure fan shroud to the radiator with four flange head screws and flat washers Make sure that clearance between shroud and fan is at least 180 4 6 mm at all points 7 Install coolant reservoir bracket and reservoir to fan shroud 8 Connectthrottle cable to the speed control lever with washer and lock nut Install cable to mounting bracket Fig 17 Adjust throttle cable see Traction Unit Opera tor s Manual 9 Connect fuel line to the injection pump Fig 17 IMPORTANT Support hydraulic pump assembly to prevent it from
10. POWER POINT Page 9 Rev D 10 TEM PULL i3 GY BK BK GY TEMP SENDER 1 Am GN ENGINE OIL PRESSURE GN 97M BU W gt ENGINE OVER TEMP ul HORS w 5 Buw OR 2 prm ty 9 8s E GLOW PLUGS 4 re 83 19 4 10 o 5 i m 4 u NOTE The wire harness and relays of the GM 4500 D and GM 4700 D gt 5 BN the same The drawing on this page uses the 4500 D Schematic Sr SS E SUB Serial Number Below 220999999 to show the operational circuits 9 Y ENGINE 4 CONTROLLER GLOW PLUG 5 START THERMO FRAME GROUND BATTERY 4 OR LAMP GLOW 1 2 GND nS cs ay 71 ka BK 2 WD 4 WD B l IN 4WD Po a GN PARKING BRAKE 1 ON 24 2 START RELAY 5 PTO SWITCH ala OR ia zi 3 80 1 1 PK BU BU W L SEAT SWITCH SEAT OCCUPIED OPTIONELE FUSE BLOCK 01 2 GN Kn E INCENTERPOSITION i 3p 19 2019 PK STOP NONE By 5 2 W CYYYY
11. 7 1 ALTERNATOR RUN SOLENOID e HOLD 4 L R BK SR 5 PULL cy w BK BK P4 F GY TEMP SENDER P2369 PK P4 D ENGINE OIL PRESSURE P4 C ENGINE OVER TEMP PASS W BU W OR 4 R BK 1 8 FUEL PUMP E E 5 GLOW PLUGS 4 P5 A OR 2 i i BN b 5 ig R BK 8 p PK PK R FL P23 82 VR FL 23 10 FUSIBLE LINK vam x Stort SP ec DTE q U 5 P23 81 BK B ENGINE ENGINE GROUND R BU P23 87 KUBOTA GLOW PLUG CONTROLER BU W START 4 4 THERMO P4 E FRAME GROUND BATTERY LAMP GLOW OR 2 5 HIN GNO i 5 BK BU R BK BK P23 A2 P23 C1 P23 A3 2 03 4 DECK UP D 0 0 T HEP CENTER POSITION 2 IN 290 7 4 WD ME 8761 ts 6 2 5 P23 C2 4700 aa H BN o8 F7 4 1 1 1 700 LEFT DECK i R P23 A5 22 5 12V s doto 4700 B P235 R as YY 25 6 04 P23 86 LEFT DECK 2 B HIGH TEMP SW PTO COIL 1 B POSITION lt 100 4918 2 C IGN SW 7 RUN DECK UP 4 W BK amp R BK T T t R PARKING BRAKE P23 B4 2 D PARKING BRAKE PTO SW 1
12. on wn P23 IELDED FUEL PUMP INTERCONNECT TO CONSOLE Groundsmaster 4500 D 4700 D GLOW RELAY ALT SEAT SW NEUTRAL SW PARKING BRAKE NTERCONNECT TO ENGINE ri PIS PH P5 P4 123 4 5 A B A B A B A B a 0 tre 5 5 x 3 5 x gt 3 a 3 a y a ORANGE v P3 RED BLACK GREEN PINK WHITE PINK PINK SLE PINK BLUE WHITE 5 2 PINK BROWN Al RER 5 5 AN BLACK M BLUE AS RED BROWN 8 RED ORANGE 83 B4 GREEN 85 BLUE WHITE 86 BLACK RED BLACK 87 GREEN 88 YELLOW 89 ORANGE 810 GREEN VIOLET YELLOW 9 BLACK 8 45 BROWN C6 GREEN e TAN co CIO BLUE D ORANGE D2 YELLOW 03 04 WHITE 05 BLACK SPI BLACK CABLE SHIELD SP6 5 BLACK gt 2 E T mn 14 1 4 A B B A B A 8 B P8 P9 P27 PIO P30 13 CENTER DECK SW 1 CENTER DECK SW 2 DIODE 3 2 WD COIL INTERCONNEC
13. Le lt FROM PTO MOW CIRCUIT 301 10 WNOI 130d03d 4 03 ox ONIH33IS Q103INVN 1081007 15155 0113 81 ONY NMOG 33M0d TO STEERING CIRCUIT 108102 83MOV 1311 Page 4 44 Groundsmaster 4500 D 4700 D Hydraulic System Rev A Procedure for Counterbalance RV1 Pressure Test 1 Make sure hydraulic oil is at normal operating tem perature by operating the machine for approximately 10 minutes Make sure the hydraulic tank is full 2 Park machine on a level surface with the cutting units lowered and off Make sure engine is off and the parking brake is engaged Prevent personal injury and or damage to equip ment Read all WARNINGS CAUTIONS and Pre cautions for Hydraulic Testing at the beginning Figure 44 of this section 1 Traction assist manifold GM 4500 D shown 2 Counterbalance test port 3 Connect a 1000 PSI gauge to counterbalance test port on power down and traction assist manifold under operator s seat Fig 44 4 Start the engine and put throttle at full engine speed 2800 50 RPM with no load on the system Do not en gage the cutting units Hyd
14. ALTERNATOR PK PK RUN SOLENOID B HOLD P4 B 1 R BK 4 8 ay o am L PULL w BK BK R P4 F GY TEMP SENDER P23 C9 PK P4 D aE GN ENGINE OIL PRESSURE GN P4 C BU W ENGINE OVER TEMP ui 110 4 6 S BU W OR 2 om R BK 5 n FUEL PUMP 5 2 z w 5 p 5 GLOW PLUGS 4 P5 A 51 5 5 OR 5 5 m 5 J 45 4 gt BN 2 E co R BK 35 3 rp PK PK R wae P23 B2 e RE P23 CIO Aa FL FUSIBLE LINK tafi m map g BK Vu P23 81 ENGINE ENGINE GROUND R BU CONTROLLER GLOW PLUG KUBOTA gt BU W START THERMO P4 E FRAME GROUND BATTERY VIO 4 LAMP GLOW OR BN 12 GND PK BK BK BU R BK P23 A2 BK P23 CI GN 2 wo 03 GN DECK UP D 01 gt 2 WD 4 WD CIN CENTER POSITION vio nn PK a 9 2 P23 C2 4100 A BU BU T sar VIS i 25 START 12 1160 8 R BU 5 5 pK E 28 27 6 23 86 2 8 HIGH TEMP SW PTO LEET DEGE eu BU W 8 5 BN i POSITION 2A 25 IGN SW 1 RUN DECK UP DI C F amp gt RIBK aN E Bk R ONT P23 on 220 PARKING BRAKE PTO CIN CENTER POSITION 1 D PK BK 26 BACKLAP NOT ESAN Bu
15. l OR GN 10 d gu A BU W OR 6500 MFD SEAT SWITCH SEAT VACANT OPTIONAL FUSE BLOCK T R gt K w e 5 NGENTER POSHION j MES t STAR ee M 2 SIS PK BU Y i nm 3 peers 2 3 5 1 ee I lt lt BK Om IGNITION l FRONT DECK FRONT DECK TOE BK MODULE mU STAR z POSITION POSITION 4 R DAAR 5 DECK RAISED DECK RAISED FRONT PTO 15 4 104A J DECKS 1 4 OR GN an NEUTRAL la NOT IN NEUTRAL VIO F2 10 x 4 1 ee 1 F 3 IO A W mg POWER POINT Groundsmaster 4500 D 4700 D Glow Plug Circuit Power Current Control Current Indicator Gauge Current 9 9 Rev D ALTERNATOR RUN SOLENOID HOLD JI
16. 982 5 EE A tad dd zw 2 ooze Q103INVN 1081107 5155 0112 1 ONY NMOG 33M0d 5 H pueros 0 1 518 rj m ET rd 4 cu m RET gi bee Jong Td mH 154 6 np zn C129 39 9 7 i 4 Yu H DL 7 ir Wm p di MEAM 830110 m 0192 H 1304034 Y S id 7 _ _ 154 H ioca MY04 ok pe d TEY ji E ghi E eS RET 511 me 1 a C1 0104INVH 1081N02 9230 m amp JAWA 1041402 83315 3ATVA 108107 83M01 13I1 9 4 12 Groundsmaster 4500 D 4700 D Hydraulic System Rev A Raise Cutting Units Athree section gear pump is coupled to the piston trac tion pump The gear pump section P3 farthest from the piston pump supplies hydraulic flow to the lift lower control valve and the steering control valve Hydraulic flow from this pump section
17. 22 8 5 2 5 1 TO MAIN HARNESS SENDER Pag ALTERNATOR HI E P7 7x DIODE J3 GROUND P2 STARTER ug H OIL PRESSURE Bean J6 STARTER S TO MAIN HARNESS Groundsmaster 4500 D 4700 D Serial Number Below 220999999 Engine Wire Harness Page 9 27 Rev D 9 28 Rev INTERCONNECT FUSIBLE LINK 1 Pe STARTER RUN SOLENOID OVER TEMP OIL PRESSURE PI J5 J4 HOLD PULL GND A B x 5 a 5 tr ea WHITE SPZ A WHITE B C D GREEN P4 E BLUE F GRAY G H EE SP BLACK BLACK GLOW TEMP SENDER 26 STARTER J3 GROUND ALTERNATOR Groundsmaster 4500 D 4700 D Serial Number Above 230000000 Engine Wire Harness 1 FUEL SOLENOID n 5 GLOW PLUGS TEMP SW 5 TO MAIN HARNESS 4 TEMP SENDER TO MAIN HA
18. 2WD CONTROL MANIFOLD TO TRACTION CONTROL omm 4 eee d MANIFOLD FNT PORTS FRONT 4 FORW FILTRATION AND CHARGE CONTROL MANIFOLD TO LIFT LOWER CIRCUIT T TO STEERING CIRCUIT 50 50 PROPORTIONAL FLOW DIVIDER FROM PTO MOW CIRCUIT Working Pressure TO PTO MOW CIRCUIT Low Pressure o FROM STEERING CONTROL Return or Suction FROM PTO MOW CIRCUIT Flow Hydraulic System Rev Page 4 28 Groundsmaster 4500 D 4700 D Procedure for Traction Circuit Relief Pressure Test 1 Make sure hydraulic oil is at normal operating tem perature by operating the machine for approximately 10 minutes Make sure the hydraulic tank is full Move machine to an open area away from people and obstructions 2 Drive machine to an open area lower cutting units turn the engine off and engage the parking brake Prevent personal injury and or damage to equip ment Read all WARNINGS CAUTIONS and Pre cautions for Hydraulic Testing at the beginning of this section 3 Connect a 10 000 psi gauge to traction
19. P31 EIE UID CZ Cu cac o P12 seh d 9 P12 P31 FUSE BLOCK 1 FUSE BLOCK 2 3 9 7 RELAY K3 RIGHT PTO RELAY K1 LEFT PTO P20 RIGHT DECK P21 CENTER DECKS P8 RELAY 2 CENTER PTO J2 OPTION 1 2 5 3 PL SPT 6 Bee eee SP2 SP9 SP5 e P19 LEFT DECK 3 2 1 6 DIODE 6 5 TEMP GAUGE 2 P2 TEMP GAUGE Groundsmaster 4500 D 4700 D Serial Number Above 260000600 Console Wire Harness Page 9 25 Rev D RUN SOLENOID OIL PRESSURE 1 HOLD PULL GROUND J5 J4 A B C x Q E 3 DT c 5 WHITE FUSIBLE unk P2 8 SP2 A WHITE B C INTERCONNECT 55 G H SP J3 GROUND 1 BLACK INTERCONNECT ORANGE TO MAIN HARNESS B BLACK 5 gt 2 J1 P7 J6 R L GLOW TEMPERATURE SENDER DIODE STARTER P6 ALTERNATOR Groundsmaster 4500 D 4700 D Serial Number Below 220999999 Engine Wire Harness Page 9 26 Rev D TEMPERATURE OEH 1 45 TEMPERATURE d J2 i P1 FUEL SOLENOID
20. Groundsmaster 4500 D Electrical Schematic Serial Number Below 220999999 All relays and solenoids are shown as de energized All ground wires are black 9 3 9 4 Rev 0 ALTERNATOR RUN SOLENOID PK HOLD P4 B R BK 69 R m W HR L PULL BK BK R P4 F GY TEMP SENDER P23 C9 PK P4 D GN ENGINE OIL PRESSURE P4 A GN Pare oo BU W ENGINE OVER TEMP oc P4 G e BU W OR 2 R BK FUEL PUMP 2 2 z 9 F ul x ut GLOW PLUGS 4 5 2 18 OR 3 2990 d 4 5 BN dr fle gt R BK 8 1 R wan P23 B2 ME V P23 CIO FUSIBLE LINK Va FL Be tafi I d 5 du 23 ENGINE d ENGINE GROUND R BU 023 87 CONTROLER GLOW PLUG 2 9 KUBOTA 7 BU W START THERMO pile FRAME GROUND BATTERY
21. 1081809 15155 0 12 81 ONY NMOQ 53 0 1081N02 3230 3ATVA 1081 0 43315 DEC ne 154 m Page 4 14 Groundsmaster 4500 D 4700 D Hydraulic System Rev A Mow Circuit Hydraulic flow for the mow circuit is supplied by two sec tions of the gear pump P1 and P2 Gear pump section P1 supplies hydraulic flow to decks 2 3 and 5 also 7 on the GM 4700 D while gear pump section P2 supplies decks 1 and 4 also 6 on the GM 4700 D On the Groundsmaster 4500 D hydraulic flow from the two pump sections is controlled by two hydraulic manifolds each equipped with a solenoid controlled proportional relief valve PRV1 PRV2 logic cartridge LC1 and brake relief cartridge RV8 When the PTO switch is OFF or if the decks are raised the deck sole noid valves PRV1 PRV2 are not energized allowing hydraulic flow to by pass the deck motors through the manifold When the PTO switch is turned ON with the decks lowered the solenoid valves PRV1 and PRV2 energize causing a shift of the logic cartridges LC1 and allowing hydraulic flow to the deck motors Brake re lief cartridges RV8 control the stopping rate of the blade
22. lt 10 ainssald W9 041 1081N02 __ 2a 9 154 gt 1 1 d 103 1 154 5 D i zl 2509 y 4 4 Rid 2 1 1 5 E 2014 Oz 1 0005 4 t e E THERE i wa 2 sud gt Y 9 Yagi Ald O E oe d n 05 05 03 ox J 9 1 8 72 1604 a 4 983 Y 1 ES Ds Br i taa T dd d zwi JAWA 1041802 0189 4 MOV 1411 1
23. GN 2 IN CENTER POSITION 5 BU i 2 W STOP NONE RUN 1 X Y PK BU Y ae 2 3 5 Y FRONT DECK 3 1 BK 5 IGNITION SW 5 POSITION POSITION ETERN PICKS RAMP UP DECK RAISED DECK RAISED 4 OFF RUN STAR 5 DECKS 1 4 15 F 4 I0 GN OR B 1 GN DECK UP 01 8 6 GN PK BN 1 NEUTRAL SWITCH CENTER POSITION lt oada NEUTRAL KRO NOT IN NEUTRAL E 1 4 814 men fa TT aise pro X ey ea PR RIGHT DECK xi f POSITION RIGHT PTO K3 DECK RAISED BK BK E23 4 Groundsmaster 4700 D Electrical Schematic Serial Number Below 220999999 All relays and solenoids are shown as de energized All ground wires are black
24. Figure 16 1 Roller tube 4 Bearing 2 Roller shaft 5 Washer 3 Inner seal 6 Bearing outer seal tool n J 7 LLL TLL IL LLL LL Figure 17 4 Bearing 5 Outer seal 6 Bearing outer seal tool Roller tube Roller shaft Inner seal 2 5 Cutting Units Rev Rev D Front Roller Service Disassembly Fig 18 1 Remove roller mounting bolt 2 Remove roller assembly from carrier frame 3 To remove bearings and spacer A Insert punch through end of roller and drive oppo site bearing out by alternating taps to opposite side of inner bearing race There should be alip of inner race exposed for this process B Remove spacer Remove second bearing from roller using a press 4 Inspect roller housing bearings and bearing spacer for damage or wear Replace components as needed Assembly Fig 18 1 Install bearings and bearing spacer into roller A Press first bearing into housing Press on outer race only or equally on inner and outer races B Insert bearing spacer C Press second bearing into roller housing press ing equally on inner and outer races until the inner race comes in contact with the spacer 2 Install roller assembly into deck frame Cutting Units Rev B Page 8 18 Rev D Figure 18 3 Spacer 4 Front roller 1 Mounting bolt
25. PULL GY 6 BK BK GY TEMP SENDER Ale GN ENGINE OIL PRESSURE poe BU W ENGINE OVER TEMP 110 Ww E BU W N R BK 5 FUEL PUMP E m GLOW PLUGS 4 EC 18 T77 OC AS 1 5 NOTE The wire harness and relays of the GM 4500 D and GM 4700 D g i jd are the same The drawing on this page uses the GM 4500 D Schematic z R BK Serial Number Below 220999999 to show the operational circuits r 7 t FUSIBLE LINK EI gee ORE T toc YR M e ENGINE ENGINE GROUND CONTROLLER GLOW PLUG KUBOTA MCN CP METER RTT M ls START THERMO 11 FRAME GROUND BATTERY Ha LAMP GLOW sope ND K BK 2 WD 4 WD BK IN 4WD PARKING BRAKE i GN ON 2 WD PTO SWITCH START RELAY 5 i n
26. ROM LIFT LOWER CIRCUIT TO LIFT LOWER CIRCUIT TO STEERING CIRCUIT FORW ARD PROPORTIONAL FLOW DIVIDER L 180 PSI FILTRATION CHARGE CONTROL MANIFOLD coz Working Pressure Low Pressure DECK CONTROL MANIFOLD Return or Suction ot gt Flow j 5 2 L Fx GM 4700 D ROM LIFT LOWER CIRCUIT O LIFT LOWER CIRCUIT O STEERING CIRCUIT FORW ARD 50 50 PROPORTIONAL FLOW DIVIDER 180 PSI C02 FILTRATION AND CHARGE CONTROL MANIFOLD Hydraulic System Rev A Page 4 30 Groundsmaster 4500 D 4700 D Procedure for Cutting Deck Circuit Pressure Test 1 Make sure hydraulic oil is at normal operating tem perature by operating the machine for
27. STEERING CONTROL NEUTRAL POSITION LEFT TURN STEERING CONTROL STEERING CONTROL RIGHT TURN Figure 18 Groundsmaster 4500 D 4700 D Page 4 19 Hydraulic System Rev A 2 6 0 Special Tools Order these special tools from your Toro Distributor Hydraulic Pressure Test Kit TOR47009 Use to take various pressure readings for diagnostic tests Quick disconnect fittings provided attach directly to mating fittings on machine test ports without tools A high pressure hose is provided for remote readings Contains one each 1000 PSI 70 Bar 5000 PSI 350 Bar and 10000 PSI 700 Bar gauges Use gauges as recommended in Testing section of this chapter Hydraulic Tester Pressure and Flow TOR214678 Figure 20 This tester requires O ring Face Seal ORFS adapter fittings for use on this machine 1 INLET HOSE Hose connected from the system cir cuit to the inlet side of the hydraulic tester 2 LOAD VALVE A simulated working load is created in the circuit by turning the valve to restrict flow 3 LOW PRESSURE GAUGE Low range gauge to pro vide accurate reading at low pressure 0 to 1000 PSI A protector valve cuts out when pressure is about to exceed the normal range for the gauge The cutout pressure is adjustable Hydraulic System Rev A Page 4 20 4 HIGH PRESSURE GAUGE High range gauge which accommodates pressures beyond the capacity
28. umous q oost IND SHUN 1901 1 00 00 _ za 7 19 Q103INVW 1081N02 393VH ONY ine e p 4 ow eg a L B Y 4 c 2 1 1 Groundsmaster 4500 D 4700 D S 8401 10 MOTH WNOI 30d0td 05 09 19 ld H fu ZAud bi lt gt giu 4 10 A t 9 ZL 1081409 2230 PRIORITY FLOW JAWA 1041802 83315 t SERA 2 uH i3 caa t
29. aca lt gt I ZW al L v poa a eee ee v vt Y d P 4 4 4 sun 9 1 ld D t du us E L a 1 m 1231 q a 2 s bla 4 8 Groundsmaster 4500 D 4700 D Hydraulic System Rev A Traction Circuit The traction circuit piston pump is a variable displace ment pump that is directly coupled to the engine fly wheel Pushing the top of the traction pedal engages a hydraulic servo valve which controls the variable dis placement piston pump swash plate to create a flow of oil This oil is directed to the front wheel and rear axle motors Operating pressure on the high pressure side of the closed traction circuit loop is determined by the amount of load developed at the fixed displacement wheel and axle motors As the load increases circuit pressure can increase to relief valve settings 5000 PSI in both forward and reverse If pressure exceeds the re lief setting oil flows through the relief valve to the low pressure side of the closed loop traction circuit The traction circuit provides operation in either mow four wheel drive or transport two wheel drive Traction circuit pressure forward and reverse can be me
30. POWER POINT Ty P3 GLOW CONTROLLER TEMPERATURE GAUGE A B P18 DIODE 8 P6 2 TEMPERATURE GAUGE 2 DIODE PACK P19 LEFT DECK P23 INTERCONNECT TO MAIN HARNESS Console Wire Harness Groundsmaster 4500 D 4700 D Serial Number Below 220999999 Page 9 21 Rev D RELAY KI LEFT PTO RELAY K2 CENTER PTO RELAY K3 RIGHT PTO FUSE BLOCK 2 POWER POINT FUSE BLOCK 1 Page 9 22 Rev D TEMP GAUGE GLOW CONTROLLER PTO SWITCH P JI P3 FLOW DIVIDER 4WD SWITCH 5 J4 P4 45 6 4 5 6 7 8 1 y BLACK 3 P
31. zag JAYA 7081803 L 83 07 1311 1081007 lSISSV NOILIVYL ONY NMOG Hydraulic System Rev A Lower Cutting Units Athree section gear pump is coupled to the piston trac tion pump The gear pump section P3 farthest from the piston pump supplies hydraulic flow to both the lift lower control valve and the steering control valve Hy draulic flow from this pump section is delivered to the circuits through a proportional flow divider This pump section takes its suction from the hydraulic reservoir Maximum lift lower circuit pressure 2200 PSI is limited by a relief valve in the power down and traction assist control manifold RV7 Onthe Groundsmaster 4500 0 a single lift lever is used to lift and lower the five cutting decks The Groundsmas ter 4700 D has three lift levers to control the cutting decks the center lever is for the five center decks the left lever controls the left rear deck 6 and the right lever controls the right rear deck 7 Pressure to the lift lower control valve can be monitored at a port on the end of the gear pump When the cutting units are in a stationary position flow from the gear pump is by passed through the lift lower control valve power down and traction assist control manifold oil filter and traction charge circuit To lower the center five cutting decks the lift lever on the lift lower co
32. 5 9 VACUATOR DIRECTION Figure 3 1 Air cleaner hose 7 Hose clamp 12 Air cleaner body 2 Hose clamp 8 Air cleaner hose 13 Filter element 3 Air cleaner assembly 9 Hose clamp 14 Filter element 4 Service indicator 10 Cap screw 15 Air cleaner cover 5 Air cleaner strap 11 Flat washer 16 Vacuator valve 6 Lock nut Removal 1 Remove air cleaner components as needed using Figure 3 as a guide Installation IMPORTANT Any leaks in the air filter system will cause serious engine damage Make sure daily that all air cleaner components are in good condition and are properly secured during reassembly 1 Assemble air filter system using Figure 3 as a guide 2 When installing air cleaner hose 8 between air cleaner and turbo charger Fig 4 Figure 4 A Make sure that hose does not contact engine 4 Air cleaner hose 4 Air cleaner body valve cover To modify clearance move and or rotate 2 Engine valve cover 5 Muffler bracket air cleaner body in air cleaner strap Verify that tabs 3 Air cleaner strap in strap mesh fully with slots in air cleaner body B Position hose to allow 5 16 7 9 mm clearance between air cleaner hose and muffler bracket Groundsmaster 4500 D 4700 D 3 5 Kubota Diesel Engine Rev A Exhaust System 41 7U 161022 ft lb 21 to 29 N m 16 to 22 ft Ib 21 to 29 N m 16 to 22 ft lb 21 to 29 N m Figure 5 1 Muffler 6 Lock nut 11
33. B 154 08 i F um mge T i 8301 10 MOT Working Pressure bow re GM 4500 D SHOWN Low Pressure Return or Suction FROM PTO MOW CIRCUIT Le FROM PTO MOW CIRCUIT WNOI 120d08d 05 09 SNIH33ILS E 23 o t o o 2 o o 1081403 83MOV 1311 GIOSINVW 1081002 1SISSV NOIL2VHL ONY NMOQ Page 4 50 Groundsmaster 4500 D 4700 D Hydraulic System Rev A Procedure for Traction Assist RV2 Pressure Test 1 Make sure hydraulic oil is at normal operating tem perature by operating the machine for approximately 10 minutes Make sure the hydraulic tank is full 2 Park machine on a level surface with the cutting units lowered and off Make sure engine is off and the parking brake is engaged Figure 51 Prevent personal injury and or damage to equip 1 Traction assist manifold GM 4500 0 shown ment Read all WARNINGS CAUTIONS and Pre Go nterbalarics test port
34. Engine Run Solenoid The engine run solenoid must be energized for the en gine to run The solenoid is mounted on the engine block near the injection pump In Place Testing NOTE Prior to taking small resistance readings with a digital multimeter short the meter test leads together The meter will display a small resistance value usually 0 5 ohms or less This resistance is due to the internal resistance of the meter and test leads Subtract this val ue from from the measured value of the component you are testing 1 Disconnect the connector from the engine run sole noid 2 Using a digital multimeter touch one lead to the pin of the black wire and the other lead to the pin of the white wire The resistance of the pull coil should be about 0 26 ohms 3 Using a digital multimeter touch one lead to the pin of the black wire and the other lead to the pin of the red wire The resistance of the hold coil should be about 10 9 ohms 4 Connect solenoid to the wiring harness Live Testing 1 Disconnect connector from the engine run solenoid NOTE The solenoid may be removed from the engine or tested in place 2 If the solenoid is removed from the engine make sure that the solenoid linkage moves freely and is free of dirt debris and corrosion Connect a positive test lead a 12 VDC source to the pins of the red and white wires 4 Touch a negative test lead from the 12 VDC source to the pin o
35. 16 When changing attachments tires or performing other service use correct blocks hoists and jacks Make sure machine is parked on a solid level floor such as a concrete floor Prior to raising the machine remove any attachments that may interfere with the safe and proper raising of the machine Always chock or block wheels Use jack stands or solid wood blocks to support the raised machine If the machine is not properly sup ported by blocks or jack stands the machine may move or fall which may result in personal injury see Jacking Instructions Safety Jacking Instructions When changing attachments tires or perform ing other service use correct blocks hoists and jacks Make sure machine is parked solid level surface such as a concrete floor Prior to raising machine remove any attach ments that may interfere with the safe and prop er raising of the machine Always chock or block wheels Use jack stands or solid wood blocks to support the raised machine If the machine is not properly supported by blocks or jack stands the machine may move or fall which may result in personal inju Jacking the Front End Fig 1 1 Set parking brake and chock both rear tires to pre vent the machine from moving IMPORTANT Do not place jack jack stands or blocks under the wheel motors Wheel motors can be damaged if used for jacking or support points 2 Position jack securely under the frame just to the in
36. 212 DECK RAISED DECK RAISED BK MODULE 4 OFF RUN START g FRONT PTO 5 1 4 F 154A Y 5 GN GN p cus MM m GN GN T NEUTRAL K9 NEUTRAL SWITCH NOT IN NEUTRAL VIO 2 I0 A x Lee Li ye ee es ee ep PE E any EE ey A Py PSR C Pe Groundsmaster 4500 D 4700 D Run Transport Circuit Power Current Control Current Indicator Gauge Current POWER POINT Page 9 11 Rev D Reo 2 1 1 0 EF B HOLD SUR R GO L PULL dy cr 18 BK SS ee m ww mom wow ee wmm m mimi mam im m wow woe iw wie m mm mom wo m um Signe mm mom ee R e 5
37. essary before returning machine to service 2 Read the General Precautions for Removing and Installing Hydraulic System Components at the begin ning of the Service and Repairs section of this chapter NOTE Before disconnecting the hydraulic lines clean the port area of the lift lower control valve assembly 3 Tag hydraulic lines for proper reassembly 4 Remove lift lower control valve using Figure 86 as a guide 2 5 i gt Groundsmaster 4500 D 4700 D Page 4 95 Hydraulic System Rev A Lift Lower Control Valve Service GM 4500 D 4 to 5 ft lb 5 to 7 N m 30 to 35 1 41 to 48 N m 9 26 27 7 20 to 25 ft lb 27 to 33 N m 1 Poppet 2 Plunger 3 Spacer 4 Spool 5 Seat 6 Plug 7 Seat retaining plug 8 Bushing 9 Lockout spring 10 Spool cap Hydraulic System Rev A Figure 85 Detent plunger Control valve body Detent plug Spool spring O ring Retaining ring Detent spring Disc Plug Page 4 96 10 to 12 ft Ib 13 to 16 N m 30 to 35 1 41 to 48 N m 20 Washer 21 Wiper seal 22 Backup washer 23 O ring 24 O ring 25 O ring 26 O ring 27 Backup washer 28 O ring Groundsmaster 4500 D 4700 D NOTE Cleanliness is extremely important when repairing hydraulic components Work in a clean area Before disassembly drain the oil then plug the ports and thoroughly clean the exterior During repairs
38. 20 to 25 ft Ib 10 710 33 N m 30 to 35 1 41 to 48 N m Figure 87 1 Poppet 11 Control valve body 21 Plug 2 Plunger 12 O ring 22 Wiper seals 3 Spacer 13 Retaining ring 23 Backup washer 4 Spool 14 Washer 24 O ring 5 Seat 15 Spool spring 25 O ring 6 Plug 16 Plunger 26 O ring 7 Seat retaining plug 17 Detent plunger 27 O ring 8 Bushing 18 Detent plug 28 O ring 9 Lockout spring 19 Disc 29 Backup washer 10 Spool cap 20 Detent spring Hydraulic System Rev A Page 4 100 Groundsmaster 4500 D 4700 D NOTE Cleanliness is extremely important when repairing hydraulic components Work in a clean area Before disassembly drain the oil then plug the ports and thoroughly clean the exterior During repairs always protect machined surfaces Disassembly 1 Plug all ports and clean outside of valve thoroughly 2 Remove spool caps 10 Do not remove retaining rings 13 from spools unless spool spring 15 is bro ken NOTE Spools and spool bores are matched sets Be sure each spool is identified with the correct control valve body spool bore 3 Remove spools 4 from control valve body 11 4 Remove bushings 8 and O rings 12 from spools and O rings from spool bores 5 Remove plugs 6 IMPORTANT Check location and positioning of plungers when removing from body to assure prop er assembly 6 Remove seat retaining plugs 7 lockout springs 9 poppets 1 seats 5 and plu
39. 3 Install plug 6 with new back up washer 22 andO ring 23 Torque plug from 30 to 45 ft lb 41 to 48 N m 4 Lubricate plunger 2 with clean hydraulic oil and install it into control valve body IMPORTANT Check location and positioning of plunger during installation 5 Install new O ring 28 on seat 5 Install new back up washer 27 and O ring 26 on seat retaining plug 7 6 Lubricate seat 5 with clean hydraulic oil Install seat 5 new poppet 1 lockout spring 9 and seat retaining plug 7 Torque plug from 30 to 45 ft Ib 41 to 48 N m 7 Install plug 19 with new O ring 24 8 Lubricate detent plunger 11 with clean hydraulic oil Install plunger detent spring 17 disc 18 and detent plug 13 with new O ring 25 9 If retaining ring 16 was removed to replace spool spring 14 install washer 20 spring 14 spacer 3 and secure with retaining ring 16 10 Slide bushing 8 over spool Slide new O ring 21 over spool and position next to bushing Dip spool in clean hydraulic oil and install spool assembly into proper location of control valve body 11 Install spool cap 10 and tighten from 20 to 25 ft Ib 27 to 33 N m 12 Install new wiper seal 21 Hydraulic System Rev A 2 6 Oo Lift Lower Control Valve GM 4700 D Figure 86 1 Control valve assembly 3 spool 10 Spacer 19 Lock nut 2 O ring 11 Left lift lever 20
40. 75 L E 3 wi 2 R 1 m rn x S ibn 54 i 0008 4 i FO ime T i ni 5 15 5 ID 1 830110 5 XC T 0005 4 05 05 A n 1 2 NM 254 4 TES rd H mu 9 5 5 ES Ll XS 154 MES 7 Low 05 2 ES IH AH 22 x al C1 29 2 1081N02 3230 a ox z 1 8 1041402 8331 E gt BIRD a vX J 1 L 5 1 va 8 HE 5 4 2 8 53 dd Ja 2 Sd I 0 1 i 1081002 isa rl oS 4 83 MOV 1411 7 Q104INVW 1081403 1SISSV 112 81 ONY NMOG 33M0d 4 6 Groundsmaster 4500 D 4700 D Hydraulic System Rev A wia sAS se IV 00 Je sewspunoly Hydraulic System Rev
41. Removal 1 Park machine on level surface lower cutting units stop engine engage parking brake and remove key from the ignition switch 2 To prevent contamination of hydraulic system during removal thoroughly clean exterior of pump assembly 3 Remove traction rod from control arm on piston pump by removing lock nut spacer and cap screw 4 Disconnect two wires from neutral switch on traction pump 5 Read the General Precautions for Removing and Installing Hydraulic System Components at the begin ning of the Service and Repairs section of this chapter 6 Puta drain pan below the pump assembly Remove hydraulic hoses and fittings connected to piston and gear pumps Put plugs or caps on disconnected hydrau lic hoses to prevent contamination of the system Put plugs in open ports of pumps 7 Remove gear pump from machine see Gear Pump Removal 8 Support the piston pump to prevent it from falling while removing two 2 cap screws and washers retain ing pump assembly to engine adapter plate Carefully pull pump assembly from adapter plate and raise it out of the machine Groundsmaster 4500 D 4700 D Page 4 63 Installation 1 Carefully lower piston pump into the machine and position it to the engine adapter plate Support pump to prevent it from falling while installing two 2 cap screws and washers securing piston pump to engine adapter plate Torque screws from 85 to 95 ft lb 115 to 128 2
42. 15 in Ib 0 5in 16 7 in fasteners Conversion Factors in lb X 11 2985 X 0 08851 in Ib ft lb X 1 3558 N m N m X 0 7376 ft lb Product Records and Maintenance Page2 6 Groundsmaster 4500 D 4700 D TORO Table of Contents GENERAL INFORMATION 5 ADJUSTMENTS Engine Run Solenoid SERVICE AND REPAIRS Air Filter System Exhaust System Fuel System Check Fuel Lines Connections Drain and Clean Fuel Tank Fuel Tank Removal Fuel Tank Installation Chapter 3 Kubota Diesel Engine Radiator ne 6 teta db E 10 mh NE nip gen 12 Engine 13 Engine Installation 14 Pump Adapter Plate 16 KUBOTA WORKSHOP MANUAL DIESEL ENGINE V2003 T SERIES Groundsmaster 4500 D 4700 D Page 3 1 Kubota Diesel Engine Rev A 8 General Information This Chapter gives information about specifications and repair of the diesel engine used in the Groundsmaster 4500 D 4700 D General maintenance procedures are described in your Traction Unit Operator s Manu
43. Groundsmaster 4500 D 4700 D Page 5 27 Rev D 4 Store battery in a cool atmosphere to avoid quick de terioration of the battery charge 5 Tohelp preventthe battery from freezing make sure it is fully charged see Battery Service 3 Battery cables must be tight on terminals to provide good electrical contact Connecting cables to the wrong post could re sult in personal injury and or damage to the electrical system 4 corrosion occurs at terminals disconnect cables Always disconnect negative cable first Clean clamps and terminals separately Reconnect cables with positive cable first Coat battery posts and cable connectors with skin over grease Toro Part No 505 165 or petroleum jelly to prevent corrosion 5 Check electrolyte level every 25 operating hours and every 30 days if machine is in storage 6 Maintain cell level with distilled or demineralized wa ter Do not fill cells above the fill line Electrical System Rev A SE s2 o gt iu 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 A CAUTION When working with batteries use extreme cau tion to avoid splashing or spilling electrolyte Electrolyte can destroy clothing and burn skin or eyes Always wear safety goggles and a face shield when working with batter
44. Preface The purpose of this publication is to provide the service technician with information for troubleshooting testing and repair of major systems and components on the Groundsmaster 4500 D and 4700 D REFER TO THE TRACTION UNIT AND CUTTING UNIT OPERATOR S MANUALS FOR OPERATING MAINTENANCE AND ADJUSTMENT INSTRUC TIONS Space is provided in Chapter 2 of this book to insert the Operator s Manuals and Parts Catalogs for your machine Replacement Operator s Manuals and Parts Catalogs are available on the internet at www Toro com or by sending complete Model and Seri al Number to The Toro Company Attn Technical Publications 8111 Lyndale Avenue South Bloomington MN 55420 1196 The Toro Company reserves the right to change product specifications or this publication without notice PART NO 02104SL Rev D Service Manual Groundsmaster 4500 D 4700 D This safety symbol means DANGER WARNING or CAUTION PERSONAL SAFETY INSTRUC TION When you see this symbol carefully read the instructions that follow Failure to obey the instructions may result in personal injury NOTE A NOTE will give general information about the correct operation maintenance service testing or re pair of the machine IMPORTANT The IMPORTANT notice will give im portant instructions which must be followed to pre vent damage to systems or components on the machine The Toro Company 2002 2003 2005 2007 This
45. RUN BHI A E Bk START 8 1 5 5 BU Y YYYY 3 DECKS 2 3 5 m 24402526 gt 89 IGNITION SW 2 SENTER PTOKE BK NODULE POSITION POSITION 4 R OFF RUN START DECK RAISED DECK RAISED FRONT PTO PET o DECKS 1 4 GN NEUTRAL SWITCH IN NEUTRAL _ 2 10 CD PP nr ee F 3 Groundsmaster 4500 D 4700 D Crank Circuit Power Current Control Current Indicator Gauge Current ALTERNATOR RUN SOLENOID 4 8 HOLD ue R BK bd 5 3 PULL GY 1 1 15 W BK R D exe dm om oq m wmm uw mcum mm mI TIRE RR meum c A EUR UR EUROS S xu USE Vd SENDER D Y SN ENGINE OIL PRESSURE D 1 1 GN oo BU W
46. s Manual 5 Iflift arm for either deck 4 or 5 was removed slide hydraulic hoses through the hose retaining loop on the lift arm and install hoses to the deck motor Fig 5 Make sure that deck is lowered to the ground before tightening hoses 6 Lubricate lift arm and lift cylinder grease fittings after assembly is complete see Traction Unit Operator s Manual 7 After assembly raise and lower the cutting deck to verify that hydraulic hoses and fittings do not contact anything gt EN VY 1 2 Pressure out hose Groundsmaster 4500 D 4700 D Page 7 5 Figure 5 3 Case drain hose 4 Hose retaining loop Chassis Lift Arms for Cutting Decks 2 and 3 Thread locking Compound Figure 6 1 Flange nut 12 Lift arm 2 deck shown 22 Flange head screw 2 Bulkhead bracket 13 Flange bushing 23 Lift cylinder pin 3 Hydraulic t fitting 14 Flange nut 24 Cap screw 4 Flange head screw 15 Retaining ring 25 Hydraulic fitting 5 Locknut 16 Lift cylinder 26 Cap screw 6 Slotted roll pin 17 Grease fitting 27 Lift arm rotation stop 7 Pivot pin 18 Lock nut 28 Set screw 8 Bumper 19 Hydraulic fitting 29 O ring 9 Thrust washer 20 Lift cylinder pin 30 O ring 10 Rebound washer 21 Thrust washer 31 Grease fitting 11 Deck pivot shaft Chassis Page 7 6 Groundsmaster 4500 D 4700 D Removal 1 Park machine on level surface lower cutting units s
47. table to the right 1 Diode 3 Female terminal 2 Male terminal Multimeter Multimeter Red Lead Black Lead Continuity on Terminal on Terminal wae fme Electrical System Rev A Page 5 24 Groundsmaster 4500 D 4700 D Diode Circuit Board The diode circuit board contains four diodes Fig 40 and is located under the console housing Diode D1 A provide logic for the interlock switches Diodes D1 C D1 B GM 4700 D right deck and D1 D GM 4700 D left deck are used for circuit protection from voltage spikes when PTO relays are de energized Diode Circuit Board Test n mnm Hl i n 1 The diodes can be individually tested using a digital In multimeter ohms setting and the table to the right If u i any of the diodes are damaged the diode circuit board CIRCUIT BOARD must be replaced DIODE DIAGRAM Figure 40 Red Lead Black Lead on on Continuity Terminal Terminal 6 9 gy Groundsmaster 4500 D 4700 D Page 5 25 Electrical System Rev A Standard Control Module Groundsmaster 4500 D and 4700 D machines with Serial Numbers above 230000000 are equipped with a Standard Control Module to monitor and control electri cal components required for safe operation This Mod ule is located under the console cover Inp
48. 2 Bearing NOTE Securing roller assembly with a gap larger than 060 inch 1 5 mm creates a side load on bearings and can lead to premature bearing failure 3 Verify that there is no more than a 060 inch 1 5 mm gap between roller assembly and the roller mount brack ets of the deck frame If this gap is larger than 060 inch 1 5 mm shim excess clearance with 5 8 washers 4 Insert mounting bolt and tighten to 80 ft lb 108 Groundsmaster 4500 D 4700 D This page is intentionally blank 2 5 Groundsmaster 4500 D 4700 D Page 8 19 Cutting Units Rev B Rev D Decks 1 4 and 5 Figure 19 1 Carrier frame 6 Cap screw 11 Flat washer 2 Lynch pin 7 Rebound washer 12 Compression spring 3 Thrust washer 8 Pivot shaft 13 Pivot shaft 4 Pivot shaft 9 Lift arm 2 shown 14 Lift arm 6 shown 5 Lift arm 4 shown 10 Lock nut Cutting Units Rev B Page 8 20 Groundsmaster 4500 D 4700 D Rev D Installation Each cutting deck is suspended from a carrier frame Decks should be attached to the carrier frame using the lower hole in deck bracket Fig 20 The cutting deck carrier frame is attached to the lift arm and allows the cutting deck to pivot on the lift arm pivot shaft Carrier frames are secured to lift arms as follows 1 Carrier frames for the front three cutting decks 1 4 and 5 have a thrust wash
49. BLUE WHITE PINK ORANGE P20 FUEL PUMP gt gt 2 Va PINK 1B GREEN 2A PINK alt 2 WHITE oil press WARNING LIGHTS PI PINK 1B BLUE WHITE SP2 2A PINK over temp WARNING LIGHTS glow BROWN Al RED SP5 BLACK A3 A4 BLUE AS A RED BROWN el STARTER B ORANGE 82 GRAY 83 ORANGE 84 GREEN 85 BLUE WHITE 66 BLACK RED BLACK 87 GREEN 88 YELLOW 89 810 GREEN e VIOLET e YELLOW P23 INTERCONNECT TO CONSOLE gt gt wn IGNITION SWITCH C5 18 4 SHIELDED BROWN GREEN BLACK BLUE DI ORANGE 02 YELLOW 03 WHITE 05 SP BLACK BLACK NY BLACK CABLE SHIELD SP6 SPT BLACK BLUE GREEN BROWN BROWN Pid CENTER DECK PTO 1 4 B A 8 A B A B 8 P9 P27 10 P30 CENTER DECK SW 1 CENTER DECK SW 2 DIODE 3
50. Flange nut 2 Muffler bracket lift tab 7 Cap screw 12 Flange head screw 3 Exhaust tailpipe 8 Flat washer 13 Engine mount 4 Flange head screw 9 Spacer 14 Muffler clamp 5 Exhaust gasket 10 Rubber hanger Kubota Diesel Engine Rev A Page 3 6 Groundsmaster 4500 D 4700 D Removal The muffler and exhaust pipe may be hot To avoid possible burns allow the engine and ex haust system to cool before working on the muf fler 1 Park machine on level surface lower cutting units stop engine engage parking brake and remove key from the ignition switch 2 Remove muffler and or muffler bracket from the en gine as necessary using Figure 5 as a guide 8 Installation Figure 6 NOTE Make sure muffler flange and exhaust manifold sealing surfaces are free of debris or damage that may prevent a tight seal 1 Install new gasket if original gasket is damaged or torn IMPORTANT Failure to follow the suggested muf fler fastener sequence may result in premature muf fler failure 2 Install muffler and or muffler bracket to the engine using Figure 5 as a guide Hand tighten and then torque the following fasteners from 16 to 22 ft lb 21 to 29 N m in the sequence listed Fig 6 A Locknuts used on rubber hanger cap screws B Flange nuts that secure muffler to muffler brack et C Flange head screws that secure muffler flange to engine D Flange nuts that secu
51. Install gear pump to piston pump Gear Pump Installation 3 Position traction rod to control arm on piston pump by installing cap screw spacer and lock nut 4 Connect two wires to neutral switch on traction pump 5 Remove plugs and caps from disconnected hydrau lic hoses and open ports of the pump assembly Install fittings and hoses to correct location on gear and piston pumps 6 Install new filter and fill hydraulic reservoir with cor rect oil 7 Disconnect engine run solenoid electrical connector to prevent engine from starting Prime pumps by turning ignition key switch to crank engine for 10 seconds Re peat cranking procedure again 8 Connect engine run solenoid electrical connector start the engine and check for proper operation 9 Properly fill hydraulic system See Charge Hydraulic System 10 Stop engine and check for hydraulic oil leaks Check hydraulic reservoir oil level Hydraulic System Rev A 2 6 Piston Traction Pump Service 100 to 110 ft Ib 136 to 149 N m 1 150 to 160 in Ib 17 to 18 N m 40 to 48 in Ib 4 5 to 5 4 N m 1 Jamnut 16 2 Retaining ring 17 3 Retaining ring 18 4 Seal washer 19 5 Socket head screw 20 6 Rotating kit assembly 21 7 Servo piston assembly 22 8 Piston follower 23 9 Cover plate 24 10 Cover plate 25 11 Camplate assembly 26 12 Thrust race 27 13 Thrust bearing 28 14 Bypass valv
52. P vol 5 2 23 TER BK a gt 1 1 D FRONT PTO cr m did 225 SEAT SW KF oy BN NE o AC P23 C5 PCS VIO W 582 E BK FRONT DECK NEUTRAL SWITCH 23 85 246 NEUTRAL sw FRONT DECK FRoNTaEG D IGNITION SW GN GN 4100 MODULE 4 P23 C6 FR acy IGN SW 5 R RUN STAR vio FRONT Boek STANDARD CONTROL MODULE 3 ai OR Y DECK UP B 01 8 6 BN gt BN CIN CENTER POSITION ____ _ l Y 1 P23 C6 F 6 10 A BU 00 T i P23 C3 4100 1 4100 C 23 10 RIGHT 7 F2 P23 DI P23 D5 245 is ut BT lt 7 BK BK F 3 I0 A a Groundsmaster 4700 D 9 LI m Electrical Schematic Serial Number From 230000001 to 260000600 All relays and solenoids are shown as de energized ground wires are black 9 7 Rev
53. Remove rear idler gear 25 slip fit gear 20 and key 22 10 Remove drive gear assembly 11 from rear adapter plate 24 11 Place rear idler gear assembly 25 back into gear pocket and tap protruding end with soft face hammer to remove rear body 26 from the backplate assembly 27 or the rear adapter plate 24 IMPORTANT Note position of the open and closed side of the wear plates before removing 12 Remove the wear plates 12 and o rings 4 from front plate 15 front adapter plate 23 and rear adapt er plate 24 13 Remove backup gaskets 14 and pressure seals 13 from wear plates 15 by carefully prying out with a sharp tool IMPORTANT Do not damage the seal bore in the front plate during seal removal 14 Remove shaft seal 1 and washer 2 from front plate 15 15 Remove plug 7 and o ring 9 from rear adapter plate 24 16 Remove proportional valve 6 from backplate as sembly 27 Groundsmaster 4500 D 4700 D Page 4 59 Inspection 1 Clean and dry all pump components Remove nicks and burrs from all parts with emery cloth 2 Check spline drive shaft for twisted or broken teeth Also check for damaged keyway on drive shaft that drives the slip fit gears of the pump 3 Inspect both the drive gear and idler gear shafts at bushing points and seal area for rough surfaces and ex cessive wear 4 Replace gear assembly if shaft measures less than 873 22 17mm in bushing
54. The valve should go in easily without binding C Torque cartridge valve using a deep socket to val ue identified in manifold illustration D If cartridge is solenoid operated carefully install solenoid coil to the cartridge valve Apply Loctite 242 or equivalenttothe threads ofthe valve Torque nut to value identified in manifold illustration 8 If problems still exist remove valve and clean again or replace valve Hydraulic System Rev A 2 FE 6 0 Hydraulic Control Manifold Service Filtration and Charge Control 35 to 40 ft lb 47 to 54 N m 60 to 70 ft Ib 6 81 to 95 N m PLUG TORQUE SAE 4 6 to 10 ft Ib 8 to 13 N m SAE 5 10 to 15 ft Ib 13 to 20 N m SAE 6 15 to 20 ft Ib 20 to 27 N m SAE 10 35 to 40 ft Ib 48 to 54 N m Figure 66 1 Filter manifold assembly 7 Seal 12 Plug SAE 5 2 Check valve Reservoir return 8 Plug SAE 4 13 O ring 3 Seal 9 O ring 14 Plug SAE 10 4 Check valve Filter bypass 10 Plug SAE 6 15 O ring 5 Seal kit 11 O ring 16 Oil filter element 6 Check valve Charge pressure NOTE The ports on the manifold are marked for easy identification of components Example P2 is the gear pump connection port and 1 is the connection from the oil cooler See Hydraulic Schematics to identify the function of the hydraulic lines and cartridge valves at each port For cartridge valve service procedures see Hydraulic Con
55. cal connector are located directly under the seat Test ing of the switch can be done without seat removal by disconnecting the seat wire from the machine wiring harness 1 Make sure the engine is off 2 Disconnect electrical connector for the seat switch 3 Check the continuity of the switch by connecting a multimeter ohms setting across the connector termi nals Figure 12 1 Electrical connector 2 Seat switch 4 With no pressure on the seat there should be no continuity between the seat switch terminals 5 Press directly onto the seat switch through the seat cushion There should be continuity as the seat cushion approaches the bottom of its travel 6 Replace switch as needed Reconnect switch con nector Parking Brake Switch 9 The switch used for the parking brake is normally open proximity switch The parking brake switch is located un der the steering tower cover Fig 13 and closes when the parking brake is released The sensing plate for the switch is an integral component of the parking brake rod Switch Testing 1 Make sure the engine is off Locate switch for testing 2 Disconnect electrical connector from the switch 3 Check the continuity of the switch by connecting a multimeter ohms setting across the connector termi nals Figure 13 4 With the parking brake released there should be 1 Parking brake switch 3 Brake rod brake ON is 2 Sensing pla
56. from the ignition switch gt EN VY 2 Remove cutting deck from lift arm see Unit Operator s Manual 3 Remove pin that secures lift links 10 to lift arm 4 Loosen and remove lock nut from pivot pin 5 Support lift arm and pull lift arm pivot pin from lift arm and support arm Locate and remove thrust washer from rear of lift arm during pivot pin removal 6 Remove lift arm from machine CUTTING DECK LOCATIONS 7 Clean lift arm and pivot pin Inspect lift arm flange bushings and pivot pin for damage or wear Figure 9 Installation 1 Position lift arm to support arm Fig 8 Fit thrust washer between rear of lift arm and support arm Slide pivot pin into support arm and lift arm Align roll pin piv ot pin with slot in support arm flange 2 Install andtighten lock nutto secure lift arm pivot pin 3 Install lift cylinder to lift arm with cylinder pin Secure cylinder pin to lift arm with flange head screw and flange nut NOTE Install compression spring and thrust washer on carrier pivot pin before installing cutting deck on pivot pin 4 Position and install cutting deck to lift arm see Cut ting Unit Operator s Manual 5 Lubricate lift arm and lift cylinder grease fittings after assembly is complete see Traction Unit Operator s Manual 6 After assembly raise and lower the cutting deck to verify that hydraulic hoses and fittings do not contact anything Groundsmaster
57. 0 1250 3 175 5 8 0 6250 15 875 9 64 0 140625 3 572 41 64 0 640625 16 272 5 32 0 15625 3 969 21 32 0 65625 16 669 11 64 0 171875 4 366 43 64 0 671875 17 066 3 16 0 1875 4 762 11 16 0 6875 17 462 13 64 0 203125 5 159 45 64 0 703125 17 859 7 32 0 21875 5 556 2332 0 71875 18 256 15 64 0 234375 5 953 47 64 0 734375 18 653 1 4 0 2500 6 350 3 4 0 7500 19 050 17 64 0 265625 6 747 49 64 0 765625 19 447 9 32 0 28125 7 144 25 32 0 78125 19 844 19 64 0 296875 7 541 51 64 0 796875 20 241 5 6 0 3125 7 938 13 16 0 8125 20 638 21 64 0 328125 8 334 53 64 0 828125 21 034 11 32 0 34375 8 731 27 32 0 84375 21 431 23 64 0 359375 9 128 55 64 0 859375 21 828 3 8 0 3750 9 525 7 8 0 8750 22 225 25 64 0 390625 9 922 57 64 0 890625 22 622 13 32 040625 10 319 29 32 0 90625 23 019 27 64 0 421875 10 716 59 64 0 921875 23 416 716 0 4375 11 112 15 16 0 9375 23 812 29 64 0 453125 11 509 61 64 0 953125 24 209 15 32 0 46875 11 906 31 32 0 96875 24 606 31 64 0 484375 12 303 63 64 0 984375 25 003 1 2 05000 12 700 1 1 000 25 400 1 mm 0 03937 in 0 001 in 0 0254 mm U S to Metric Conversions To Convert Into Multiply By Linear Miles Kilometers 1 609 Measurement Yards Meters 0 91
58. 1 Press bearings onto differential shaft Place correct combination of bearing shims in axle support and drive differential shaft and bearing assembly into axle sup port 2 Install bevel gear and retaining ring 3 Coat new O ring with grease Align differential shaft splines with differential gear assembly and slide differ ential shaft assembly onto axle support 4 Install bevel gear case axle case assembly see NOTE Axle bearing shims are available in 0 008 in 0 2 mm 0 012 in 0 3 mm and 0 020 in 0 5 mm thickness 11 Tighten axle cover screws from 17 to 20 ft lb 23 to 27 N m 12 Coat a new O ring with grease and install the bevel gear case axle case assembly on the axle support Tighten mounting screws and nuts from 35 to 41 ft lb 47 to 56 N m Fig 11 35 to 41 ft Ib 47 to 56 N m 35 to 41 ft lb 47 to 56 N m Figure 21 1 screw 5 Bevel gear axle case 2 Locknut assembly 3 Lock washer 6 O ring 4 Axle support 7 Stud Bevel Gear Case Axle Case Assembly in this section of T Figure 22 hi 1 Retaining ring 4 Bearing this manua 2 5 Bearing shims 3 Differential shaft 6 O ring Axles Planetaries and Brakes Rev B Page 6 18 Groundsmaster 4500 D 4700 D Axle Shafts The following procedures assume the rear axle assem bly has been removed from the machine Removal 1 Remove the axle cover mounting screws Remove the axle cover from the axle case a
59. 2 WD COIL INTERCONNECT TO GM 4700 CENTER DECK PTO 23 9 Groundsmaster 4500 D 4700 D Serial Number From 230000001 to 260000600 Main Wire Harness Page 9 16 Rev D ES P19 IGNITION SW P15 SEAT SW n GLOW RELAY P3 GLOW RELAY P18 D 0DE 3 9 STARTER 8N GLOW RELAY Ta P10 2WD 4 HI P30 INTERCONNECT TO 4700 5 INTERCONNECT TO CONSOLE 2 P13 CENTER DECK PTO 2 3 5 CENTER DECK 1 4 OVER TEMP Ji IGNITION SW P1 WARNING LIGHTS OIL PRESURE ALT 419 SP7 SP4 L 7 sew 1 L1 HOH m FH rr P SP5 SP1 WARNING LIGHTS om SP3 P6 17 NEUTRAL SW PS BRAKE LIGHT INTERCONNECT TO ENGINE INTERCONNECT ENGINE uu 1 PB CENTER DECK SW 1 9 CENTER DECK SW 2 Groundsmaster 4500 D 4700 D P20 FUEL PUMP Serial Number From 230000001 to 260000600 Main Wire Harness Page 9 17 Rev oil press WARNING LIGHTS PI alt overtemp WARNING LIGHTS P2 glow STARTER B IGNITION SWITCH Page 9 18 Rev D P20
60. D CENTER POSITION ides OR OR lt 522 BK us 235 Bk wo A 2 4 STOP NONE Nor ix P23 A1 1 BN NA 6 2 SEAT SWITCH 25 3 d Y START 8145 5 Z F SEAT SW GROUND 1 i Bs Y Y Yl P23 cs T 97e GY lt BN 22772 FRONT DECI BK FRONT DECK K NEUTRAL SHIGE 2 NEUTRAL SW POSITION POSITION CENTER PTO K2 RAMP UP 4700 0 IGNITION SW T GN GN lt 4700 A 100 1270 MODULE 2 06 4 lt lt 2 H sw STANDARD CONTROL MODULE R OFF RUN START PK VIO s FRONT PTO 1 5 15A P23 D2 P23 D3 F4 10A i GN 4 OR y DECK UP gt BN i IN CENTER POSITION L Y 1 P23 C3 4720 oAL 23 8 F6 10A BN vm oL l ay Y fYYYY 1 1 T 4700 C 923 810 1 1 RIGHT PTO F2 10A P23 D1 x Js P23 D5 oo OR PEOR s 1 55 W ri a 4 POSITION RIGHT PTO K3 o BK SR F3 10A Groundsmaster 4700 D 9 5 1 Electrical Schematic 9 8 Rev Serial Number Above 260000600 All relays and solenoids are shown as de energized All ground wires are black ALTERNATOR RUN SOLENOID Y Y HOLD i L 6 R BK R 5
61. D Removal Installation 1 Park machine on level surface lower cutting units 1 Install steering valve using Figure 88 as a guide stop engine engage parking brake and remove key from the ignition switch 2 sure hydraulic tank is full Add correct oil if nec essary before returning machine to service 2 Read the General Precautions for Removing and Installing Hydraulic System Components at the begin ning of the Service and Repairs section of this chapter NOTE Before disconnecting the hydraulic lines clean the port area of the steering valve assembly 3 Tag hydraulic lines for proper reassembly 4 Remove steering valve from machine using Figure 88 as a guide 2 5 29 5 gt Groundsmaster 4500 D 4700 D Page 4 103 Hydraulic System Rev A Steering Valve Service 140 to 160 in Ib 16 to 18 N m Figure 89 1 Steering valve housing 9 Cap screw 17 Geroter drive 2 Dust seal 10 End cap 18 Wear plate 3 O ring 11 O ring 19 Bearing race 4 Spool 12 Seal ring 20 Thrust bearing 5 Spring retaining ring 13 O ring 21 Plug 6 Pin 14 Geroter 22 O ring 7 Sleeve 15 O ring 23 Relief valve 8 Centering springs spacers 16 Spacer 24 Quad seal Disassembly NOTE Cleanliness is extremely important when repairing hydraulic components Work in a clean area Before disassembly drain the oil then plug the ports and thoroughly clean the exterior During repairs always protect mac
62. ENGINE OVER TEMP w 5 Buw i R BK Fude oe S 58 2 a 5 9 GLOW PLUGS 4 re Teo 19 Qi lt 9 lt C NOTE The wire harness and relays of the 4500 D and 4700 D d dz E are the same The drawing on this page uses the GM 4500 D Schematic D i E L o Serial Number Below 220999999 to show the operational circuits 2 R BK 4 49 1101 Y D FUSIBLE LINK 5 D 1 D ENG INE BK i R BK D D CONTROLLER GLOW PLUG D FRAME GROUND VIO START 4 THERMO BATTERY LAMP GLOW 1 OR BN GND ak 7 D d d BK spp eee eere EE D 2 WD 4 WD BK BK IN 2WD tassi 1 2 WD START RELAY used FEET OR OR OFF GN K g bee 03 BU 1 K BU 6 eee v w sia BU W T SEAT SWITCH SEAT OCCUPIED OPTIONAL FUSE BLOCK R gt i e c oog F N e i mere BK K w IN CENTER POSITION ar B 14 PK 777 o MEI BU T wg 5 2 1 SEAT FRONT PTO QUEE Sid 2 T MES v VIO PRONT POSITION CENTER PTO KE RAMP UP E IGNITION SW
63. Fig 49 4 Start the engine and put throttle at full engine speed 2800 50 RPM 5 Sitonseat apply brakes fully and slowly depress the traction pedal in the reverse direction While pushing traction pedal look at pressure reading on gauge GAUGE READING TO BE 420 to 470 PSI 6 Pressure reducing valve PR1 is located on the low er rear side of the 2WD 4WD control manifold Fig 50 Adjustment of this valve can be performed as follows NOTE Do not remove the valve from the hydraulic manifold for adjustment A To increase pressure setting remove cap on re ducing valve and turn the adjustment socket on the valve in aclockwise direction A 1 8 turn on the sock et will make a measurable change in pressure set ting B To decrease pressure setting remove cap on re ducing valve and turn the adjustment socket on the valve in a counterclockwise direction A 1 8 turn on the socket will make a measurable change in pres sure setting C Recheck pressure setting and readjust as need ed 1 2WD 4WD control manifold GM 4500 D shown 2 Relief valve test port 5 gt Figure 50 1 Manifold lower side 2 Reducing valve PR1 Groundsmaster 4500 D 4700 D Page 4 49 Hydraulic System Rev A TEST 13 Traction Assist RV2 Pressure Using Pressure Gauges ONIH33IS Jc 20 110 1081N02 J9YVHI NOIIV3LIIJ 5 D E
64. Fig 91 1 Park machine on level surface lower cutting units stop engine engage parking brake and remove key from the ignition switch 2 Read the General Precautions for Removing and Installing Hydraulic System Components at the begin ning of the Service and Repairs section of this chapter NOTE To ease reassembly tag the hydraulic hoses to show their correct position on the lift cylinder Also clean hydraulic fittings and hose ends prior to disconnecting the hoses 3 Disconnect hydraulic hoses from lift cylinder 4 Remove flange nut and flange head screw that se cure the cylinder pin 4 to the lift arm Remove pin from lift arm and cylinder shaft clevis which will free lift cylin der from lift arm 5 Remove flange nut and flange head screw that se cure the cylinder pin 13 to the frame Pull pin from frame and cylinder barrel clevis 6 Remove lift cylinder from machine Installation Fig 91 1 Position cylinder barrel clevis to frame and insert inder pin 13 into frame and clevis Secure pin with flange nut and flange head screw 2 Insert cylinder pin 4 through lift arm and cylinder shaft clevis Secure pin to lift arm with flange nut and flange head screw 3 Attach hydraulic hoses to lift cylinder 4 Fill reservoir with hydraulic fluid as required see Traction Unit Operator s Manual 5 After assembly is completed operate lift cylinder to verify that hydraulic hoses and fittings
65. Flange head screw 3 Hydraulic adapter 12 Control knob 3 used 21 Switch plate 4 O ring 13 Center lift lever 22 Nut insert 5 Hydraulic fitting 14 Right lift lever 23 Flange nut 6 O ring 15 Curved washer if equipped 24 Extension spring 3 used 7 Orifice port D 16 Cotter pin 25 Cap screw 8 Cap screw 17 Thread forming screw 26 Valve support 9 90 hydraulic fitting 18 Proximity switch 3 used 27 Link 3 used Hydraulic System Rev A Page 4 98 Groundsmaster 4500 D 4700 D Removal Installation 1 Park machine on level surface lower cutting units 1 Install control valve using Figure 86 as a guide stop engine engage parking brake and remove key from the ignition switch 2 Make sure hydraulic tank is full Add correct oil if nec essary before returning machine to service 2 Read the General Precautions for Removing and Installing Hydraulic System Components at the begin ning of the Service and Repairs section of this chapter NOTE Before disconnecting the hydraulic lines clean the port area of the lift lower control valve assembly 3 Tag hydraulic lines for proper reassembly 4 Remove lift lower control valve using Figure 86 as a guide 2 5 i gt Groundsmaster 4500 D 4700 D Page 4 99 Hydraulic System Rev A Lift Lower Control Valve Service 4700 D 30 to 35 ft Ib 3 6 41 to 48 N m 10 to 12 ft Ib 13 to 16 N m 4 to 5 ft lb 5 to 7 N m
66. Groundsmaster 4500 D 4700 D Page 4 89 Hydraulic System Rev A Cutting Deck Motor Service 30 to 35 ft lb 41 to 47 N m Figure 78 1 Outer shaft seal 6 Front bearing block 11 Idler gear 2 Inner shaft seal 7 O ring 12 Rear bearing block 3 Retaining ring 8 Dowel pin 13 Rear cover 4 Front flange 9 Housing 14 Cap screw 5 Pressure seal 10 Drive gear 15 Relief valve assembly Disassembly Fig 78 SCRIBE MARK 1 Plug motor ports and clean the outside of the motor thoroughly After cleaning remove plugs and drain any oil out of the motor 2 Use a marker or scribe to make a diagonal mark across the front flange housing and rear cover for reas sembly purposes Fig 79 IMPORTANT Avoid using excessive clamping pressure on the motor housing to prevent distorting the housing 3 Clamp front flange of motor in a vise with the shaft Figure 79 end down 4 Loosen cap screws from the rear cover 5 Remove motor from the vise Turn motor so that the shaft end is facing down Remove cap screws 6 Remove rear cover from the housing Hydraulic System Rev A Page 4 90 Groundsmaster 4500 D 4700 D 7 Carefully remove housing by lifting housing straight up Make sure the rear bearing block remains on the drive and idler gear shafts Remove and discard o rings from the housing IMPORTANT Note position of the open and closed side of the bearing blocks before removing Also identify bearing blocks front a
67. NOTE PUMP SECTION P1 TEST SHOWN TO LIFT LOWER CIRCUIT TO STEERING CIRCUIT FORW ARD PROPORTIONAL FLOW DIVIDER y930 N lav 180 PSI FROM DECK CONTROL 7 7 7 7 02 7 a FILTRATION AND CHARGE CONTROL MANIFOLD MANIFOLDS FROM LIFT LOWER CIRCUIT Working Pressure Low Pressure Return or Suction gt Hydraulic System Rev Page 4 32 Groundsmaster 4500 D 4700 D Procedure for Cutting Deck Gear Pump Flow NOTE oftime the gears and wear plates in the pump can wear A worn pump will by pass oil and make the pumpless efficient Eventually enough oilloss will occur to cause the cutting unit motors to stall under heavy cutting conditions Continued operation with a worn inefficient pump can generate excessive heat and cause damage to the seals and other components in the hydraulic system 1 Make sure hydraulic oil is at normal operating tem perature by operating the machine for approximately 10 minutes Make sure the hydraulic tank is full 2 Park machine on a level surface with the cutting units lowered and off Make sure engine is off and the parking brake is engaged Prevent personal injury and or damage to equip ment Read al
68. P31 STANDARD CONTROL MODULE 29 i FUSE BLOCK 1 FUSE BLOCK 2 STANDARD CONTROL MODULE o P12 P8 RELAY K2 CENTER PTO RELAY LEFT EL LE 0 05 RIGHT DECK P21 CENTER DECKS 33 28 OPTION 2 RAMP UP MODULE J2 Am OPTION 1 HOUR METER Jh FLOW DIVIDER gS 23 INTRCONNECT TO MAIN SP3 5 amp 5 6 Lis 4 y EN ta 1 cs T LLL 5 9 5 2 SP5 2WD 4WD SWITCH 22 POWER POINT 5 PTO SW 1 19 LEFT DECK 4 6 DIODE PACK P3 GLOW CONTROLER n TEMP GAUGE 2 2 TEMP GAUGE 1 3 Groundsmaster 4500 D 4700 D Serial Number From 230000001 to 260000600 Console Wire Harness Page 9 23 Rev D RELAY KI LEFT PTO RELAY K2 CENTER PTO RELAY K3 RIGHT PTO FUSE BLOCK 2 POWER POINT FUSE BLOC
69. PTO MOW CIRCUIT 05 05 OL gt CHARGE CIRCUIT 1041403 AMZ MANIFOLD TO TRACTION CONTROL TO LIFT LOWER CIRCUIT TO STEERING CIRCUIT Page 4 46 Groundsmaster 4500 D 4700 D Hydraulic System Rev A Procedure for Rear Traction Circuit RV5 Relief Pressure Test 1 Make sure hydraulic oil is at normal operating tem perature by operating the machine for approximately 10 minutes Make sure the hydraulic tank is full 2 Park machine alevel surface with the cutting units lowered and off Make sure engine is off and the parking brake is engaged Prevent personal injury and or damage to equip ment Read all WARNINGS CAUTIONS and Pre cautions for Hydraulic Testing at the beginning of this section 3 Connect a 1000 PSI gauge to test port on 2WD 4WD control manifold under operator s seat Fig 46 4 Start the engine and put throttle at full engine speed 2800 50 RPM 5 Operate the machine in 4WD with the cutting units lowered Drive down a slope in a forward direction de crease pressure on the traction pedal and monitor the pressure gauge Pressure should increase until
70. RV1 port 4 6 Lift relief valve RV7 port 7 2 Traction assist valve RV2 port 2 5 Traction pressure sensing valve 7 Expanding plug not serviced 3 Power down valve deck 6 PD3 port 5 8 Power down valve deck 7 NOTE The ports on the manifold are marked for easy identification of components Example C1 is the con nection port from the LH deck lift cylinder and CHG is the charge circuit connection See Hydraulic Schematics to identify the function of the hydraulic lines and cartridge valves at each port For cartridge valve service procedures see Hydraulic Control Manifold Service 2 Wheel 4 Wheel Drive Con trol in this section Refer to Figure 68 for cartridge valve installation torque Hydraulic System Rev A Page 4 76 Groundsmaster 4500 D 4700 D 2 FE 6 0 This page is intentionally blank Groundsmaster 4500 D 4700 D Page 4 77 Hydraulic System Rev A Hydraulic Control Manifold Deck Drive GM 4500 D Figure 69 1 Hydraulic manifold decks 2 3 8 5 7 90 hydraulic fitting 13 O ring 2 Hydraulic adapter 8 Quick fitting 14 O ring 3 90 hydraulic fitting 9 Dust cap 15 O ring 4 90 hydraulic fitting 10 O ring 16 Flange nut 5 Hydraulic manifold decks 1 8 4 11 O ring 17 Cap screw 6 Straight hydraulic fitting 12 O ring 18 Plug Removal 3 Disconnect hydraulic lines from manifold and put NOTE The ports on the manifold are marked for easy identi
71. TEMP u 5 OR 5 R BK S FUEL PUMP gt lt 5 9 fl gt w GLOW PLUGS 4 68 75 5 29 x 4 o lt 5 3 BN i a Ls m R BK d 48 o o Y R m FL i H FUSIBLE LINK g ENGINE TA ENGINE GROUND i R R BK CONTROLLER GLOW PLUG e START THERMO FRAME GROUND REEF VIO 1 4 LAMP 5 GLow OR BN GND BK K BK 2 WD 4 WD Bk BK IN 4WD 2 PARKING BRAKE GN ON START RELAY 5 PTO SWITCH m3ic7 i OR Se OFF GR et VIO 52 1 1 i e gy 1 Tu eee ce En W BU W 6500 MFD OR Gye SEAT SWITCH VIO SEAT VACANT OPTIONAL FUSE BLOC m 5 T DECK UP AED gt GN Ki CENTER POSITION 08 Lan 3 8 BU 11 5 2 RUNS 2 Bk START 8 1 5 B PK BU Y Bs YY B 3l DECKS 2 3 5 a FRONT DECK FRONT DECK nme BK lt gt IGNITION POSITION POSITION CENTER PTO K2 BK RAMP UP DECK RAISED DECK RAISED MODULE RR OFF RUN START z FRONT PTO F 15 F4 00A i 1 4 1 GN OR 4 GN GN NEUTRAL SWITCH NEUTRALS NOT IN NEUTRAL 1 vio 2 x GY p PK o BK BK F 3 W POWER POINT
72. Transport Circuit 11 Run Mow Circuit Diagram 12 WIRE HARNESS DRAWINGS Main Wire Harness Drawing Serial Number Below 220999999 14 Serial Number From 230000001 to 26000060016 Serial Number Above 260000600 18 Console Wire Harness Drawing Serial Number Below 220999999 20 Serial Number From 230000001 to 26000060022 Serial Number Above 260000600 24 Engine Wire Harness Drawing Serial Number Below 220999999 26 Serial Number Above 230000000 28 Cutting Deck 6 and 7 Wire Harness Drawing Groundsmaster 4700 D 30 ES 55 Groundsmaster 4500 D 4700 D Page 9 1 Electrical Diagrams Rev A Em Rev D This page is intentionally blank Electrical Diagrams Rev A Page 9 2 Groundsmaster 4500 D 4700 D RUN SOLENOID Y HOLD R BK pm L PULL oF W BK BK GY TEMP SENDER G ENGINE OIL PRESSURE GN BU W ENGINE OVER
73. Unit Manual for fluid level checking procedure and oil recommendations Sc 52 Figure 8 1 Hydraulic reservoir cap Groundsmaster 4500 D 4700 D 4 5 Hydraulic System Rev Hydraulic Schematics UMOUS SpIOUSJOS 209 14 z 19 z OI0JINYW 1081NO2 ONY 7 7 x 2 154 is Hm T 1 158 E 07 oo ib i J m
74. approximately 10 minutes Make sure the hydraulic tank is full 2 machine on a level surface with the cutting units lowered and off Make sure engine is off and the parking brake is engaged Prevent personal injury and or damage to equip ment Read all WARNINGS CAUTIONS and Pre cautions for Hydraulic Testing at the beginning of this section 3 Install test gauge with hydraulic hose attached to deck control manifold test port for the gear pump section to be tested Fig 28 or 29 Keep away from decks during test to prevent per sonal injury from the cutting blades 4 Start engine and move throttle to full speed 2800 50 RPM Engage the cutting units 5 Watch pressure gauge carefully while mowing with the machine 6 Cutting deck circuit pressure should be from 1000 to 3500 PSI and will vary depending on mowing condi tions 7 Disengage cutting units Shut off engine 8 Disconnect test gauge with hose from manifold test port GM 4500 D DECK CONTROL MANIFOLDS Figure 28 1 Test port decks 2 3 amp 5 2 Test port decks 1 amp 4 5 9 gt 4700 D DECK CONTROL MANIFOLDS Figure 29 1 Test port decks 2 3 5 7 2 Test port decks 1 4 6 CUTTING DECK LOCATIONS Figure 30 Groundsmaster 4500 D 4700 D Page 4 31 Hydraulic System Rev A TEST NO 4 Cutting Deck Gear Pump Flow Using Tester with Pressure Gauges Flow Meter
75. at each deck manifold by the proportional relief valve PRV1 and PRV2 The deck relief valve pressure is 3500 PSI Mow circuit pressure can be measured at port G1 of the deck control manifold CUTTING DECK LOCATIONS Figure 13 FROM GEAR PUMP P2 GM 4700 D C2 me TO OIL COOLER ALL DECKS LOWERED PTO SWITCH ON 61 5 2 PEE DECK CONTROL MANIFOLD 83 gt Figure 14 4 15 Groundsmaster 4500 D 4700 D Hydraulic System Rev A 2 FE Ga Oo Se Cutting Deck Blade Braking When the operator turns the cutting decks OFF propor tional relief valve PRV shift occurs in the deck control manifold Fig 15 This shifted valve allows oil return to the oil cooler and gear pump Hydraulic pressure is re duced to the cutting deck motors which begins to slow the cutting blades and also allows the manifold relief valve RV to shift The inertia of the rotating cutting blades increases pres sure of the oil return to the deck control manifold This pressure increase along with the orifice in the manifold and the shifted relief valve RV cause logic cartridge LC1 to shift Fig 16 The oil from the deck motors is finally directed through the orifice and to relief valve RV which bleeds the residual pressure in the circuit and al lows the bla
76. bevel gear Differential shaft gear Figure 20 4 Dial indicator 5 Axle bearing shims 1 Axle cover assembly 2 Lower bevel gear 3 Axle gear Axles Planetaries and Brakes Rev B o 5 a 2 x and Brakes 9 Remove bevel gear case axle case assembly from the axle support Coat a new O ring with grease and temporarily install axle cover assembly Position a dial indicator at the tooths center Prevent the axle from turning and measure the lower bevel gear to axle gear backlash Fig 20 LOWER BEVEL GEAR BACKLASH 0 004 to 0 016 in 0 10 to 0 40 mm 10 Adjust backlash by increasing or reducing axle bear ing shim thickness see Axle Shafts in this section of this manual Differential Shafts The following procedures assume the rear axle assem bly has been removed from the machine Removal IMPORTANT Donotinterchange right and left dif ferential shaft assemblies 1 Remove the mounting screws nuts and lock wash ers Remove the bevel gear case axle case assembly and O ring from the axle support Fig 21 2 Mark and pull the differential shaft assembly from the axle support 3 Remove the retaining ring and bevel gear Fig 22 4 Drive the differential shaft out of the bearings Re move the bearings and bearing shims 5 Inspect all gears shafts bearings and cases for damage and wear Replace components as necessary Installation
77. circuit test port for function to be checked Fig 26 Test ports are located on hydraulic lines toward the front of machine Forward traction port faces the front and reverse port faces rearward 4 Startthe engine and move throttle to full speed 2800 50 RPM Release parking brake 5 Sitonseat apply brakes fully and slowly depress the traction pedal in the appropriate direction While pu shing traction pedal look at pressure reading on gauge GAUGE READING TO BE Forward 5000 PSI Reverse 5000 PSI 6 If traction pressure is too low inspect traction pump relief valves in piston traction pump Fig 27 Clean or replace valves as necessary These cartridge type valves are factory set and are not adjustable If relief valves are in good condition piston traction pump wheel motors and or rear axle motor should be sus pected of wear and inefficiency NOTE Forward and reverse relief valves are identical Relief valves can be switched in piston traction pump to help in identifying a faulty relief valve Figure 26 1 Forward traction port faces forward 2 Reverse traction port faces rearward 9 gt gt Figure 27 Forward relief valve 3 Traction pump 2 Reverse relief valve Groundsmaster 4500 D 4700 D Page 4 29 Hydraulic System Rev A TEST 3 Cutting Deck Circuit Pressure Using Pressure Gauge DECK CONTROL MANIFOLD GM 4500 D
78. coating of oil 4 Put the tube and nut squarely into position on the face seal end of the fitting and tighten the nut until finger tight 5 Mark the nut and fitting body Hold the body with a wrench Use another wrench to tighten the nutto the cor rect Flats From Finger Tight F F F T The markings on the nut and fitting body will verify that the connection has been tightened Size 4 1 4 in nominal hose tubing 0 75 0 25 6 3 8 in 0 75 0 25 8 1 2 in 0 75 0 25 10 6 8 in 1 00 0 25 12 3 4 in 0 75 0 25 16 1 in 0 75 0 25 Groundsmaster 4500 D 4700 D Page 4 3 Before disconnecting or performing any work on hydraulic system relieve all pressure in system Stop engine lower or support all at tachment s 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 If fluid is injected into the skin it must be surgi cally removed within a few hours by a doctor familiar with this type of injury Gangrene may result from such an injury Figure 1 Final Position Mark Nut and Body Initial Extend Line Position Finger Tight After Proper Tightening Figure 2 Hydraulic System Rev A Hydraulic System SAE Straight Thread O Ring Port Non adju
79. done with the solenoid on the hydraulic valve NOTE Prior to taking small resistance readings witha digital multimeter short the meter test leads together The meter will display a small resistance value usually 0 5 ohms or less This resistance is due to the internal resistance of the meter and test leads Subtract this val ue from from the measured value of the component you are testing 1 Make sure engine is off Disconnect hydraulic valve solenoid electrical connector Fig 25 2 Apply 12VDC source directly to the solenoid Listen for solenoid to switch on 3 Remove 12VDC source from the solenoid Listen for solenoid to switch off 4 Measure resistance between the two connector ter minals The resistance for the solenoid coil should be about 7 2 ohms 5 Install new solenoid if necessary A Apply Loctite 242 or equivalent to threads on end of valve stem before installing nut B For traction manifold solenoid torque nut from 4 to 6 ft lb 5 to 8 N m For cutting deck solenoid torque nut to 5 ft lb 7 N m Over tightening may damage the solenoid or cause the valve to malfunc tion 6 Reconnect electrical connector to the solenoid 1 Deck manifold 4500 D 2 Valve solenoid Figure 25 3 Solenoid connector Figure 26 1 Deck manifold 4700 D 2 Valve solenoid Groundsmaster 4500 D 4700 D Page 5 17 3 Solenoid connector Electrical System Rev A 9 o0
80. dowels in locating holes of coupling spacer Fig 19 4 Position spring center coupling coil springs toward engine Fig 20 over dowels Secure coupling to cou pling spacer with cap screws and lockwashers Torque cap screws from 35 to 43 ft Ib 48 to 58 N m 5 Install plate pins into engine casting Position pump adapter plate to engine using plate pins as alignment points Secure adaptor plate with cap screws and lock washers using a star pattern tightening procedure Groundsmaster 4500 D 4700 D Page 3 17 Figure 19 3 Cap screw position 4 Dowel position 1 Coupling spacer 2 Shoulder bolt position Hydraulic Pump Side Engine Side Spring Coupling Figure 20 Kubota Diesel Engine Rev A 8 This page is intentionally blank Kubota Diesel Engine Rev A Page 3 18 Groundsmaster 4500 D 4700 D TORO Table of Contents SPECIFICATIONS 2 GENERAL INFORMATION 3 Hydraulic Hoses 3 Hydraulic Fitting Installation 3 Towing Traction Unit 5 Check Hydraulic Fluid 5 HYDRAULIC SCHEMATICS 6 GM 4500 D Hydraulic Schematic 6 GM 4700 D Hydraulic Schematic 7 HYDRAULIC FLOW DIAGRAMS 8 Traction 8 L
81. engage parking brake and remove key from the ignition switch 2 Remove console cover from machine 3 Locate cutting deck lift lower switch that requires testing Disconnect switch connector from machine wir ing harness 4 Check the continuity of the switch by connecting a multimeter ohms setting across the switch connector terminals Electrical System 5 With the lift lever in the neutral position there should be continuity across the switch terminals 6 Pull back on the lift lever enough to take up all free play inthe lever The switch should open before the lever Figure 17 applies any pressure to the spool in the lift lower control 1 Lever support 4 Lift lower switch valve 2 Switch plate 5 Thread forming screw 3 Switch plate screw 7 Switch position can be adjusted for correct operation by loosening the switch plate screw and moving switch plate After any adjustment recheck switch operation LIFT LOWER FROM PTO SWITCH SWITCH PTO SWITCH ON C c IN CENTER POSITION o 814 PK 1 60 b _ L L i FRONTPTO _ L pm frin DECKS 2 3 5 i 4 p RAMP UP 5 POSITION POSITION MODULE DECK LOWERED DECK LOWERED DECKS 1 4 lt TO GROUND Figure 18 Ground
82. faulty A hydraulic problem exists see Troubleshooting section of Chapter 4 Hydraulic System Cutting deck s operation is intermittent over rough The cutting deck lift lower switch or circuit wiring for the terrain affected decks is faulty Diode D1 C on Diode Circuit Board is faulty Groundsmaster 4500 D 4700 D Page5 5 Electrical System Rev A Electrical System Electrical System Quick Checks Battery Test Open Circuit Test 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 60 to 100 F 16 to 38 C The ignition key should be off and all accessories turned off Connect the positive meter lead to the positive battery post and the negative meter lead to the nega tive battery post NOTE This test provides a relative condition of the bat tery Load testing of the battery will provide additional and more accurate information Check Operation of Interlock Switches A CAUTION Do not disconnect safety switches They are for the operator s protection Check the operation of the interlock switches daily for proper operation Replace any malfunctioning switches before op erating the machine Electrical System Rev A Page5 6 Rev D Voltage Measured Battery Charge Level 12 68 V or higher Fully charged 100 12 45V 75 charged 12 24V 50 charged 12 06 V 25 charged 11 89 V 0 ch
83. from starting 3 Place ignition switch in the ON position Verify the fol lowing while in the ON position A Glow indicator lamp is on B Glow relay is energized C Glow plugs are energized D Glow indicator lamp goes out and glow plugs deenergize after 10 seconds 4 Place ignition switch in the START position Verify the following while in the START position A Glow indicator lamp is out B Glow relay is energized C Glow plugs are energized D Power to terminal 1 of the glow controller NOTE Ifthere is no power to terminal 1 ofthe glow con troller verify continuity of the circuitry from the ignition switch to the controller and perform step 4 again see Chapter 9 Electrical Schematics and Diagrams Electrical System Rev A Page 5 20 x lt gt B DEL Figure 30 1 Glow controller end view 3 Controller side view 2 Controller top view 5 ofthe conditions in step are not met or power to terminal 1 exists and any of the other conditions in step 4 are not met A Verify continuity of the circuitry from the battery to the glow relay and glow plugs see Chapter 9 Elec trical Schematics and Diagrams B Verify continuity of the circuitry from the battery to ignition switch glow controller glow lamp glow relay and ground see Chapter 9 Electrical Sche matics and Diagrams C Replace
84. further axle disassembly remove steer ing cylinder from axle see Steering Cylinder in Service and Repairs section of Chapter 4 Hydraulic System 11 required remove tie rod ends from steering arms on rear axle Fig 9 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 12 Clean the rear axle pivot pin and pivot bushings In spect the pin and bushings for wear or damage Replace components as necessary Install Rear Axle 1 install steering cylinder to axle assembly see Steering Cylinder in Service and Repairs section of Chapter 4 Hydraulic System 2 If removed install the tie rod to rear axle Fig 9 Tighten ball joint castle nuts and install new cotter pins 3 Support axle under machine with a jack Position axle assembly to rear frame mount 4 Install axle pivot pin to secure axle to frame Make sure to install thrust washer between axle pivot and frame on both ends of the pivot With washers installed there should be from 002 to 020 inch 05 to 51 mm clearance between rear frame mount and axle mounting boss Add thrust washers if needed to adjust clearance 5 Install flat washer and lock nut onto pivot pin Lock nut should be tightened enough to allow pivot pin to ro tate 70 ft lb 94 N m maximum 6 Install hydraulic motor to axle assembly see Rear Axle Motor in Service and Repai
85. hydraulic fluid 1 Install the quad seal A Put one of the bearing races and sleeve into the housing B Together the housing and bearing race create a groove into which the quad seal will be installed C Hold the bearing race tightly against the input end of the housing by pushing on the gerotor end of the sleeve D Fitthe quad seal into its seat through the input end of the housing Be sure the seal is not twisted E Remove the sleeve and bearing race 2 Lubricate and install the dust seal 3 Install the centering springs in the spool It is best to install the two flat pieces first Next install the curved pieces three at a time 4 Fit the retaining ring over the centering springs 5 Apply a light coating of clean hydraulic fluid to the spool and slide it into the sleeve Be sure the centering springs fit into the notches in the sleeve 6 Install the pin 7 Apply a light coating of petroleum jelly to the inner edge of the dust and quad seals Groundsmaster 4500 D 4700 D Page 4 105 8 Put the thrust bearing and races into the housing The thrust bearing goes between the two races Fig 90 IMPORTANT Do not damage the dust or quad seals when installing the spool and sleeve assembly 9 Apply a light coating of clean hydraulic fluid to the spool and sleeve assembly and slide carefully the as sembly into the housing 10 Clamp the housing in a vise Use only enough clamp ing force to hold th
86. in position with petroleum jelly Position the feed back link at 90 degrees from control housing Install manual servo control assembly 28 onto housing mak ing sure feedback link entered small groove in servo pis ton assembly 7 20 Secure control assembly with six socket head screws 17 Torque screws from 40 to 48 in Ib 4 5 to 5 4 N m 21 Install control arm 27 onto control assembly input shaft Retain with lock washer 23 and nut 22 Torque nut from 4 to 6 ft lb 5 to 8 N m 22 Install remaining plugs that were removed from pump Torque 3 4 in plug from 21 to 24 ft Ib 28 to 32 N m Torque 1 1 4 in plug from 40 to 45 ft Ib 54 to 61 N m Hydraulic System Rev A 2 FE 6 Oo Piston Pump Manual Servo Control Assembly 24 17 to 26 77 2 to 3 N m 44 to 52 ft Ib 60 to 70 N m 28 to 34 in Ib 3 2 to 3 8 N m Figure 62 1 Plug 9 O ring 17 Set screw 2 O ring 10 Wiper seal 18 Set screw 3 Retaining ring 11 O ring 19 Pin 4 Spring retainer 12 Adaptor 20 Retaining ring 5 Spring 13 Ball 21 Feedback link 6 Spool valve 14 Pin 22 Dowel pin 7 Control housing 15 Neutral switch 23 Bell crank 8 Input shaft 16 O ring 24 Set screw Disassembly Reassembly 1 Remove wiper seal with screw driver Remove set screw 18 that retains input shaft and remove input shaft from control housing Remove o ring from shaft 2 Remove set screw 24 from plug that retains
87. is intentionally blank Groundsmaster 4500 D 4700 D Table Of Contents Chapter 1 Safety General Safety Instructions 1 2 Jacking 1 4 Safety and Instruction Decals 1 5 Chapter 2 Product Records and Maintenance Product Records 2 1 Maintenance 2 1 Equivalents and Conversions 2 2 Torque Specifications 2 3 Chapter 3 Kubota Diesel Engine General Information 3 2 Specifications 3 3 5 ies 3 4 Service and Repairs 3 5 KUBOTA WORKSHOP MANUAL DIESEL ENGINE V2003 T SERIES Chapter 4 Hydraulic System Specifications 4 2 General Information 4 3 Hydraulic Schematics 4 6 Hydraulic Flow Diagrams 4 8 Special Tools 4 20 Troubleshooting 4 22 iu nce ebbe Eb n ke 4 25 Service and Repairs 4 52 Groundsmaster 4500 D 4700 D Rev D Chapter 5 Electrical System Electrical Schematics and Electrical Harness and Connectors DrawingS Special Tools Troubleshooting Electrical S
88. leakage Fig 36 7 Have another person measure flow from the case drain line for 15 seconds then move the PTO switch to OFF and stop the engine TEST RESULTS Flow less than 0 7 GPM less than 22 4 ounces 662 ml of hydraulic fluid in 15 sec onds 8 Disconnect tester from motor and hose Reconnect hose to the deck motor Remove cap from bulkhead fit ting and reconnect case drain hose 9 If flow is more than 0 7 GPM the motor is worn or damaged and should be repaired or replaced Figure 35 1 Pressure return hose 2 Case drain hose Figure 36 Hydraulic System Rev A Se TEST 7 Steering Circuit Relief Pressure Using Pressure Gauge STEERING CYLINDER NOTE LEFT TURN SHOWN STEERING CONTROL VALVE TO LIFT LOWER CIRCUIT CHARGE CIRCUIT lt TO PTO MOW CIRCUIT RESERVOIR lt 50 50 PROPORTIONAL FLOW DIVIDER TRACTION CIRCUIT FROM RESERVOIR FROM OIL FILTER Working Pressure Low Pressure Return or Suction gt Hydraulic System Rev Page 4 38 Groundsmaster 4500 D 4700 D Procedure for Steering Circuit Relief Pressure Test 1 Make sure hydraulic oil is at normal operating tem perature by operating the machine for approximately 10 minutes Make sure the hydraulic tank is full 2 Park machine on a level s
89. location of cable ties used to secure wires Dis connect the following electrical components A The temperature sender and alternator Fig 12 Note red wire attached to alternator with washer nut and boot does not have to be removed B The engine run solenoid Fig 13 C The high temperature shutdown switch and glow plug connection Fig 14 D Battery frame and wire harness ground at the engine block Fig 15 E The electric starter Fig 15 F Fusible link harness connector and low oil pres sure switch located on alternator side of engine near electric starter Fig 16 Groundsmaster 4500 D 4700 D Page 3 13 Figure 12 Alternator 3 Coolant hose Temperature sender Figure 13 1 Engine run solenoid 2 Solenoid harness Figure 14 1 Glow plug connection 3 Engine lift tab 2 High temp shutdown Kubota Diesel Engine Rev A 8 o 7 Disconnect fuel line from injection pump Fig 17 Cap fuel line and injector pump fuel inlet to prevent con tamination 8 Disconnect throttle cable from the speed control le ver by removing the washer and lock nut Loosen jam nut and take cable from mounting bracket Fig 17 9 Remove coolant reservoir and bracket from fan shroud 10 Remove four flange head screws and flat washers securing the fan shroud to the radiator 11 Disconnect two wires from neutral switch on hydrau lic traction
90. motor mounting 7 Cap screw 3 Spindle plate 8 Cutting blade 4 Cutting deck 9 Anti scalp cup 5 O ring Cutting Units Rev B Page 8 8 85 to 110 ft Ib 115 to 149 N m 10 Blade bolt 11 Rubber flap if equipped 12 Flap plate if equipped 13 Pop rivet steel if equipped Groundsmaster 4500 D 4700 D Removal 1 Park machine on a level surface lower cutting units stop engine engage parking brake and remove key from the ignition switch 2 Remove two socket head screws that secure hy draulic motor to the cutting unit Fig 4 Remove hydrau lic motor and O ring from deck 3 Cover top of spindle to prevent contamination Spindle plug Toro Part No 94 2703 can be used to cover spindle Figure 4 4 Start the engine and raise the cutting unit Stop en 1 Socket head screw 2 Hydraulic motor gine and remove key from the ignition switch Block up the cutting unit so it cannot fall accidentally If required for easier service remove cutting unit see Cutting Unit Operator s Manual 5 Remove blade bolt anti scalp cup and cutting blade see Cutting Unit Operator s Manual 6 Remove cap screws and flange nuts securing spindle assembly to cutting deck Slide spindle assem bly out the bottom of the deck Remove spindle plate from top of deck Installation 1 Install spindle assembly and spindle plate to cutting deck with cap screws and flange nuts Notches on cut ting deck and spind
91. not contacted by anything Groundsmaster 4500 D 4700 D Page 4 111 gt EN VY CUTTING DECK LOCATIONS Figure 96 gt LU gt Hydraulic System Rev Lift Cylinder Service Figure 97 1 Barrel with clevis 5 Rod seal 9 O ring 2 Collar 6 O ring 10 Uni ring 3 Shaft with clevis 7 Back up ring 11 Piston 4 Dust seal 8 Head 12 Locking nut Hydraulic System Rev A Page 4 112 Groundsmaster 4500 D 4700 D Disassembly 1 Remove oil from lift cylinder into a drain pan by slowly pumping the cylinder shaft Plug both ports and clean the outside of the cylinder 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 2 Mount lift cylinder into a vice Remove collar with a spanner wrench 3 Extract shaft with head and piston by carefully twist ing and pulling on the shaft IMPORTANT Do not clamp vise jaws against the shaft surface Protect shaft surface before mount ing in a vice 4 Mountshaft securely ina vise by clamping on the cle vis of the shaft Remove lock nut and piston from the shaft Slide head off the shaft 5 Remove Uni ring and O ring from the piston Re move O ring back up ring rod seal and dust seal from the head Groundsmaster 4500 D 4700 D Page 4 113 Assembly 1 Make sure all parts are clean before reassembly 2 Coatnew O rings Uni rin
92. of the low pressure gauge 0 to 5000 PSI 5 FLOW METER This meter measures actual oil flow in the operating circuit with a gauge rated at 15 GPM 6 OUTLET HOSE A hose from the outlet side of the hydraulictester connects to the hydraulic system circuit Groundsmaster 4500 D 4700 D Rev D Hydraulic Test Fitting Kit TOR4079 This kit includes a variety of O ring Face Seal fittings to Toro Test Fitting Kit enable you to connect test gauges into the system TOR4079 Tool Number Fitting 2 The kit includes tee s unions reducers plugs caps and male test fittings gt teet ett Figure 21 Measuring Container TOR4077 Use this container for doing hydraulic motor efficiency testing motors with case drain lines only Measure effi ciency of a hydraulic motor by restricting the outlet flow from the motor and measuring leakage from the case drain line while the motor is pressurized by the hydraulic system Se 5 5 E The table in Figure 23 provides gallons minute GPM conversion for measured milliliter or ounce motor case drain leakage Figure 22 Milliliters in 15 sec Ounces in 15 sec 95 3 2 189 6 4 9 6 12 8 16 0 19 2 22 4 25 6 28 8 lala 2 32 0 E Figure 23 Groundsmaster 4500 D 4700 D Page 4 21 Hydraulic Syst
93. open or exposed to prevent contamination 4 Put labels on disconnected hydraulic lines and hoses for proper installation after repairs are completed 5 Note the position of hydraulic fittings especially el bow fittings on hydraulic components before removal Mark parts if necessary to make sure they will be aligned properly when reinstalling hydraulic hoses and tubes Check Hydraulic Lines and Hoses 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 If fluid is in jected into the skin it must be surgically re moved within a few hours by a doctor familiar with this type of injury Gangrene may result from such an injury Hydraulic System Rev A Page 4 52 After Repair or Replacement of Components 1 Check oil level in the hydraulic reservoir and add cor rect oil if necessary Drain and refill hydraulic system reservoir and change oil filter if component failure was severe or system is contaminated see Flush Hydraulic System 2 Lubricate O rings and seals with clean hydraulic oil before installing hydraulic components 3 Make sure caps or plugs are removed from the hy draulic tubes hydraulic fittings and components before reconnecting 4 Use proper tightening methods when inst
94. parts as necessary 6 Connect electrical connector to the run solenoid Groundsmaster 4500 D 4700 D Temperature Sender The temperature sender is located near the alternator on the water flange attached to the engine cylinder head Fig 31 There is a gray wire attached to the terminal of the switch Temperature Sender Test 1 Lower coolant level in the engine and remove the temperature sender from water flange 2 Put switch in a container of oil with a thermometer and slowly heat the oil Fig 32 A CAUTION Handle the hot oil with extreme care to prevent Figure 31 personal injury or fire 1 Temperature sender 2 Alternator NOTE Prior to taking resistance readings with a digital multi meter short the meter test leads together The me ter will display a small resistance value usually 0 5 ohms or less This resistance is due to the internal re sistance of the meter and test leads Subtract this value from from the measured value of the component you are testing 9 3 Check resistance of the sender with a multimeter ohms setting as the temperature increases A The meter should indicate more than 600 ohms at 70 F 21 C B The meter should indicate approximately 460 ohms at 100 F 38 C C The meter should indicate from 54 to 78 ohms at 200 F 93 C D Replace sender if specifications are not met 4 Install sender to the water flange A Clean threads of wate
95. relay ter minals 30 and 87 Ground terminal 86 and apply 12 VDC to terminal 85 The relay should make and break continuity between terminals 30 and 87 as 12 VDC is applied and removed from terminal 85 3 Disconnect voltage and leads from the terminals Hobbs M QUARTZ 00 00 T HOURS Figure 20 Electrical System Figure 22 Groundsmaster 4500 D 4700 D Page 5 15 Rev D Electrical System Rev A Start Neutral Seat Cutting Deck Parking Brake and High Temperature Relays The relays are located under the console cover Fig 23 The wiring harness is tagged to identify each relay NOTE Machines with serial numbers above 230000000 use a standard control module to monitor several switches These machines do not use a start neutral seat parking brake or high temperature relay NOTE The relays may be manufactured by one of two different manufacturers Verify manufacturer name and part number before performing the resistance check on the relay coil NOTE Prior to taking small resistance readings with a digital multi meter short the meter test leads together The meter will display a small resistance value usually 0 5 ohms or less This resistance is due to the internal resistance ofthe meter and test leads Subtractthis val ue from from the measured value of the component you are testing 1 Verify coil resistance between terminals 85 and 86 with a multimeter ohms setti
96. rotating kit assembly 6 still in housing 19 3 From backplate 20 remove bypass valve 14 for ward relief valve 26 and reverse relief valve 16 Note Mark the valves in relationship to the cavity it was re moved for reassembly purposes 4 Remove housing gasket 32 from housing 19 or backplate 20 5 With pump still in vise remove the six socket head screws 17 retaining the servo control assembly 28 Remove the control assembly and control housing gas ket 34 from the housing Remove orifice plates 30 noting location for reassembly Remove nut 22 lock washer 23 and control arm 27 from servo control in put shaft Note position of control arm for reassembly 6 To remove rotating kit assembly 6 from housing first remove pump from vise holding the rotating kit as sembly in position Lower pump so that the shaft end flange end is up Setthe rear of housing onto table with housing flat and rotating kit assembly at rest on table Hole in table for protruding shaft is required Lift and remove the housing 19 and drive shaft 21 from rotat ing kit assembly 6 and camplate assembly 11 7 Remove camplate 11 from rotating kit assembly 6 and servo piston follower 8 from camplate 11 8 Remove the four socket head screws 5 and wash ers 31 retaining each cover plate 9 amp 10 9 Remove jam nut 1 washer 29 and seal washer 4 Hold the servo piston bolt with hex key an
97. screen and oil cooler away from radiator see Traction Unit Operator s Manual 9 Remove flange head screws and lock nuts securing the radiator to the support frame Pull radiator from the machine 10 Plug any radiator or hose openings to prevent con tamination Installation 1 Remove any plugs used during the removal proce dure 2 Position radiator to the support frame Secure radia tor to the support frame with lock nuts and flange head screws 3 Pivot and secure oil cooler and rear screen see Traction Unit Operator s Manual Groundsmaster 4500 D 4700 D Page 3 11 4 Attach radiator fan shroud to the radiator with flange screws and flat washers Make sure that clearance be tween shroud and fan is at least 180 4 6 mm at all points 5 Connect reservoir hose to the vent tube 6 Connect hoses upper and lower to the radiator 7 Reinstall air cleaner hose 8 Make sure coolant drain is closed Fill radiator with coolant see Traction Unit Operator s Manual 9 Install hood on the machine Figure 9 1 Oil filter housing 3 Coolant draincock 2 Coolant drain hose Figure 10 1 Coolant drain hose 2 Coolant draincock Kubota Diesel Engine Rev A 5 9 16 to 22 ft lb 21 to 29 N m ao 1 Flange head screw Rubber engine support Flange nut Rebound washer LH engine mount Lock washer Cap screw
98. seal making sure to not crush the installed outer seal Again make sure that shaft and bearings still freely rotate IMPORTANT Make sure that all grease is removed from shaft threads to prevent bearing lock nut loos ening 5 Thoroughly clean threads on both ends of roller shaft NOTE If original bearing lock nut s are being used apply Loctite 242 or equivalent to threads of lock nut s 6 Install bearing lock nut onto each end of the roller shaft Make sure that outer seals are not damaged dur ing nut installation Torque lock nuts from 50 to 60 ft Ib 68 to 81 N m 7 set screw was removed from either end of roller shaft apply Loctite 242 or equivalent to threads of re moved set screw and install into roller shaft Tighten set screw until it bottoms in shaft and is recessed in shaft IMPORTANT When roller assembly is installed to cutting deck make sure that grease groove in each roller mount aligns with the grease hole in each end of roller shaft Groundsmaster 4500 D 4700 D Page 8 17 NOTE After roller is installed to cutting deck lubricate roller grease fittings rotate roller to properly distribute grease in bearings and clean excess grease from roller ends A properly assembled roller should rotate with less than 5 in Ibs 0 68 N m resistance Figure 15 4 Outer seal 5 Bearing outer seal tool 1 Roller tube 2 Inner seal 3 Bearing
99. side of the front tire 3 Jack front of machine off the ground 4 Position jack stands or hardwood blocks under the frame as close to the wheels as possible to support the machine Jacking the Rear End Fig 2 1 Set parking brake and chock both front tires to pre vent the machine from moving 2 Place jack securely under the center of rear axle 3 Jack rear of machine off the ground 4 Position jack stands or hardwood blocks under the rear axle to support the machine Safety Page 1 4 Figure 1 2 Front tire RH shown Figure 2 1 Rear axle 2 Rear tire Groundsmaster 4500 D 4700 D Safety and Instruction Decals Numerous safety and instruction decals are affixed to the Groundsmaster 4500 D 4700 D If any decal be comes illegible or damaged install a new decal Decal part numbers are listed in your Parts Catalog Groundsmaster 4500 D 4700 D 1 5 Safety This page is intentionally blank Safety Page 1 6 Groundsmaster 4500 D 4700 D 2 TORO Product Records and Maintenance 28 Table of Contents PRODUCT RECORDS 1 Standard Torque for Dry Zinc Plated and 55 1 Steel Fasteners Inch Series 4 EQUIVALENTS AND CONVERSIONS 2 Standard Torque for Dry Zinc Plated and Decimal and Millimeter Equivalents 2 Steel Fasteners Metric Fast
100. side with sharp edges faces end of roller out 6 Use tool TOR4071 to install outer oil seal 7 Use tool TOR4067 to install washer 8 Put opposite end of roller facing up and support bot tom end with tool TOR4067 Repeat steps 3 7 9 Use a hand operated grease gun and No 2 general purpose lithium base grease to lubricate bearings until grease appears at washer Wipe off excess grease Cutting Units Rev B Rev D 2 5 Rear Roller Service Greasable Bearings with Bearing Nut Disassembly Fig 12 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 Remove second set of outer seals and bearing from roll er tube by tapping on opposite end of shaft Remove shaft from roller tube 3 Carefully remove inner seal from both ends of roller tube taking care to not damage tube surfaces 4 Discard removed seals and bearings 5 Cleanroller shaft and all surfaces onthe inside ofthe roller tube Inspect components for wear or damage Also carefully inspect seating surface and threads of bearing lock nuts Replace all damaged components Assembly Fig 12 1 Install inner seals into roller tube making sure that seal lip and garter spring faces end of tube Use inner sealtool see Special Tools and softface hammer
101. snap ring must be installed Replacement bearings are sold only with a matched spacer set and snap ring These parts cannot be purchased separately 1 If large snap ring was removed or if replacing the spindle housing install snap ring into spindle housing groove Make sure snap ring is seated in groove IMPORTANT If bearings are being replaced make sure to use the large spacer inside spacer and spacer ring that are included in bearing set 2 Install large spacer into top of spindle housing The spacer should fit against the snap ring 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 spacer previously installed and the bottom bearing cup must contact the snap ring Make sure thatthe assembly is correct by supporting the first bearing cup and pressing the second against it Fig 6 4 Packthe bearing cones with grease Apply a film of grease on lips of seals Cutting Units Rev B Page 8 10 130 to 160 ft Ib 177 to 216 N m Figure 5 1 Spindle housing 7 Grease fitting 2 Spindle plug 8 Bearing 3 Spindle shaft 9 Spacer ring 4 Oil seal 10 Spacer set 2 piece 5 Shaft spacer 11 Bearing 6 Spindle nut 12 Large snap ring Figure 6 1 Bearing cups 4 Arbor press 2 Large snap ring 5 Support 3 Large spacer 6 Arbor press base Groundsmaster 4500 D 4700 D 5 Insta
102. the re lief valve lifts GAUGE READING TO BE 520 to 570 PSI 6 Relief valve RV5 is located on the lower rear side of the 2WD 4WD control manifold Fig 47 Adjustment of the relief valve can be performed as follows NOTE Do not remove the valve from the hydraulic manifold for adjustment A To increase relief pressure setting remove cap on relief valve and turn the adjustment socket on the relief valve in a clockwise direction A 1 8 turn on the socket will make a measurable change in relief pres sure Fig 48 To decrease pressure setting remove cap lief valve and turn the adjustment socket on the relief valve in a counterclockwise direction A 1 8 turn on the socket will make a measurable change in relief pressure Fig 48 C Recheck relief pressure and readjust as needed Figure 46 1 2WD AWD control manifold GM 4500 D shown 2 Relief valve test port 5 gt Figure 47 1 Manifold lower side 2 Relief valve RV5 Figure 48 1 Relief valve cap 2 Adjustment socket Groundsmaster 4500 D 4700 D Page 4 47 Hydraulic System Rev A TEST 12 Traction Circuit Reducing Valve PR1 Pressure Using Pressure Gauge CHARGE CIRCUIT 2WD CONTROL MANIFOLD gt gt P1 CHG TO
103. therefore shut engine off and adjust traction pedal linkage until machine does not move when traction pedal is released 3 Do not run engine in a confined area without ade quate ventilation Exhaust fumes are hazardous and could possibly be deadly 4 Do not touch engine muffler or exhaust pipe while engine is running or soon after itis stopped These areas could be hot enough to cause burns Safety Page 1 2 or death To reducethe potentialfor injury or death com ply with the following safety instructions To reduce the potential for injury or death comply with the following safety instructions 3 Assure interlock switches are adjusted correctly so engine cannot be started unless traction pedal is in NEUTRAL and cutting units are DISENGAGED 4 Since diesel fuel is highly flammable handle it care fully A Use an approved fuel container B Donot remove fuel tank cap while engine is hot or running C Do not smoke while handling fuel D Fill fuel tank outdoors and only to within an inch of the top of the tank not the filler neck Do not overfill E Wipe up any spilled fuel 5 Before getting off the seat A Ensure that traction pedal is in neutral B Set parking brake C Disengage cutting units and wait for blades to stop D Stop engine and remove key from switch E Toro recommends that anytime the machine is parked short or long term the cutting units should be lowered to the groun
104. valve spool Remove plug from control housing and o ring from plug 3 Remove retaining ring 20 from pin that retains feed back link and spool valve Remove pin feedback link spool valve and bell crank from control housing 4 Compress spring and remove retaining ring 3 Re move spring retainer spring and second spring retainer from spool valve 5 Clean all parts and lubricate in clean hydraulic oil for reassembly Hydraulic System Rev A Page 4 68 1 Install spring retainer spring and second spring re tainer onto spool valve Compress spring to allow retain ing ring 8 to be installed onto spool valve 2 Install spool valve into control housing making sure that metering notches on spool valve can be seen in the metering ports 3 Position bell crank in housing Slide feedback link into position between clevis on valve spool aligning holes and install dowel pin and retaining ring 20 4 Install new o ring 9 onto input shaft Hold bell crank in position with feedback link slot and align splined hole of bell crank with input shaft cavity Install input shaft into control housing and bell crank Groundsmaster 4500 D 4700 D 5 Apply Loctite 242 or equivalent to set screw 18 and install into control housing Adjust set screw until it bottoms out on input shaft and back out one quarter turn 6 Install wiper seal on input shaft 7 Install new o ring 2 onto plug and install plug Ad just p
105. water then rinse it with clean water Electrical System Rev A Page 5 28 Figure 43 3 Battery strap 1 Negative cable 2 Positive cable D Checkthatthe cover seal is not broken away Re place the battery if the seal is broken or leaking E Check the electrolyte level in each cell Ifthe level is below the tops ofthe plates in any cell fill all cells with distilled water between the minimum and max imum fill lines Charge at 15 to 25 amps for 15 min utes to allow sufficient mixing of the electrolyte 2 Conduct a hydrometer test of the battery electrolyte IMPORTANT Make sure the area around the cells is clean before opening the battery caps A Measure the specific gravity of each cell with a hydrometer Draw electrolyte in and out of the hydrometer barrel prior to taking a reading to warm up the hydrometer At the same time take the tem perature of the cell B Temperature correct each cell reading For each 109F 5 59C above 80 F 26 79C add 0 004 to the specific gravity reading For each 109F 5 59 be low 809 26 79C subtract 0 004 from the specific gravity reading Example Cell Temperature 1009F Cell Gravity 1 245 1009F minus 809F equals 209F 37 79C minus 26 7 C equals 11 0 C 209F multiply by 0 004 109F equals 0 008 119C multiply by 0 004 5 5 C equals 0 008 ADD conversion above 0 008 Correction to 809F 26 79C 1 253 Groundsmaster 4500 D 4700 D If the difference between
106. with 7 gauge side supports HEIGHT OF CUT RANGE 3 4 to 4 inch 1 91 to 10 16 cm in 1 4 inch 64 cm increments Height of cut ad justment is made by repositioning deck on deck frame DECK DRIVE Closed loop integrated relief hydraulic system operates cutting deck hydraulic motors Blade spindles are 1 1 4 inch 31 7 mm shafts supported by greaseable tapered roller bearings CUTTING BLADE Each cutting unit equipped with 27 inch 68 6 cm length 250 inch 6 mm thick heat treated steel blade Anti scalp cup installed on cutting blade The standard blade is optimized for most cutting applications Optional high lift angle sail and Atomic blades are available for those situations where the stan dard blade is not ideal Cutting Units Rev B 8 2 DISCHARGE Clippings are discharged from rear of the mowing decks Pre drilled mounting holes allow at tachment of optional mulching baffle CUTTING UNIT LIFT Cutting units on the Ground smaster 4500 D are controlled with one lift lever The Groundsmaster 4700 D uses three lift levers one for the right wing deck one for the left wing deck and the third center lever for the remaining five decks SUSPENSION SYSTEM A fully floating suspension with hydraulic counterbalance Main center pivot allows side to side deck oscillation Individual decks sup ported with two front rollers and one full width rear roll er WEIGHT Complete cutting unit weighs 19
107. 0 Ib 86 kg Groundsmaster 4500 D 4700 D Troubleshooting There are a number of factors that can contribute to un Remember that the effective or actual height of cut satisfactory quality of cut some of which may be turf depends on cutting unit weight counterbalance setting conditions Turf conditions such as excessive thatch and turf conditions Effective height of cut will be differ sponginess uneven ground conditions or attempting ent than the bench set height of cut to cut offtoo much grass height may not always be come by adjusting the machine It is important to re member that the lower the height of cut the more critical these factors are Factors That Can Affect Quality of Cut 1 Maximum governed engine speed Check maximum governed engine speed Adjust speed to specifications if necessary 2 Blade speed All deck blades should rotate at the same speed See items in Troubleshooting Section of Chapter 4 Hydraulic System 3 Tire pressure Check air pressure of each tire Adjust to pressures specified in Cutting Unit Operator s Manual 4 Blade condition Sharpen blades if their cutting edges are dull or nicked Inspect blade sail for wear or damage Replace blade if needed 5 Mower housing condition Make sure that cutting chambers are in good condition Keep underside of deck clean Debris buildup will reduce cutting performance 6 Height of cut Make sure all cutting units are set at
108. 0 to 3750 PSI 9 Disengage cutting units Shut off engine If specifica tion is not met clean or replace relief valve PRV1 or PRV2 located in the hydraulic deck control manifold Fig 33 and 34 10 Disconnect tester from motor and hose Reconnect hydraulic hose to deck motor Rotation Direction p Figure 32 1 Pressure IN 3 Case drain 2 Pressure OUT 2 5 gt gt 4500 D DECK CONTROL MANIFOLDS m F Figure 33 1 Deck 2 3 amp 5 relief valve section P2 2 Deck 1 amp 4 relief valve pump section P1 ee y 1 7 GM 4700 0 DECK CONTROL MANIFOLDS 54 7 x b Figure 34 1 Deck 2 3 5 amp 7 relief valve pump section P2 2 Deck1 4 amp 6 relief valve pump section P1 Groundsmaster 4500 D 4700 D Page 4 35 Hydraulic System Rev A TEST 6 Cutting Deck Motor Case Drain Leakage Using Tester with Pressure Gauges and Flow Meter TESTER GM 4500 D DECK 2 TEST SHOWN LOCATION FOR DECK 2 DECK CONTROL MANIFOLD LIFT LOWER CIRCUIT STEERING CIRCUIT G FORW ARD 50 50 PROPORTIONAL FLOW DIVIDER ieee 1 t P2 5 S 5 PSI 1 4 5 E gt te 180 PSI h 02 FILTRATION AND CHARGE CONTROL MANIFOLD
109. 0N m on the fastener size the aluminum or base material strength length of thread engagement etc NOTE The nominal torque values listed above are based on 75 of the minimum proof load specified in SAE J1199 The tolerance is approximately 10 ofthe nominal torque value Product Records and Maintenance Product Records 2 Other Torque Specifications SAE Grade 8 Steel Set Screws Wheel Bolts and Lug Nuts Thread Size Square Head Hex Socket 716 200 65 10 ft lb 88 14 5 1 2 20 UNF 80 10 ft lb 108 14 N m 5 16 18 UNC 215 35 in Ib 145 20 in Ib 5 3 8 16 UNC 35 10 ft lb 184 3 ft lb M12 X 1 25 80 10 ft Ib 108 14 N m Class 8 8 1 2 13 UNC 75 15 ft lb 50 10 ft Ib M12 X 1 5 80 10 ft lb 108 14 Class 8 8 For steel wheels and non lubricated fasteners Thread Cutting Screws Thread Cutting Screws Zinc Plated Steel Zinc Plated Steel Type 1 Type 23 or Type F Thread Size Baseline Torque No 6 32 UNC 20 5 in Ib No 8 32 UNC 30 5 in Ib Baseline Torque 10 24 38 7 1 4 20 UNC 85 15 in Ib 5 16 18 UNC 110 20 in Ib Hole size material strength material thickness amp finish must be considered when determining specific torque 3 8 16 UNC 200 100 in Ib values All torque values are based on non lubricated 85
110. 10 35 to 40 ft Ib 48 to 54 N m Figure 65 1 Manifold body 10 Reducing valve port 8 19 O ring 2 Solenoid valve SV port 2 11 Seal kit 20 Plug SAE 10 3 Seal kit 12 Plug SAE 2 21 O ring 4 Check valve CV port 3 13 O ring 22 Solenoid coil 5 Seal kit 14 Plug SAE 4 23 Nut 6 Expander plug not serviced 15 O ring 24 Expander plug not serviced 7 Seal kit 16 Plug SAE 5 25 Control valve PD1 amp PD2 ports 5A amp 8 Relief valve RV5 port 7 17 O ring 5B 9 Seal kit 18 Plug SAE 6 NOTE The ports on the manifold are marked for easy identification of components Example P1 is a piston pump connection port and 2 is the location for the sole noid valve See Hydraulic Schematics to identify the function of the hydraulic lines and cartridge valves at each port Cartridge Valve Service 1 Make sure the manifold is clean before removing the valve 2 If cartridge is solenoid operated remove nut secur ing solenoid to the cartridge valve Carefully slide sole noid off the valve Hydraulic System Rev A Page 4 72 IMPORTANT Use care when handling the cartridge valve Slight bending or distortion of the stem tube can cause binding and malfunction 3 Remove cartridge valve with a deep socket wrench Note correct location for o rings sealing rings and backup rings Remove and discard seal kit 4 Visually inspect the port in the manifold for damage to the sealing su
111. 20 to 26 ft Ib 28 to 35 N m 33 Cotter pin 34 Flat washer 35 Parking brake rack 36 Hydraulic fitting 37 O ring 38 O ring 39 Switch plate 40 Carriage bolt 41 Flat washer 42 Lock nut 43 Parking brake proximity switch 44 Screw 45 Flat washer 46 Lock washer 47 Nut 48 Ignition key Groundsmaster 4500 D 4700 D Disassembly Assembly 1 Park machine on level surface lower cutting units 1 Assemble steering tower using Figure 2 as a guide stop engine engage parking brake and remove key from the ignition switch 2 Disassemble steering tower as needed using Figure 2 as a guide Groundsmaster 4500 D 4700 D Page 7 3 Chassis Lift Arms for Cutting Decks 1 4 and 5 Figure 3 1 Lock nut 14 Lift cylinder pin 27 Lock nut 2 Flange nut 15 Flange nut 28 Bumper support bracket 3 Lift arm 1 deck 16 Washer head screw 29 Bumper 4 Lift cylinder pin 17 Skid plate 30 Lift arm 5 deck 5 Flange head screw 18 Lift arm 4 deck 31 Lock nut 6 Hydraulic fitting 19 Cap screw 32 Flange bushing 7 Cap screw 20 Carrier frame shaft 33 Front carrier frame 8 Lift cylinder 4 and 5 decks 21 Lynch pin 34 Grease fitting 9 Lift cylinder 1 deck 22 Thrust washer 35 Deck carrier frame 10 Thrust washer 23 Carriage bolt 36 Grease fitting 11 Lock nut 24 Switch bracket 37 O ring 12 Pivot pin 25 Proximity switch 38 O ring 13 Slotted roll pin 26 Proximi
112. 38 1 Steering control valve 3 Steering relief valve 2 Steering column Groundsmaster 4500 D 4700 D Page 4 39 Hydraulic System Rev A f Pressure Us Reli TEST 8 Lift Lower GM 4500 D SHOWN 010 1 1081 0 ONY NOIIVBITIJ ALINDYID 9 8 NOHID MON 14 Working Pressure Low Pressure Return or Suction Q103INVA 1041403 AMZ ceu FROM PTO MOW CIRCUIT 1 WNOI 180d03d 05 09 2 VET GR 2 4 ZL Va ha Me 19 LINDYIO SNIH33IS TO MOW 9 GIRCUIT 010 1081007 15155 ONY NMOG 53 STEERING CIRCUIT JAVA 10810 41 01 1411 4 40 Groundsmaster 4500 D 4700 D Hydraulic System Rev A Procedure for Lift Lower Circuit Relief Pressure Test 1 Make sure hydraulic oil is at normal operating tem perature by operating the machine
113. 4 Locknut 10 O ring 16 Gasket 5 Stake washer 11 Input shaft Pinion gear 17 Cover plate 6 Oil seal 12 Bearing case 18 Dowel pin The following procedures assume the rear axle assem bly has been removed from the machine Removal 1 Remove the cover plate gasket and gear case as sembly from the axle assembly Remove the gasket and any remaining gasket material 2 Remove the retaining rings and the driven gear from the input shaft pinion gear 3 Remove input shaft pinion gear assembly from the gear case Remove the shims and bearing case O rings 4 Release the stake washer and remove the locknut Remove and discard the stake washer 5 Drive the input shaft pinion gear out from the outer bearing cone and bearing case Remove and discard the oil seal and O ring 6 Inspect all gears shafts bearings spacers and cases for damage and wear Replace components as necessary Axles Planetaries and Brakes Rev B Page 6 20 NOTE Replacement input shaft pinion gear 11 is only available in matched set with differential ring gear Installation 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 Placethe shaft and bearing assembly in the bearing case and install the outer bearing cone NOTE The bearings must be comple
114. 44 Feet Meters 0 3048 Feet Centimeters 30 48 Inches Meters 0 0254 Inches Centimeters 2 54 Inches Millimeters 25 4 Area Square Miles Square Kilometers 2 59 Square Feet Square Meters 0 0929 Square Inches Square Centimeters 6 452 Acre Hectare 0 4047 Volume Cubic Yards Cubic Meters 0 7646 Cubic Feet Cubic Meters 0 02832 Cubic Inches Cubic Centimeters 16 39 Weight Tons Short Metric Tons 0 9078 Pounds Kilograms 0 4536 Ounces Grams 28 3495 Pressure Pounds Sq In Kilopascal 6 895 Pounds Sq In Bar 0 069 Work Foot pounds Newton Meters 1 356 Foot pounds Kilogram Meters 0 1383 Inch pounds Kilogram Centimeters 1 152144 Liquid Volume Quarts Liters 0 9463 Gallons Liters 3 785 Liquid Flow Gallons Minute Liters Minute 3 785 Temperature Fahrenheit Celsius 1 Subract 32 2 Multiply by 5 9 Product Records and Maintenance 2 2 Groundsmaster 4500 D 4700 D Torque Specifications 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 spe cified in this Service Manual These Torque Specifications for the installation and tightening of fasteners shall apply to all fasteners which do not have a specific requirement identified in this Ser vice Manual The following factors shall be considered when applying torque cleanliness of the fastener use of a thread sealan
115. 4500 D 4700 D Page 7 9 Chassis RH hood frame tube Front hood tube Front shroud Shroud divider Hair pin Screen Keeper Hood Flat washer Lock nut Pop rivet RH tube cover Lock nut Cap screw Cap screw RH support Flange nut Chassis Figure 10 Cap screw LH hood frame tube LH support Rear hood tube Flange head screw Hood receiver LH tube cover Cap screw Bumper weight Rear bumper Rubber bumper Flange head screw Bumper weight clamp Back washer Foam seal Lock nut Cap screw Page 7 10 Hood receiver retainer Spring washer Hood receiver spacer Axle stop Flat washer Hood latch Poprivet Cap screw Cap screw Draw latch Hood lock pin Poprivet Latch plate Foam seal Foam seal Foam seal Poprivet Groundsmaster 4500 D 4700 D Removal 1 Park machine on level surface lower cutting units stop engine engage parking brake and remove key from the ignition switch 2 Release hood latches Fig 11 and raise hood 3 Unhook lanyard from hood lock pin remove pin and slide hood tubes rearward off guides Fig 12 m Installation 1 Slide hood tubes onto guides install hood lock pin and hook lanyard to hood pin Fig 12 2 Secure hood to frame with latches Fig 11 11 1 Hood latch 3 Check hood alignment for correct
116. 7 to 56 N m 10 Insert a screwdriver through the drain plug hole to hold ring gear and measure the pinion gear to ring gear backlash Fig 29 PINION GEAR TO RING GEAR BACKLASH 0 004 to 0 016 in 0 10 to 0 40 mm 11 Adjust backlash by increasing or reducing gear case shim thickness 12 Check pinion gear to ring gear engagement see Pin ion Gear to Ring Gear Engagementin this section of this manual 13 Place the correct combination of shims on the gear case Tighten mounting nuts and screws from 35 to 41 ft lb 47 to 56 N m 14 Install retaining rings and driven gear on input shaft pinion gear 15 If the drive gear on drive motor shaft was removed install the retaining rings and drive gear on the motor shaft 16 Use a new gasket and install the cover plate Use a new O ring and install the drive motor Groundsmaster 4500 D 4700 D Page 6 21 0 04 in 1 0 mm Figure 27 3 Seal garter spring Design Cone Center Distance 1 Oil seal 2 Bearing case Figure 28 1 Input shaft pinion gear 2 Bearing case Figure 29 1 Axle case 3 Dial indicator 2 Screwdriver 4 Input shaft pinion gear Axles Planetaries and Brakes Rev B and Brakes o 5 S 9 x Differential Gear The following procedures assume the rear axle assem bly has been removed from the machine Removal 1 Remove bevel gear case axle case assembli
117. 8 Grease fitting 16 Lock washer 24 Hydraulic fitting Remove Rear Axle 1 Park machine on a level surface lower cutting units stop engine engage parking brake and remove key from the ignition switch 2 Drain oil from rear axle and axle gearbox see Trac tion Unit Operator s Manual When servicing rear axle use correct blocks hoists and jacks Make sure machine is parked on a solid level surface such as a concrete floor Always chock or block wheels Use jack stands or solid wood blocks to support the raised machine If the machine is not properly supported by blocks or jack stands the ma chine may move or fall which may result in per sonal injury Axles Planetaries and Brakes Rev B Page 6 12 3 Chockfront wheels and jack up rear of machine see Jacking Instructions in Chapter 1 Safety Support ma chine with jack stands or solid wood blocks 4 Remove wheels from rear axle 5 Remove hydraulic motor from axle assembly see Rear Axle Motor in Service and Repairs section of Chap ter 4 Hydraulic System 6 Remove hydraulic hoses from steering cylinder 7 Remove hydraulic hose from hydraulic fitting on side of input gear case 8 Remove lock nut and flat washer from pivot pin 9 Support rear axle to prevent it from falling Remove pivot pin Lower rear axle from machine Note location of thrust washer on both ends of axle mounting boss Groundsmaster 4500 D 4700 D 10 If needed for
118. 8 P9 P27 P10 P30 P13 P14 CENTER DECK SWITCH 1 CENTER DECK SWITCH 2 DIODE 3 2 WD COIL INTERCONNECT TO GM 4700 CENTER DECK PTO CENTER DECK PTO 2 3 5 1 4 Groundsmaster 4500 D 4700 D Serial Number Below 220999999 Main Wire Harness 15 SEAT SWITCH p J3 ALTERNATOR B P27 DIODE 3 b P13 e P18 CENTER DECK P10 STARTER B GLOW PTO 2 3 5 2WD COIL BELAY 84 H H P14 P19 CENTER DECK 1 4 IGNITION SWITCH P 585 P30 E INTERCONNECT INTERCONNECT TO 4700 TO CONSOLE 5 4 5 2 5 6 WARNING LIGHTS 5 I H Ld 02 Eo 5 5 P20 5 7 5 1 gt 23 FUEL PUMP Im INTERCONNECT TO ENGINE IGNITION H P6 SWITCH Z e NEUTRAL SWITCH SP3 PARKING BRAKE WARNING LIGHTS OIL PRESSURE ALT L INTERCONNECT TO ENGINE 5 P8 P9 CENTER DECK CENTER DECK SWITCH 1 SWITCH 2 Groundsmaster 4500 D 4700 D Serial Number Below 220999999 Main Wire Harness Page 9 15 Rev D GLOW RELAY ALT B SEAT SW NEUTRAL SW PARKING BRAKE NTERCONNECT TO ENGINE P3 Ji J2 15 P6 PH P5 P4 152 1 1 1 A B A B B A B a DE GH BLACK BLACK BLACK BLACK GRAY RED BLACK
119. Cap screw 10 Flat washer Figure 73 Page 4 82 6 Hydraulic fitting 5 O ring 7 O ring Axle motor 2 O ring 4 External snap ring 3 Pinion gear 1 Hydraulic System Rev A Removal 1 Park machine on level surface lower cutting units stop engine engage parking brake and remove key from the ignition switch 2 Read the General Precautions for Removing and Installing Hydraulic System Components at the begin ning of the Service and Repairs section of this chapter NOTE To ease reassembly tag the hydraulic hoses to show their correct position on the axle motor Also clean the port areas of the motor before disconnecting hydrau lic lines 3 Disconnect hydraulic hoses from motor Put caps or plugs on ports to prevent contamination IMPORTANT Support axle motor to prevent motor from falling during removal 4 Remove motor using Figure 73 as a guide Groundsmaster 4500 D 4700 D Page 4 83 Installation 1 If removed install pinion gear to axle motor 2 Install o ring onto motor Position motor to rear axle assembly making sure that arrows on the side of motor case point upward Align gear teeth and slide motor into place 3 Secure motor to axle with cap screws and flat wash ers Torque screws from 59 to 73 ft Ib 80 to 99 N m 4 Remove plugs from ports Attach hydraulic hoses to axle motor 5 Fill hydraulic reservoir with hydraulic fluid as quired see Traction Unit Ope
120. Fig 41 Adjust the relief valve by rotating adjust ment socket clockwise increasing relief pressure C If pressure is still too low after relief valve adjust ment pump or lift cylinder s should be suspected of wear damage or inefficiency Groundsmaster 4500 D 4700 D 1 Lift circuit test port Page 4 41 Figure 39 2 Gear pump 2 gt i gt lt Figure 40 1 GM 4500 D control manifold 2 GM 4700 D control manifold 3 Lift lower relief valve m Figure 41 2 Adjustment socket 1 Relief valve cap Hydraulic System Rev A TEST 9 Steering Lift Lower Gear Pump Flow Using Tester with Pressure Gauges and Flow Meter NOTE LIFT LOWER GEAR PUMP FLOW TEST SHOWN TO STEERING CIRCUIT TO LIFT LOWER CIRCUIT TO PTO MOW CIRCUIT TO PTO MOW CIRCUIT FORWARD gt gt 50 50 PROPORTIONAL FLOW DIVIDER _ TRACTION P2 P1 CIRCUIT J N JN UA TOW VALVE RESERVOIR FROM OIL CHARGE FILTER CIRCUIT Working Pressure Low Pressure Return or Suction gt Hydraulic System Rev A Page 4 42 Groundsmaster 4500 D 4700 D Procedure for Steering and Lift Lower Gear Pump Flow Test Output from the steering and lift lower gear pump sec tion is equally divided b
121. Front Wheel Motor Service 86 Cutting Deck 89 Cutting Deck Motor 90 Lift Lower Control Valve GM 4500 D 94 Lift Lower Control Valve Service GM 4500 D 96 Lift Lower Control Valve GM 4700 D 98 Lift Lower Control Valve Service GM 4700 0 100 Steering Valve 102 Steering Valve Service 104 Lift Cylinders Decks 1 4 and 5 106 Lift Cylinders Decks 2 and 3 108 Lift Cylinders Decks 46 and 7 GM 4700 D 110 Lift Cylinder Service 112 Steering 114 Steering Cylinder Service 116 Hydraulic Reservoir 118 Hydraulic Oil Cooler 119 Hydraulic System Rev A 2 Ga 0 Specifications Item Description Piston Traction Pump System Relief Pressure Forward System Relief Pressure Reverse Charge Pressure Variable displacement piston pump 5000 PSI 345 bar 5000 PSI 345 bar 260 PSI 17 9 bar Gear Pump Cutting Deck Relief Pressure Steering Relief Pressure Lift Lower Relief Pressure 3 section positive displacement gear type pump 3500 PSI 241 5 bar 1180 PSI 81 4 bar 2200 PSI 151 8 bar Front Wheel Motors Fixed displacement piston motors Rear Axle Motor Fixed displacement pist
122. GHTS P2 glow STARTER B P18 wn IGNITION SWITCH J4 9 14 Rev ALT B SEAT SWITCH NEUTRAL SWITCH PARKING BRAKE P3 Ji J2 J3 P15 P6 P17 P5 P4 1 1 1 A B B B a bE GH x 5 5 5 5 a m a YI E mo E Qa ORANGE gt RED BLACK Sp3 P20 FUEL PUMP YELLOW GREEN YELLOW WHITE YELLOW YELLOW YELLOW Spa BLUE WHITE ms YELLOW PINK RED a XP BLACK AS 5 M BLUE AS RED BROWN RED ORANGE 82 TAN 83 ORANGE B4 GREEN 85 BLUE WHITE 86 BLACK RED BLACK 87 GREEN 88 YELLOW INTERCONNECT BIO men ORANGE E P23 TO CONSOLE VIOLET YELLOW WHITE 5 BLACK 05 3 SHIELDED CABLE a BROWN GREEN VIOLET C9 C10 PINK 02 GREEN 03 i D4 GRAY 05 PINK BLACK SPI BLACK BLACK SHIELD GROUND SP6 SP7 BLACK BLUE GREEN x 2 8 A 8 A B P
123. INK amp BLACK 2 n 9 RED 3 30 1 BLACK z WHITE 4 85 5 P7 8 3 6 14 1 PINK JSHIELDED CABLE 86 5 BLACK L gt PINK 1 SP1 BLUE 2 BLACK P8 3 BROWN Al 4 5 BLACK X BLACK LE px AG AS BI 2 GRAY 3 B d GREEN 85 5 BLACK 5 BLUE WHITE Be B1 SP3 x GREEN GREEN 5 1 3 YELLOW BE YELLOW _ m T ORANGE 810 WHITE BLACK GREEN cl 2 2 C3 3 PE YELLOW a PINK 5 RED c5 6 C6 1 8 GRAY ce PINK clo BLUE n XE ORANGE 2 WHITE x YELLOW W 9 04 eB 3 m WHITE 05 x isa A 2 2 a M HER 3 a 3 gt gt 4 gt A 5 BROWN 6 0 1 PINK m 8 VIOLET BLACK F 6 x 2 YELLOW A BLACK m g a amp z S x 2 A PIS P21 P20 A B CD G H A CD cbs DEC DEC ECK 2 P29 P30 d CENTER RIGHT HOUR METER OPTIONS STANDARD CONTROL MODULE GND SOLI SOLI 5012 5012 PWR 7 RAMP UP MODULE P23 INTERCONNECT TO MAIN pe DIODE PACK Groundsmaster 4500 D 4700 D Serial Number From 230000001 to 260000600 Console Wire Harness P9 RELAY K3 RIGHT PTO 0 10086108 P34 11 1 1 P30 md hg 12
124. K 1 Page 9 24 Rev D TEMP GAUGE GLOW CONTROLLER PTO SWITCH Jl P3 FLOW DIVIDER 4WD SWITCH P5 J4 P4 12 3 12 5 6 1 23 4 5 6 1 1 I 2 5 5 5 BLACK PINK BLACK 2 SP9 RED 3 30 1 BROWN BLACK a WHITE 4 85 2 5 87 3 81 4 PINK TAN lt SHIELDED CABLE 86 5 BLACK mu M z A BROWN SPI BROWN BROWN 2 BLACK 8 3 DA 4 DAZ 5 BLACK BLACK AK bA4 BLUE DAS 281 BROWN fi ORANGE 432 GRAY P9 3 gt ORANGE 4 GREEN 85 5 BLACK BLUE WHITE 85 5 x 181 lt Z GREEN GREEN 88 m YELLOW ETT E YELLOW 89 3810 19 WHITE BLACK GREEN 1 2 2 YELLOW 3 4 PINK 4 5 RED SP6 5 6 5 1 T 8 TAN 8 GRAY PINK 10 BLUE 2 WHITE YELLOW 4 8 2 WHITE 5 c a rm x 4 5 gt a T a 2 RED 3 a 3 gt 4 5 5 BROWN 8 5 C 1 PINK 8 VIOLET SP BLACK x 6 YELLOW BLACK 5 8 x tr z 2 9 SH A B B A B J2 J3 29 P30 PI9 P21 P20 HOUR METER LEFT CENTER RIGHT OPTIONS STANDARD CONTROL MODULE DEC DEC
125. Lock washer gt Kubota Diesel Engine Rev 16 to 22 ft lb 21 to 29 N m Figure 11 Bolt LH engine mount Muffler bracket lift tab Flange nut Cap screw Flat washer Spacer Rubber hanger exhaust Page 3 12 18 Lock nut 19 RH engine mount 20 Cap screw 21 RH engine mount 22 Fusible link 23 Engine wire harness 24 Cap screw 25 Lift tab Groundsmaster 4500 D 4700 D Engine Removal 1 Park machine on level surface lower cutting units stop engine engage parking brake and remove key from the ignition switch Raise hood 2 Remove battery strap and cover Disconnect nega tive battery cable first and then positive battery cable Remove battery from machine Do not open radiator cap or drain coolant if the radiator or engine is hot Pressurized hot cool ant can escape and cause burns Ethylene glycol antifreeze is poisonous Dis pose of coolant properly or store it in a properly labeled container away from children and pets 3 Drain coolant from radiator into a suitable container see Radiator Removal Disconnect coolant hoses from the radiator Fig 12 The muffler and exhaust pipe may be hot To avoid possible burns allow the exhaust system to cool before working on or near the muffler 4 Remove exhaust system from engine see Muffler Removal 5 Remove air cleaner system from engine see Air Cleaner Removal 6 Note
126. ON CONTROL MANIFOLD FNT PORTS FILTRATION AND CHARGE CONTROL MANIFOLD 180 PSI e C M G PTO MOW CIRCUIT gt TO LIFT LOWER CIRCUIT TO STEERING CIRCUIT 50 50 PROPORTIONAL FLOW DIVIDER UO lt gt FROM PTO MOW CIRCUIT FROM STEERING CONTROL Working Pressure Low Pressure FROM PTO MOW CIRCUIT Return or Suction gt Hydraulic System Rev Page 4 26 Groundsmaster 4500 D 4700 D Procedure for Traction Circuit Charge Pressure Test 1 Make sure hydraulic oil is at normal operating tem perature by operating the machine for approximately 10 minutes Make sure the hydraulic tank is full 2 Park machine on a level surface with the cutting units lowered and off Make sure engine is off and the parking brake is engaged Prevent personal injury and or damage to equip ment Read all WARNINGS CAUTIONS and Pre cautions for Hydraulic Testing at the beginning Figure 24 of this section 1 Right side frame rail 2 Filter manifold 3 Connect a 1000 PSI gauge onto charge pressure test port located on rear of filter manifold under right hand frame rail Fig 24 and 25 4 Start the engine a
127. P SECTION P2 Or FS Hydraulic System Rev A Page 4 34 Groundsmaster 4500 D 4700 D Procedure for Cutting Deck Manifold Relief Pressure Test 1 Make sure hydraulic oil is at normal operating tem perature by operating the machine for approximately 10 minutes Make sure the hydraulic tank is full 2 machine on a level surface with the cutting units lowered and off Make sure engine is off and the parking brake is engaged Prevent personal injury and or damage to equip ment Read all WARNINGS CAUTIONS and Pre cautions for Hydraulic Testing at the beginning of this section 3 Determine deck manifold relief to be tested Discon nectthe inlet hydraulic hose to the appropriate deck mo tor Fig 32 A For pump section P1 deck manifold relief is tested at the inlet to the motor on deck 5 B For pump section P2 deck manifold relief is tested at the inlet to the motor on deck 1 4 Install hydraulic flow meter in series with the the dis connected hose and deck motor inlet 5 Make sure the flow control valve on the tester is fully caution open Keep away from decks during test to prevent per sonal injury from the cutting blades 6 Start engine and move throttle to full speed 2800 50 RPM Engage the cutting units 7 Watch pressure gauge carefully while slowly closing the flow control valve to fully closed 8 As the relief valve lifts system pressure should be 340
128. P SW PTOCOL 1 8 BU W lt BN F5 2 IGN SW RUN xd Es W BK lt R BK 4 1 R PARKING 25 4 2 0 PARKING BRAKE Pro sw 1 0 IN CENTER POSITION OR lt roses S pK 235 30 4 97 e P234C4 BK NONE 2 E BACKLAP USED M E P23 A1 BN 2 P i BH4S SEAT SWITCH P23 B3 GROUND like 25 89 1 mmn ai aite FRONT PTO 8 9 7o 2 3 FRONT DECK FRONT DECK St o SS EN r23 85 2 NEUTRAL SW POSITION POSITION CENTER PTO K2 SUM T IGNITION SW s 5 2 H sw 5 STANDARD CONTROL MODULE R OFF RUN START PK VIO FRONT 23 7 1_15 P23 p2 P23 D3 F4 10A ON E l P25 CB F6 10A 0 5 T F2 10A P23 01 P23 D5 Y BU W 1 BK F3 10A UT D Groundsmaster 4500 D POWER POINT Electrical Schematic Serial Number Above 260000600 All relays and solenoids are shown as de energized All ground wires are black 9 5 Rev RUN SOLENOID
129. RING ARC Heel the portion of the gear tooth at the outer end HEEL lt a Top Land top surface of tooth 1 Paint the teeth of the ring gear both drive and coast side with a gear marking compound such as DyKem Steel Blue Figure 37 2 Install the input shaft pinion gear assembly into axle case More than 3596 total tooth contact 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 Ideal tooth contact observed on the ring gear should cover more than 3596 of each tooth surface The contact areashould be inthe center of each tooth and extend 1 3 1 3 to 1 2 of entire width to 1 2 way across each tooth from the toe end Fig 38 from small Gnd ot Adjustments to the gear contact position are made by moving the input shaft pinion gear bearing case shims or by moving the differential gear case differential bear ing shims Fig 39 NOTE Bearing case shims are available in 0 004 in 0 10 mm and 0 008 in 0 20 mm thickness and Brakes NOTE Differential bearing shims are available in 0 004 in 0 10 mm 0 008 in 0 20 mm and 0 016 in 0 40 mm thickness o 5 o S 9 x Study the different contact patterns Figs 40 and 41 and correct gear engagement as necessary NOTE When making changes note that two variables are involved see Gear Pattern Movemen
130. RING CYLINDER NO PISTON MOVEMENT STEERING CYLINDER PISTON MOVEMENT a left turn The rotary meter ensures that the oil flow to the cylinder is proportional to the amount of the turning on the steering wheel Fluid leaving the cylinder flows back through the spool valve then through the T port and to the hydraulic reservoir The steering wheel and steering control valve return to the neutral position when turning is completed Right Turn When a right turn is made with the engine running the turning ofthe steering wheel positions the spool valve so that flow goes through the bottom of the spool Flow en tering the steering control valve at the P port goes through the spool and is routed to two places As in a left turn most of the flow through the valve is by passed out the PB port back to the oil filter and traction charge cir cuit Also like a left turn the remainder of the flow is drawn through rotary meter V1 but goes out port R Pressure extends the piston for a right turn The rotary meter ensures that the oil flow to the cylinder is propor tional 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 reser voir The steering wheel and steering control valve return to the neutral position when turning is completed STEERING CYLINDER PISTON MOVEMENT
131. RNESS 6 ALTERNATOR 36 STARTER 75 OIL PRESSURE 2 STARTER 6 Groundsmaster 4500 D 4700 D Serial Number Above 230000000 Engine Wire Harness J3 GROUND Page 9 29 Rev D 12 RIGHT DECK PTO LEFT DECK PTO P P6 LEFT DECK SW B B 5 1 ME lt INTERCONNECT TO GM 4500 INTERCONNECT TO GM 4500 P30 4 E PEO 9 LEFT DECK SW PINK 8 GREEN YELLOW SPI RIGHT DECK e PINK PINK 2 ORANGE 3 a SP6 BLACK P7 RIGHT DECK SW BLACK BLACK 6 5 d 5 gt gt P24 P25 PUE DIODE 4 LEFT DECK PTO DIODE 5 RIGHT DECK PTO Page 9 30 Rev D Groundsmaster 4700 D Deck 6 and 7 Wire Harness
132. RPM FLOW GAUGE READING TO BE Flow approxi mately 3 2 GPM at 1000 PSI 6 Stop engine Remove tester and reinstall hydraulic hoseto gear pump Complete steps 3 through 6 for other circuit hose Groundsmaster 4500 D 4700 D Page 4 43 7 Ifthe total of the two flows is lower than 6 4 GPM or a pressure of 1000 PSI could not be obtained check for restriction in pump intake line If intake line is not re stricted remove gear pump and repair or replace as necessary Ifthe total ofthe two flows is 6 4 GPM but individual cir cuit flow is less than 3 2 GPM e g steering circuit has 2 GPM and lift circuit has 4 4 GPM suspect a problem with the proportional valve in the gear pump Figure 42 1 Gear pump 3 Steering circuit hose 2 Lift circuit hose Figure 43 3 Steering circuit 4 Proportional valve 1 Gear pump backplate 2 Lift circuit Hydraulic System Rev A 5 gt ing Pressure Gauge 10 Counterbalance RV1 Pressure Us TEST NO GM 4500 D SHOWN GIOSINVW 1081NO2 393VH NOIIV3L1IJ 203 ONIH33IS gt 31002 154 08 Working Pressure Low Pressure Return or Suction FROM PTO MOW CIRCUIT 51804 1N4
133. T TO GM 4700 CENTER I PTO 2 3 5 260000600 Main Wire Harness 19 IGNITION SW 5 2 e amp t 15 SEAT SW 23 INTERCONNECT TO CONSOLE J3 ALT B P18 STARTER B P11 PB GLOW C P RELAY CENTER DECK PTO 2 3 5 P14 CENTER DECK 1 4 P30 INTERCONNECT TO 4700 2 ES 1 1 H H 1e P2 a Sp1 W ARNING LIGHTS P20 OVER TEMP FUEL PUMP Ji IGNITION SW INTERCONNECT ENGINE a P20 Ph FUEL PUMP RI INTERCONNECT TO ENGINE WARNING LIGHTS 01 PRESURE ALT L P9 CENTER DECK SW 2 SN 280000001 AND UP Groundsmaster 4500 D 4700 D Serial Number Above 260000600 Main Wire Harness Page 9 19 Rev D K1 RELAY LEFT PTO K2 RELAY CENTER PTO K3 RELAY RIGHT PTO K5 RELAY START 1 POWER POINT P22 FUSE BLOCK 1 Page 9 20 Rev D TEMPERATURE GAUGE
134. TE The ports on the manifold are marked for easy identification of components Example P1 is the gear pump connection port See Hydraulic Schematics to identify the function of the hydraulic lines and cartridge valves at each port 1 Read the General Precautions for Removing and Installing Hydraulic System Components at the begin ning of the Service and Repairs section of this chapter 2 Disconnect electrical connector from the solenoid valve Hydraulic System Rev A Page 4 80 caps or plugs on open hydraulic lines and fittings Label disconnected hydraulic lines for proper reassembly 4 Remove hydraulic manifold from the frame using Figure 71 as guide Installation 1 Install hydraulic manifold to the frame using Figure 71 as guide 2 Remove caps and plugs from fittings and hoses Properly connect hydraulic lines to manifold 3 Connect electrical connector to the solenoid valve Groundsmaster 4500 D 4700 D Hydraulic Control Manifold Service Deck Drive GM 4700 D 8 4 to 5 ft lb 8 5 4 to 6 8 N m 20 ft Ib 27 1 y 25 ft lb 2 33 9 N m 120 in Ib 13 6 N m 20 ft Ib 27 1 N m 25 ft Ib 33 9 N m 198 in Ib 9477 024 10 2 75 ft lb 101 7 N m 9 7 198 in Ib 22 4 N m 165 in Ib 18 6 N m Figure 72 1 Manifold body 5 2 Proportional relief solenoid PRV2 6 Pilot piston 3 Solenoid valv
135. TRACTION CONTROL r 55 lt H MANIFOLD FNT PORTS FRONT d 4 sa lt a FILTRATION AND CHARGE CONTROL MANIFOLD CD1 t LIFT LOWER CIRCUIT T TO STEERING CIRCUIT 50 50 PROPORTIONAL FLOW DIVIDER FROM PTO MOW CIRCUIT Working Pressure TO PTO MOW CIRCUIT Low Pressure o FROM STEERING CONTROL Return or Suction FROM PTO MOW CIRCUIT Flow Hydraulic System Rev Page 4 48 Groundsmaster 4500 D 4700 D Procedure for Traction Circuit Reducing Valve PR1 Pressure Test 1 Make sure hydraulic oil is at normal operating tem perature by operating the machine for approximately 10 minutes Make sure the hydraulic tank is full 2 Park machine alevel surface with the cutting units lowered and off Make sure engine is off and the parking brake is engaged Prevent personal injury and or damage to equip ment Read all WARNINGS CAUTIONS and Pre cautions for Hydraulic Testing at the beginning of this section 3 Connect a 1000 PSI gauge to test port on 2WD 4WD control manifold under operator s seat
136. VIG OR a BN 1 GND PK E BK BK BU B R BK P23 A2 P23 CI mm GN P23 A3 2 40 03 GN K PTO SWITCH 2 WD 4 WD PK Quar 14 i BU P23 A5 2 5 START 12 VLA NS 23 86 229 HIGH TEMP sw PTO COIU B 5 BU W gt BN 256 IGN SW I RUN K UP pe F8 W BK SS BK DEKU iN c 4 R BRAKE 2384 220 PARKING BRAKE IN CENTER POSITION pretend 2 OR OR 934 m 23 BK STOP NONE ai age NOT USEDE P23 Al BU b xp 6 2 w BeltA 1 FRONT PTO START 8 145 SEAT SWITCH P23 83 2 E SEAT SW GROUND LF P23 89 P23 C5 6Y BN BU fa m 3 gk 5 RONT NEUTRAL SWITCH P3785 M 2291 sw POSTION POSITION CENTER PTO K2 RAMP UP lt gt IGNITION SW GN MODULE zzy IGN sw 5 R OFF RUN STAR PK VIO FRONT PTO EISA A Basis PALINA STANDARD CONTROL MODULE 1 5 GN OR Y 1 1 oAte P23 CB 6 I0 A 19 iL E 2 10 P23 DI 2 P23 D5 BU ot w o BK BK F3 10A gt E c gt POWER POINT Groundsmaster 4500 D Electrical Schematic Serial Number From 230000001 to 260000600 All relays and solenoids are shown as de energized All ground wires are black
137. W PINK F G YELLOW YELLOW RED BLACK z x E 2 4 5 m 5 im im Q zm i 5 tt os gt 5 n E gt gt gt 4653 12 3 4 5 E lt 5 B A B A B P13 P1 P16 P17 J2 93 18 19 21 20 OPT FUSE BLOCK 2 HOUR METER K8 SEAT K9 NEUTRAL CAPACITOR DIODE 8 LEFT DECK CENTER DECKS RIGHT DECK Groundsmaster 4500 D 4700 D Serial Number Below 220999999 Console Wire Harness P4 2WD 4WD SWITCI 2 P1 HOUR METER Du J3 CAPACITOR RAMP UP MODULE gt n y 15 J2 CAPACITOR K7 PARKING BRAKI 2 SS S K9 NEUTRAL 17 14 6 HIGH TEMP P9 RELAY RIGHT PTO PB nawan K2 RELAY 5 48 dr 12 pop FUSE BLOCK 1 4 2 3 P7 BELA RELAY REA LEFT PTO P13 OPT FUSE BLOCK 2 9 5 P20 SP1 a 5 5 P21 CENTER DECKS RIGHT DECK SP4 Tin LEI ETI PS PTO SWITCH
138. a voltage reading at 15 seconds then re move the load Groundsmaster 4500 D 4700 D Page 5 29 H Using the table below determine the minimum voltage for the cell temperature reading Minimum Battery Electrolyte Voltage __ 21190 95 Hs 15 10 0 C 9 3 4 4 C 30 F 1 19C 89 20 6 7 12290 Ifthe test voltage is below the minimum replace the battery If the test voltage is at or above the mini mum return the battery to service 9 4 50 F Charging To minimize possible damage to the battery and allow the battery to be fully charged the slow charging meth od is presented here This charging method can be ac complished with a constant current battery charger which is available in most shops A CAUTION Follow the manufacturer s instructions when us ing a battery charger NOTE Using specific gravity of the battery cells is the most accurate method of determining battery condition 1 Determine the battery charge level from either its specific gravity or open circuit voltage Battery Charge Specific Open Circuit Level Gravity Voltage 100 1 1265 12 1268 LL _ 12 24 12 06 50 1 190 25 1 155 Electrical System Rev SE s2 o0 o gt Tr 2 Determine the charging time and rate using the manufacturer s battery charger instructions or the following table Battery Battery Charge Level Reser
139. al Information on engine troubleshooting testing disassembly and reassembly is identified in the Kubota Workshop Manual Diesel En gine V2003 T that is included at the end of this section Most repairs and adjustments require tools which are commonly available in many service shops Special Kubota Diesel Engine Rev A Page 3 2 tools are described in the Kubota Workshop Manual Diesel Engine V2003 T The use of some specialized test equipment is explained However the cost of the test equipment and the specialized nature of some re pairs may dictate that the work be done at an engine re pair facility Service and repair parts for Kubota engines are sup plied through your Authorized Toro Distributor If no parts list is available be prepared to provide your distrib utor with the Toro model and serial number Groundsmaster 4500 D 4700 D Specifications Item Description Make Designation Kubota 4 Cycle 4 Cylinder Water Cooled Turbocharged Diesel Engine Horse Power 58 HP 43 3 kW 2600 RPM Bore mm 83 0 8 27 Stroke mm in 92 4 3 64 Total Displacement cc cu in 1999 122 12 Firing Order 1 3 4 2 Combustion Chamber Spherical Type Fuel No 2 Diesel Fuel ASTM D975 Fuel Capacity liters U S gallons 79 5 21 0 Fuel Injection Pump Bosch Type Mini Pump PFR Governor Centrifugal Mechanical Low Idle
140. alling hy draulic hoses and fittings see Hydraulic Fitting Installa tion 5 After repairs check control linkages or cables for proper adjustment binding or broken parts 6 After disconnecting or replacing any hydraulic com ponents operate machine functions slowly until air is out of system see Charge Hydraulic System 7 Check for hydraulic oil leaks Shut off engine and cor rect leaks if necessary Check oil level in hydraulic reser voir and add correct oil if necessary IMPORTANT Check hydraulic lines and hoses daily for leaks kinked lines loose mounting supports wear loose fittings weather deterioration and chemical deterioration Make all necessary repairs before operating Groundsmaster 4500 D 4700 D Flush Hydraulic System IMPORTANT Flush the hydraulic system any time there is a severe component failure or the system is contaminated oil appears milky black or contains metal particles IMPORTANT Flush hydraulic system when chang Ing from petroleum base hydraulic fluid to a biode gradable fluid such as Mobil EAL 224H Operate machine under normal operating conditions for at least four 4 hours before draining 1 Park machine on alevel surface Lower cutting units stop engine and engage parking brake Remove key from the ignition switch Operate all hydraulic controls to relieve system pressure and avoid injury from pressurized hy draulic oil Controls must be operated with the ignition s
141. always protect machined surfaces Disassembly 1 Plug all ports and clean outside of valve thoroughly 2 Remove spool cap 10 Donotremove retaining ring 16 from spool 4 unless spool spring 14 is broken 3 Remove spool 4 from control valve body 12 4 Remove bushing 8 and O rings 15 from spool and O ring from spool bore 5 Remove plug 6 IMPORTANT Check location and positioning of plunger when removing from body to assure proper assembly 6 Remove seat retaining plug 7 lockout spring 9 poppet 1 seat 5 and plunger 2 7 Remove plug 19 8 Remove detent plug 13 disc 18 spring 17 and detent plunger 11 9 Remove all O rings and back up rings from all plugs and seats Inspection 1 Remove all nicks and burns from parts and inspect for excessive wear 2 Inspect plunger and seats for burrs or roughness Inspect spool spring 14 lockout spring 9 and det ent spring 17 for breakage 4 If spool 4 has excessive wear the control valve be comes non serviceable as the spool and spool bore are matched Damaged spools cannot be replaced Groundsmaster 4500 D 4700 D Page 4 97 Assembly 1 Thoroughly clean and dry all parts Apply a light coat ing of clean hydraulic oil to parts prior to assembly NOTE All O rings back up washers wiper seals and nylon poppet should be replaced as new items 2 Install new O ring 15 in proper groove in spool bore
142. and tapping on roller shaft 4 Discard removed bearings Inspect shaft retaining rings and roller for damage Replace components as needed Roller Assembly Fig 9 1 Press new bearing onto one end of roller shaft Apply pressure equally to inner and outer bearing races 2 Place spiral retaining ring on same end of shaft as installed bearing 3 Install shaft with single bearing into roller 4 Install second new bearing onto roller shaft Apply pressure equally to inner and outer bearing races The inner race will contact shoulder of shaft before outer race contacts shoulder of roller Groundsmaster 4500 D 4700 D Page 8 13 5 Install second spiral retaining ring onto roller shaft to secure second bearing 6 Install new seals to 030 inch 76 mm recessed into roller Figure 9 1 Roller 4 Retaining ring 2 Roller shaft 5 Oil seal 3 Bearing 188 dia 2 625 dia Tap 1 4 20 UNC 2 Figure 10 Cutting Units Rev B 2 5 Rear Roller Service Greasable Bearings with Retaining Ring Figure 11 1 Roller shaft 5 Grease fitting 8 Ball bearing 2 Outer seal 6 Washer 9 Inner seal 3 Retaining ring 7 Inner seal 10 Roller tube 4 Outer
143. aphite or thread sealant such as Loctite NOTE The nominal torque values listed above for Grade 5 and 8 fasteners are based on 75 of the mini NOTE Torque values may have to be reduced when mum proof load specified in SAE J429 The tolerance is installing fasteners into threaded aluminum or brass approximately 10 of the nominal torque value Thin The specific torque value should be determined based height nuts include jam nuts Product Records and Maintenance Page 2 4 Groundsmaster 4500 D 4700 D Standard Torque for Dry Zinc Plated and Steel Fasteners Metric Fasteners Regular Height Nuts Class 8 or Stronger Nuts Thread Size M5 X 0 8 M6 X 1 0 57 96 9 in Ib M8 X 1 25 M10 X 1 5 19 2 ft lb 38 4 ft lb M12 X 1 75 M16 X 2 0 M20 X 2 5 NOTE Reduce torque values listed in the table above by 25 for lubricated fasteners Lubricated fasteners are defined as threads coated with a lubricant such as oil graphite or thread sealant such as Loctite 66 7 ft Ib 166 15 ft lb 325 33 ft lb NOTE Torque values may have to be reduced when installing fasteners into threaded aluminum or brass The specific torque value should be determined based Groundsmaster 4500 D 4700 D Class 8 8 Bolts Screws and Studs with 2 5 Class 10 9 Bolts Screws and Studs with Regular Height Nuts Class 10 or Stronger Nuts 225 20 229 22 1 310 30 450 37 filo 6104 5
144. are not contacted by anything Groundsmaster 4500 D 4700 D Page 4 107 gt EN TN CUTTING DECK LOCATIONS Figure 92 5 i gt Hydraulic System Rev Lift Cylinders Decks 2 and 3 Figure 93 1 Lift arm deck 2 shown 6 O ring 11 Lift cylinder 2 Cylinder pin 7 Retaining ring 12 Flange nut 3 Flange head screw 8 Cylinder pin 13 Rotation stop 4 O ring 9 Hydraulic fitting 14 Set screw 5 90 hydraulic fitting 10 Grease fitting Hydraulic System Rev A Page 4 108 Groundsmaster 4500 D 4700 D Removal Fig 93 1 Park machine on level surface lower cutting units stop engine engage parking brake and remove key from the ignition switch 2 Read the General Precautions for Removing and Installing Hydraulic System Components at the begin ning of the Service and Repairs section of this chapter NOTE Before disconnecting the hydraulic lines clean the port area of the steering valve assembly NOTE To ease reassembly tag the hydraulic hoses to show their correct position on the lift cylinder Also clean hydraulic fittings and hose ends prior to disconnecting the hoses 3 Disconnect hydraulic hoses from lift cylinder 4 Remove flange head screw and flange nut that se cure the cylinder pin 2 to the lift arm Remove pin from lift arm and cylinder shaft clevis 5 Remove one retaining ring from the cylinder pin 8 Remove cylinder pin from the fra
145. area One gear assembly may be replaced separately shafts and gears are avail able as assemblies only The slip fit gear is available separately 5 Inspect gear faces for scoring or excessive wear 6 Replace gear assembly if gear width is below 1 181 30 00 mm 7 Assure that snap rings are in grooves on either side of drive and idler gears 8 If any edge of gear teeth is sharp break edge with emery cloth 9 Oil groove in bushings in front plate backplate and adapter plates should be in line with dowel pin holes and 180 degrees apart This positions the oil grooves closest to respective dowel pin holes 10 Replace the backplate front plate or adapter plates if I D of bushings exceed 879 22 33mm Bushings are not available as separate items 11 Bushings in front plate and backup gasket side of adapter plates should be flush with face of plate 12 Check for scoring on face of backplate and adapter plates Replace if wear exceeds 0015 038mm 13 Check bodies inside gear pockets for excessive scoring or wear 14 Replace bodies if 1 0 of gear pockets exceeds 2 100 53 34mm Hydraulic System Rev A 2 6 0 Reassembly It is important that the relationship of the backplate adapter plates bodies wear plates and front plate is correct The two half moon cavities in the bodies must face away from the front plate or adapter plate The smaller half moon port cavity mus
146. arged Interlock switch operation is described in the Traction Unit Operator s Manual Testing of interlock switches and relays is included in the Component Testing section of this Chapter Groundsmaster 4500 D 4700 D Component Testing For accurate resistance and or continuity checks elec trically disconnect the component being tested from the circuit e g unplug the ignition switch connector before doing a continuity check NOTE For engine component testing information see the Kubota Workshop Manual Diesel Engine V2003 T Series at the end of Chapter 3 Kubota Diesel Engine Ignition Switch The ignition key switch has three positions OFF ON PREHEAT and START The terminals are marked as shown The circuit wiring of the ignition switch is shown in the chart With the use of a multimeter ohms setting the switch functions may be tested to determine whether continuity exists between the various terminals for each position Verify continuity between switch terminals POSITION CIRCUIT OFF NONE ON PREHEAT B l A X Y START A CAUTION When testing electrical components for continu ity with a multimeter ohms setting make sure that power to the circuit has been disconnected 1 Key 2 Hex nut Groundsmaster 4500 D 4700 D Page 5 7 Figure 3 3 Lock washer 4 Ignition switch Figure 4 Electrical System Rev A Electrical System The fu
147. ase 9 Remove the plug and sealing washer from the center of the axle case cover While holding the axle case cov er lightly tap the lower end of the bevel gear shaft out of the lower bearing and lower bevel gear 10 Remove and discard bevel gear shaft seal from axle case Fig 14 17 to 20 ft lb 7 23 to 27 N m Figure 14 1 Knuckle pin 9 Lower bevel gear 2 Mounting screw 10 Lower bearing 3 O ring 11 Axle case 4 Bevel gear case 12 Axle case cover 5 Upper bearing 13 O ring 6 Bevel gear shaft 14 Shaft seal 7 Collar 15 Bushing 8 Upper bevel gear Inspection and Brakes 1 Measurethe knuckle pin O D andthe axle case sup port bushing I D to determine the bushing to pin clear ance Fig 15 Replace components as necessary o 5 o S 9 x BUSHING PIN CLEARANCE 0 002 to 0 016 in 0 05 to 0 40 mm KNUCKLE PIN O D Factory Spec 0 982 to 0 983 in 24 95 to 24 98 mm AXLE CASE SUPPORT BUSHING Factory Spec 0 984 to 0 987 in 25 00 to 25 08 mm Figure 15 1 Knuckle pin 2 Axle case support 2 Inspect all gears shafts bearings cases and cov ers for damage and wear Replace components as nec essary Groundsmaster 4500 D 4700 D Page 6 15 Axles Planetaries and Brakes Rev B Installation 1 Coat new shaft seal with grease and install in axle case as shown Fig 16 Figure 16 Axle case 3 Shaft seal 2 Bevel gear cas
148. asured at test ports located on the traction circuit hy draulic tubes of the machine The traction pump and wheel motors use a small amount of hydraulic fluid for internal lubrication Fluid is designed to leak across pump and motor parts into the case drain This leakage results in the loss of hydraulic fluid from the closed loop traction circuit that must be re placed The gear pump section P3 that supplies oil to the steer ing and lift lower circuits also provides charge oil for the traction circuit The gear pump is driven directly off the traction pump It provides a constant supply of charge oil to the traction circuit to make up for oil that is lost due to internal leakage in the traction pump and motors Charge pump flow is directed through the oil filter and to the low pressure side of the closed loop traction circuit A filter bypass valve allows charge oil flow to the closed loop if the filter becomes plugged Groundsmaster 4500 D 4700 D Page4 9 Charge 15 limited by valve located in the filtration and charge control manifold Charge pressure can be measured atthe charge circuit pressure test port on the filtration and charge control manifold The 4WD 2WD control manifold provides hydraulic flow management in a variety of situations Pressure testing of this control manifold can be performed at a test port on the manifold 1 Four wheel drive mow and two wheel drive trans port operat
149. at retaining plugs 7 Torque plugs from 30 to 35 ft lb 41 to 48 N m 7 Install plug 21 with new O ring 27 Torque plug from 10 to 12 ft lb 13 to 16 N m 8 Lubricate detent plunger with clean hydraulic oil Install detent plunger 17 detent spring 20 disc 19 and detent plug 18 with new O ring 26 Torque plug from 4 to 5 ft lb 5 to 7 N m 9 If retaining ring 13 has been removed to replace spool spring 15 install washer 14 spring 15 spacer 3 and secure with retaining ring 13 10 Slide bushings 8 over spools Slide new O rings 12 over spools and position next to bushings Dip spools in clean hydraulic oil and install spool assemblies into proper location of body 11 Install spool caps 10 and tighten from 20 to 25 ft Ib 27 to 33 N m 12 Install new wiper seals 22 Hydraulic System Rev A 2 6 Oo Steering Valve Steering valve Steering column Flange head screw 3 used Dust cover Steering wheel Hex nut Steering wheel cover Hydraulic System Rev A Figure 88 Steering column bracket Flange head screw Flange head screw 1 used Lock washer Flat washer Steering tower cover O ring Page 4 102 Rev D 20 to 26 ft Ib 6 28 to 35 N m Hydraulic adapter O ring In port P Right turn port R Load sensing port PB Left turn port L Out port T Groundsmaster 4500 D 4700
150. cautions for Hydraulic Testing at the beginning of this section 3 Connect a 1000 PSI gauge to counterbalance test port on power down and traction assist manifold under operator s seat Fig 51 Also connect a 5000 PSI gauge to forward traction port on traction circuit hydrau lic tube Fig 52 5 3 5 gt 4 Start the engine and put throttle at full engine speed 2800 50 RPM with no load on the system Do not en gage the cutting units Figure 52 5 Sitonseat apply brakes fully and slowly depress the 1 Forward traction port faces forward traction pedal in the forward direction While pushing traction pedal monitor both pressure gauges 6 As traction circuit pressure reaches approximately 1800 PSI directional valve PD3 should shift This shift will allow counterbalance hydraulic flow to be directed to the traction assist valve RV2 While maintaining trac tion circuit pressure look at pressure reading on gauge connected to the counterbalance test port GAUGE READING TO BE 650 to 750 PSI 7 Adjustment of the traction assist valve RV2 can be performed as follows NOTE Do not remove the valve from the hydraulic manifold for adjustment Figure 53 1 GM 4500 D traction assist manifold Leod 2 GM 4700 D traction assist manifold and turn the adjusting screw on the relief valve in a 3 Traction assist valve RV2 clockwise direction A 1 8 turn on the dial will make a measurabl
151. cond thrust race 10 Secure with second retaining ring 9 4 Install shaft housing Install washer 18 new shaft seal 8 and retaining ring 6 5 Install camplate insert 5 with the lettering side of in sert to the front of the housing Use petroleum jelly to hold in place during assembly 6 Install rotating assembly 4 into housing Make sure that piston shoes make contact with the camplate insert 7 Clamp motor assembly in a protected jaw vise with the open end of the housing up 8 Ifroll pins were removed install to dimension shown in Figure 76 and with opening of roll pin oriented away from bearing within 5 of bearing center line 9 Toreplace bearing 16 in backplate 2 Press bear ing down to the dimension shown Fig 76 protruding from backplate with numbered end of bearing facing up next to valve plate 173 in 4 39 mm Roll Pin 15 090 in 2 3 mm Figure 76 10 Apply small amount of petroleum jelly to the steel side of valve plate 12 to hold in place for installation Place the valve plate in position onto the backplate 2 with steel side against backplate bronze colored side against piston block 11 Placing new o ring 11 onto backplate install back plate assembly 2 onto housing assembly Make sure valve plate stays in position 12 Insert cap screws and torque from 15 to 18 ft Ib 20 to 24 N m in a criss cross pattern 13 Fill case hal
152. d This relieves pressure from the lift circuit and eliminates the risk of cutting units accidentally lowering to the ground F Donotparkon slopesunless wheels are chocked or blocked Groundsmaster 4500 D 4700 D Maintenance and Service 1 Before servicing or making adjustments lower decks stop engine set parking brake and remove key from the switch 2 Make sure machine is in safe operating condition by keeping all nuts bolts and screws tight 3 Never store the machine or fuel container inside where there is an open flame such as near a water heat er or furnace 4 Make sure all hydraulic line connectors are tight and all hydraulic hoses and lines are in good condition be fore applying pressure to the system 5 Keep body and hands away from pin hole leaks in hy draulic lines that eject high pressure hydraulic fluid Use cardboard or paper to find hydraulic leaks Hydraulic fluid escaping under pressure can penetrate skin and cause injury Fluid accidentally injected into the skin must be surgically removed within a few hours by a doc tor familiar with this form of injury or gangrene may re sult 6 Before disconnecting or performing any work on the hydraulic system all pressure in system must be re lieved by stopping engine and lowering cutting units to the ground 7 If major repairs are ever needed or assistance is de sired contact an Authorized Toro Distributor 8 To reduce potential fire hazard kee
153. d screw 17 Retaining ring 27 Secondary gear 8 Lock washer 18 Plug 28 Secondary carrier 9 Housing 19 End cap 29 O ring 10 Dowel pin 20 O ring Planetary Wheel Drive Disassembly Figure 7 1 Remove retaining ring 17 2 Remove end cap 19 and o ring 20 3 Remove thrust plug 21 and thrust washer 22 4 Remove retaining ring 23 primary gear 24 and drive shaft 25 5 Remove primary carrier 26 secondary gear 27 and secondary carrier 28 NOTE Steps 6 10 are necessary only if inspecting or replacing bearings and or seals Axles Planetaries and Brakes Rev B Page 6 10 6 Remove socket head screws 7 and remove ring gear 16 7 Remove snap ring 15 and bearing shim 14 8 Use a puller to remove spindle 1 from housing 9 Remove bearing cone 12 9 Remove and discard all seals 10 If bearings will be replaced use a puller to remove bearing cone 4 from spindle Remove bearing cups 5 and 11 from housing 9 Groundsmaster 4500 D 4700 D Planetary Wheel Drive Assembly Figure 7 NOTE Use new seal kit when assembling planetary wheel drive 1 Clean parts in solvent Inspect parts for damage or excessive wear and replace as necessary 2 Install oil seal 3 to spindle 1 3 Press bearing cups 5 and 11 into housing 9 4 Press bearing cone 4 onto spindle 1 5 Install boot seal 2 to housing 9 Assemble hous ing 9 to spindle 1 6 Press bea
154. d unscrew cover plate 10 from bolt 10 Remove servo piston assembly 7 and seal sub as semblies two sets 37 from housing Note Disassem bly of servo piston assembly is not required 11 Remove retaining ring 2 from the front of pump housing 19 Press the drive shaft 21 shaft seal 25 and washer 24 from housing Remove retaining ring Groundsmaster 4500 D 4700 D Page 4 65 3 thrust race 12 thrust bearing 13 second thrust race 12 and second retaining ring 3 from drive shaft 21 12 Remove the two cap screws 42 that secure cradle sub assembly inside housing cradle sub as sembly back and forth to release dowel bushings 40 and remove cradle sub assembly from housing 13 Remove button head cap screw 43 to remove bushing 44 from cradle 14 Remove remaining plugs from housing 15 Discard the shaft seal 25 gaskets 32 33 34 and o rings from all assemblies Replace with new seals upon reassembly Inspection 1 Inspect backplate assembly A Check the bearing 45 press fit in backplate 20 If needles remain in cage move freely and set ting is at the dimension shown in Figure 58 bearing removal is not required B Check roll pin 38 in backplate 20 If tight and settothe dimension shown in Figure 58 removal not required Numbered end 173 inch 4 39 mm Figure 58 2 Check the bearing 39 press fit in pump housing 19 If needles re
155. denum disulfide lubricant Three Bond 1901 or equivalent to the splines and bearing surfaces of the differential pinion gears pinion washers and side gears 3 Install the side gear shims and side gears in their original location in the differential case 4 Place the differential pinion gears and pinion wash ers in their original location in the differential case Tem porarily install the differential pinion shaft 5 Secure the differential case soft jawed vise Posi tion a dial indicator on a tooth of the differential pinion gear Press the pinion and side gear against the differen tial case and measure the pinion gear to side gear back lash Fig 35 PINION GEAR TO SIDE GEAR BACKLASH 0 004 to 0 016 in 0 10 to 0 40 mm 6 Adjust backlash by increasing or reducing side gear shim thickness NOTE Side gear shims are available in 0 043 in 1 10 mm 0 047 in 1 20 mm and 0 051 in 1 30 mm thick ness 7 Apply gear marking compound such as DyKem Steel Blue lightly over several gear teeth 8 While applying a light load to either side gear rotate either pinion gear until the side gears have made one complete revolution 9 Ideal tooth contact should cover more than 35 of each tooth surface The contact area should be in the center of each tooth and extend 1 3 to 1 2 way across each tooth from the toe small end Fig 36 10 Adjust side gear shims if necessary to correct tooth contact Recheck differ
156. des to stop in a controlled manner Fig 17 Hydraulic System Rev A FROM 02 DECK MOTORS M2 gt DECK MOTORS DECK CONTROL MANIFOLD tz TO OIL M1 M2 ORIFICE gt TO DECK MOTORS M1 FROM 02 DECK MOTORS J 2 ORIFICE gt T TO DECK MOTORS Figure 16 CONTROL MANIFOLD T2 TO OIL COOLER LL M1 Page 4 16 Figure 17 COOLER 11 Groundsmaster 4500 D 4700 D 2 FE 6 0 This page is intentionally blank Groundsmaster 4500 D 4700 D Page 4 17 Hydraulic System Rev A uonong 10 eunssejd eanssaJg Burson lt 5 IND 1 Q 00Zv Q 00St Je1seuspunoJc
157. ds while the ignition switch is left in ON Charge Indicator Light The charge indicator light should come on when the igni tion switch is in ON with the engine not running or with an improperly operating charging circuit while the en gine is running Figure 9 1 Charge indicator 4 Glow plug indicator 2 Engine oil pressure 5 Warning light front 3 High temp shutdown 6 Warning light back Groundsmaster 4500 D 4700 D 5 9 Electrical System Rev A PTO and Hi Lo Speed Control Switches The PTO and Hi Lo Speed Control Switches are lo cated on the control console Fig 10 These rocker switches have common switching logic The switch terminals are marked as shown in Figure 11 The circuitry of these switches is shown in the chart be low With the use of a multimeter ohms setting the switch functions may be tested to determine whether continuity exists between the various terminals for each switch position Verify continuity between switch termi nals SWITCH NORMAL OTHER POSITION CIRCUITS CIRCUITS Ow 959 576 Figure 10 1 PTO switch 2 Hi Lo speed switch BACK OF SWITCH Figure 11 Electrical System Rev A Page 5 10 Groundsmaster 4500 D 4700 D Seat Switch The seat switch is normally open and closes when the operator is on the seat If the traction system or PTO switch is engaged when the operator raises out of the seat the engine will stop The seat switch and its electri
158. e 2 Install the lower bevel gear and bevel gear shaft the axle case cover Coat a new O ring with grease and install the axle case cover Fig 17 Tighten cover screws from 17 to 20 ft lb 23 to 27 3 Slide the bevel gear case over the bevel gear shaft and install the bevel gear and collar Make sure the bevel gear shaft is completely seated in the upper and lower bearings Fig 17 4 Install the knuckle pin Use medium strength thread locking compound and tighten the knuckle pin mounting screws from 17 to 20 ft lb 23 to 27 N m Axle case cover 5 Lower bevel gear 6 Collar 7 8 Upper bevel gear Bevel gear shaft Lower bearing Upper bearing Knuckle pin Axles Planetaries and Brakes Rev Page 6 16 Groundsmaster 4500 D 4700 D 5 Determine necessary quantity of support shims A Lubricate the axle case support bushing with a thin coat of grease and slide axle case support onto knuckle pin B Position support shims that were removed during disassembly between axle case support and axle case Install mounting screws into axle case Slowly tighten screws while frequently checking for clear ance vertical endplay between axle case support and knuckle pin If binding of components is noted before screws are fully tightened add additional sup port shims Torque screws from 57 to 67 ft lb 77 to 91 C Use dial indicator to measure vertical endplay of axle cas
159. e Fig 18 AXLE CASE ASSEMBLY ENDPLAY 0 001 to 0 008 in 0 02 to 0 20 mm D Adjust endplay by increasing or reducing number of axle case support shims NOTE Axle case support shims are available in 0 004 in 0 1 mm 0 008 in 0 2 mm and 0 016 in 0 4 mm thickness 6 After correct support shims have been determined remove mounting screws apply heavy strength thread locking compound to screw threads reinstall screws and torque from 57 to 67 ft lb 77 to 91 N m IMPORTANT Correct engagement between bevel gears is critical to axle performance and durability 7 Temporarily installthe bevel gear case axle case as sembly 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 Fig 19 UPPER BEVEL GEAR BACKLASH 0 004 to 0 016 in 0 10 to 0 40 mm 8 Adjust backlash by increasing or reducing axle bear ing shim thickness see Differential Shafts in this section of this manual NOTE Axle bearing shims are available in 0 004 in 0 1 mm 0 008 in 0 2 mm and 0 020 in 0 5 mm thickness Groundsmaster 4500 D 4700 D Page 6 17 57 to 67 ft Ib 77 to 91 N m VERTICAL ENDPLAY Figure 18 4 Dial indicator 5 Knuckle pin 6 Support shim location Axle case support Axle case Bevel gearcase Figure 19 4 Dial indicator 5 Axle bearing shims Axle support Upper
160. e SV2 7 Solenoid coil 4 Logic valve LC1 and LC2 8 Nut NOTE The ports on the manifold are marked for easy identification of components Example P1 is the gear pump connection port See Hydraulic Schematics to identify the function of the hydraulic lines and cartridge valves at each port location For solenoid and control valve service procedures see Hydraulic Control Manifold Service 2 Wheel 4 Wheel Drive Control in this section Refer to Figure 72 for car tridge valve installation torque Groundsmaster 4500 D 4700 D Relief valve RV8 and RV9 Page 4 81 9 Zero leak plug 6 10 Zero leak plug 12 11 Plug SAE 4 12 Zero leak plug 4 NOTE The Groundsmaster 4700 D deck drive man ifold uses several zero leak plugs These plugs have a tapered sealing surface on the plug head that is de signed to resist vibration induced plug loosening The zero leak plugs also have an o ring as a secondary seal If zero leak plug removal is necessary lightly rap the plug head using a punch and hammer before using an allen wrench to remove the plug the impact will allow plug removal with less chance of damage to the socket head of the plug Hydraulic System Rev A Hydraulic Rear Axle Motor 59 to 73 ft Ib 80 to 99 N m 55 96 lt S A Of amp HO 2 52 Groundsmaster 4500 D 4700 D 8 90 hydraulic fitting 9
161. e 29 15 Cap screw 30 Hydraulic System Rev A 27 to 31 ft lb 37 to 42 N m 100 to 110 ft Ib 136 to 149 N m 4 to 6 ft Ib 5 to 8 N m 40 to 48 in Ib e BN e 4 4 5 to 5 4 N m N 25 to 28 ft lb 34 to 38 N m 5 to 48 in Ib 4 5 to 5 4 N m Figure 57 Relief valve Reverse 31 Flat washer Socket head screw 32 Housing gasket Valve plate 33 Cover plate gasket Pump housing 34 Control assembly gasket Backplate assembly 35 Plug Drive shaft 36 O ring Nut 37 Seal sub assembly Lock washer 38 Roll pin Washer 39 Bearing Shaft seal 40 Dowel bushing Relief valve Forward 41 Cradle sub assembly Control arm 42 Cap screw Servo control assembly 43 Button head cap screw Washer 44 Bushing Orifice plate 3 used 45 Bearing Page 4 64 Groundsmaster 4500 D 4700 D Disassembly Work in clean area as cleanliness is extremely impor tant when repairing hydraulic pumps Thoroughly clean the outside of pump After cleaning remove port plugs and drain oil from pump 1 Position the pump into a protected jaw vise clamp ing onto the outer portion of the flange with the cap screws up Mark the relationship of the working ports for reassembly identification to the servo control as sembly with a scribe Remove the four cap screws 15 retaining backplate 20 2 Lift backplate 20 straight up off drive shaft 21 and housing 19 Remove valve plate 18 from backplate 20 or from
162. e change in pressure Fig 45 A To increase pressure setting loosen the locknut B To decrease pressure setting loosen the locknut and turn the adjusting screw on the relief valve in a counterclockwise direction A 1 8 turn on the dial will make a measurable change in pressure Fig 45 C Recheck pressure and readjust as needed Groundsmaster 4500 D 4700 D Page 4 51 Hydraulic System Rev A 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 sys tem park machine on a level surface engage parking brake lower cutting units or attachments and stop en gine Remove key from the ignition switch 2 Clean machine before disconnecting removing or disassembling any hydraulic components Make sure hydraulic components hoses connections and fittings are cleaned thoroughly Always keep in mind the need for cleanliness when working on hydraulic equipment Operate all hydraulic controls to relieve system pressure and avoid injury from pressurized hy draulic oil Controls must be operated with the ignition switch in RUN and the engine OFF Make sure all electrically operated control valves are actuated Return ignition switch to OFF when pressure has been relieved Remove key from the ignition switch 3 Putcaps or plugs on any hydraulic lines hydraulic fit tings and components left
163. e housing securely 11 Lubricate and install a new o ring seal in the groove in the housing 12 Install the wear plate and align screw holes in the wear plate with threaded holes in the housing NOTE The holes in the wear plate are symmetrical 13 Install the geroter drive making sure the slot in the drive engages the pin 14 Lubricate and install new o ring in wear plate groove 15 Install the gerotor and align the screw holes 16 Lubricate and install new o ring in gerotor ring groove 17 Lubricate and install new o ring and seal ring in gero tor star groove 18 Install the spacer 19 Install the end cap and seven cap screws Tighten the cap screws in a crossing pattern from 140 to 160 in lb 16 to 18 N m 20 Remove the steering control unit from the vise 21 Install the relief valve and plug Tighten the plug to 150 in Ib 17 N m Thrust Bearing and Race 2 Dust Seal Quad Seal Figure 90 Hydraulic System Rev A 5 gt gt 170 Lift Cylinders Decks 1 4 and 5 Figure 91 1 Lift arm deck 4 6 O ring 10 Lift cylinder deck 4 2 Flange nut 7 90 hydraulic fitting 11 Lift cylinder deck 1 3 Lift arm deck 1 8 O ring 12 Lift cylinder deck 5 4 Cylinder pin 3 used 9 Lift arm deck 5 13 Cylinder pin 3 used 5 Flange head screw Hydraulic System Rev A Page 4 106 Groundsmaster 4500 D 4700 D Removal
164. eal 11 Drive gear assembly 21 Idler gear 2 Washer 12 Wear plate 22 Key 3 screw 13 Pressure seal 23 Front adapter plate 4 O ring 14 Backup gasket 24 Rear adapter plate 5 Washer 15 Front plate assembly 25 Idler gear 6 Proportional valve 16 Idler gear 26 Rear body 7 Plug 17 Key 27 Backplate assembly 8 Plug 18 Gear 28 Plug 9 O ring 19 Middle body 29 O ring 10 Front body 20 Gear NOTE To maintain maximum pump efficiency keep body gears and wear plates for each section together do not mix parts between different pump sections IMPORTANT Avoid using excessive clamping pressure onthe pump housing to prevent distorting the housing 2 Clamp pump in vise shaft end up and remove the eight cap screws 3 Groundsmaster 4500 D 4700 D 3 Remove pump from vise hold pump in hands and bump shaft against wooden block to separate front pump sections Front body 10 will remain with either front plate 15 or front adapter plate 23 4 Place front idler gear 16 into gear pocket and tap with soft face hammer until the front body separates Remove idler gear from front plate or adapter plate 5 Remove plug 8 from front plate 15 6 Remove front adapter plate 23 from front body 10 by tapping on the adapter plate with a soft face hammer 7 Remove idler gear 21 slip fit gear 18 and key 17 8 Remove backplate 27 from rear body 26 by tap ping on backplate with soft face hammer 9
165. eight Nuts Height Nuts SAE J995 Grade 2 or Stronger Nuts SAE J995 Grade 2 or Stronger Nuts ll SAE J995 Grade 5 or Stronger Nuts 147 23 339 56 599 79 100 10 1125 100 140 15 1580 170 734 113 115 10 1300 100 160 15 1800 170 1186 169 200 25 2250 280 300 30 3390 340 1446 192 225 25 2540 280 325 30 3670 340 6 32 UNC 6 40 UNF 8 32 UNC 8 36 UNF 10 24 UNC 10 32 UNF 1 4 20 UNC 48 7 1 4 28 UNF 65 10 5 16 18 UNC 115 15 105 17 5 16 24 UNF 138 17 128 17 EN N o a a 5 8 11 UNC 65 10 88 12 119 16 150 15 203 20 210 20 285 27 5 8 18 UNF 75 10 95 15 129 20 170 15 230 20 240 20 325 27 3 4 10 UNC 93 12 140 20 190 27 265 25 359 34 375 35 508 47 3 4 16 UNF 115 15 165 25 224 34 300 25 407 34 420 35 569 47 7 8 9 140 20 225 25 305 34 430 45 583 61 600 60 813 81 7 8 14 UNF 155 25 260 30 353 41 475 45 644 61 660 60 895 81 NOTE Reduce torque values listed in the table above on the fastener size the aluminum or base material by 25 for lubricated fasteners Lubricated fasteners strength length of thread engagement etc are defined as threads coated with a lubricant such as oil gr
166. em Rev A 5 29 5 gt TEST 5 Cutting Deck Manifold Relief Pressure Using Tester with Pressure Gauges and Flow Meter DECK CONTROL MANIFOLD GM 4500 D FORW ARD LIFT LOWER CIRCUIT TO STEERING CIRCUIT G TESTER LOCATION FOR PROPORTIONAL T PUMP SECTION P1 zi i 4 E 180 PSI o2 FILTRATION AND CHARGE CONTROL MANIFOLD TESTER LOCATION FOR PUMP SECTION P2 Working Pressure DECK CONTROL MANIFOLD 63 Low Pressure Return or Suction gt 4700 0 FORW O LIFT LOWER CIRCUIT O STEERING CIRCUIT PROPORTIONAL FLOW DIVIDER 4 FROM LIFT LOWER CIRCUIT 180 PSI TESTER FILTRATION AND CHARGE CONTROL MANIFOLD LOCATION FOR PUM
167. em Rev A Troubleshooting The charts that follow contain information to assist in Refer to the Testing section of this Chapter for precau troubleshooting There may possibly be more than one tions and specific test procedures cause for a machine malfunction Hydraulic System Rev A Page 4 22 Groundsmaster 4500 D 4700 D Rev D System 2 5 gt 4 23 Hydraulic System Rev Groundsmaster 4500 D 4700 D Rev D Cutting units will not lower Hydraulic System Rev A Cutting units raise but will not stay up Page 4 24 Groundsmaster 4500 D 4700 D 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 section in this Chapter Before Performing Hydraulic Tests IMPORTANT All obvious areas such as oil supply filter binding linkages loose fasteners or improper adjustments must checked before assuming that ahydraulic component is the source of the problem Precautions for Hydraulic Testing Failure to use gauges with recommended pres sure PSI rating as listed in test procedures could result in damage to the gauge and possible personal injury from leaking hot oil All testing should be performed by two 2 people One person should be in the seat to oper ate
168. emoval 1 Park machine on level surface lower cutting units stop engine engage parking brake and remove key from the ignition switch 2 Read the General Precautions for Removing and Installing Hydraulic System Components at the begin ning of the Service and Repairs section of this chapter NOTE To ease reassembly tag the hydraulic hoses to show their correct position onthe steering cylinder Also clean hydraulic fittings and hose ends prior to discon necting the hoses 3 Remove hydraulic hoses from steering cylinder 4 Remove cotter pins hex slotted nuts axle washer and ball joint spacer from the threaded ends of ball joints Fig 98 Remove steering cylinder with ball joints from machine Locate and retrieve ball joint spacers from top of axle assembly Groundsmaster 4500 D 4700 D Page 4 115 Installation 1 Place a washer onto each ball joint Slide ram end ball joint through hole on steering arm Secure with axle washer and hex slotted nut Slide fixed end of cylinder through hole on axle Install spacer onto ball joint and secure with hex slotted nut Torque slotted nuts from 100 to 125 ft lbs 135 to 169 N m prior to inserting cotter pins 2 Install hydraulic hoses to steering cylinder 3 Fill reservoir with hydraulic fluid as required see Traction Unit Operator s Manual 4 After assembly is completed operate steering cylin derto verify that hydraulic hoses and fittings are not con tac
169. eners 5 U S to Metric Conversions 2 Other Torque Specifications 6 TORQUE SPECIFICATIONS 3 Conversion 5 6 Fastener Identification 3 Product Records Insert Operator s Manual and Parts Catalog for your Groundsmaster 4500 D 4700 D at the end of this chapter Additionally if any optional equipment or ac cessories have been installed to your machine insert the Installation Instructions Operator s Manuals and Parts Catalogs for those options at the end of this chap ter Maintenance Maintenance procedures and recommended service in tervals for the Groundsmaster 4500 D 4700 D are cov ered in the Operator s Manual Refer to that publication when performing regular equipment maintenance Groundsmaster 4500 D 4700 D Page 2 1 Product Records and Maintenance Rev D Decimal and Millimeter Equivalents Equivalents and Conversions Rev D Fractions Decimals mm Fractions Decimals mm 1 64 0 015625 0 397 33 64 0 515625 13 097 1 82 0 03125 0 794 17 32 0 53125 13 494 3 64 0 046875 1 191 35 64 0 546875 13 891 1 16 0 0625 1 588 9 16 0 5625 14 288 5 64 0 078125 1 984 37 64 0 578125 14 684 3 32 0 09375 2 881 19 32 0 59375 15 081 7 64 0 109275 2 778 39 64 0 609375 15 478 1 8
170. ength thread lock ing compound e g Loctite blue to set screws and re tighten set screws to secure stop The rotation stop should contact the lift arm across the full width of the stop 5 Lubricate lift arm and lift cylinder grease fittings after assembly is complete see Traction Unit Operator s Manual 6 After assembly raise and lower the cutting deck to verify that hydraulic hoses and fittings do not contact anything Groundsmaster 4500 D 4700 D Page 7 7 Chassis Lift Arms for Cutting Decks 6 and 7 Groundsmaster 4700 D only Retaining ring Flat washer Cap screw Hydraulic fitting Lift cylinder Plastic roller Lock nut Grease fitting Rear link 10 Lift link 11 Carriage screw 12 Neutral switch plate 13 Switch bracket 14 Carriage bolt Chassis Figure 8 Thrust washer Cap screw Lock nut Proximity switch Lock nut Thrust washer Lift arm deck 6 shown Carrier pivot pin Compression spring Thrust washer Flat washer Lock nut Pin Pivot pin 7 8 Groundsmaster 4500 D 4700 D Slotted roll pin Support arm deck 6 shown Flange nut Bushing Link Grease fitting Self tapping screw R clamp Wire harness Switch actuator Flange bushing O ring O ring Deck carrier frame Removal 1 Park machine on level surface lower cutting units stop engine engage parking brake and remove key
171. ential pinion gear to side gear backlash if any changes are made 11 After backlash and tooth contact have been ad justed align the hole in the differential pinion shaft with the hole in the differential case and install a new spring pin Axles Planetaries and Brakes Rev B Page 6 24 Figure 35 1 Vise 3 Dial indicator 2 Differential gear case More than 3596 total tooth contact 2222 1 3 to 1 2 of entire width from small end of tooth Figure 36 12 Install differential gear assembly in right side axle support half 13 Coat a new o ring with grease and install left side axle support half Tighten axle support case screws from 35 to 41 ft Ib 47 to 56 N m 14 Install input shaft pinion gear assembly see Input Shaft Pinion Gear in this section of this manual 15 Coat new o rings with grease align differential shaft splines with differential gear assembly and slide differ ential shaft assemblies onto axle support 16 Install bevel gear case axle case assemblies see Bevel Gear Case Axle Case Assembly in this section of this manual Groundsmaster 4500 D 4700 D Pinion Gear to Ring Gear Engagement The final position of the pinion gear is verified by using the gear contact pattern method as described in the fol PROFILE LAND lowing procedure GEAR TOOTH DEFINITIONS Fig 37 Toe the portion of the tooth surface at the end to wards the center BEA
172. eplace en tire cylinder if barrel is damaged Inspect piston rod and piston for evidence of excessive scoring pitting or wear Replace any damaged parts Groundsmaster 4500 D 4700 D Page 4 117 Rev Assembly 1 Use a complete repair kit when rebuilding the cylin der Put a coating of clean hydraulic oil on all new seals and O rings 2 Install new O rings and PTFE seal to the piston rod and new O ring U cup and wiper to gland 3 Lubricate shaft with clean hydraulic oil Slide gland and piston onto shaft Install and tighten lock nut 4 Put a coating of clean hydraulic oil on all cylinder parts to ease assembly 5 Slide piston rod assembly into cylinder tube 6 Install and tighten gland with spanner wrench Hydraulic System Rev A 2 5 29 5 gt Hydraulic Reservoir N 7 14 5 15 30 to 60 in Ib 3 4 to 6 8 N m 80 to 87 ft lb 108 to 118 N m Figure 100 1 Hydraulic reservoir cap 8 O ring 14 Flat washer 3 used 2 O ring 9 O ring 15 Flange head screw 3 used 3 Dipstick 10 Hydraulic tee fitting 16 Tank strainer 4 Air breather 11 O ring 17 Clamp 5 Breather adapter 12 O ring 18 O ring 6 Hydraulic tank 13 Tank mount grommet 3 used 19 Filter screen 7 Hydraulic fitting Removal Inspection 1 Park machine on a level surface lower cutting units stop engine engage parking brake and remove key from the ignition switch 2 Read t
173. er between the carrier frame and the lift arm The frame is secured to the lift arm pivot shaft with a lynch pin Fig 19 Figure 20 1 Carrier frame 3 Deck bracket 2 Carrier frames for the center two cutting decks 2 2 Lower hole and 3 have a thrust washer between the carrier frame and the lift arm The frame is secured to the lift arm pivot shaft with a rebound washer and cap screw Fig 19 3 Carrier frames for the rear two cutting decks 6 and 7 on the GM4700 D have a compression spring and thrust washer between the carrier frame and the lift arm The frame is secured to the lift arm pivot shaft with a flat washer and lock nut Fig 19 CUTTING DECK LOCATIONS Figure 21 2 D 5 Groundsmaster 4500 D 4700 D Page 8 21 Cutting Units Rev B Rev D This is intentionally blank Cutting Units Rev B Page 8 22 Groundsmaster 4500 D 4700 D Rev D Chapter 9 TORO Electrical Diagrams Table of Contents ELECTRICAL SCHEMATICS 3 Groundsmaster 4500 D Serial Number Below 220999999 3 Serial Number From 230000001 to 260000600 4 Serial Number Above 260000600 5 Groundsmaster 4700 D Serial Number Below 220999999 6 Serial Number From 230000001 to 260000600 7 Serial Number Above 260000600 8 CIRCUIT DIAGRAMS Glow Plug Circuit Diagram 9 Crank Circuit Diagram 10 Run
174. erator s Manual 20 Bleed fuel system see Traction Unit Operator s Manual 21 Operate hydraulic controls to properly fill hydraulic system see Charge Hydraulic System in Chapter 4 Hydraulic Systems Kubota Diesel Engine Rev A 8 Pump Adapter Plate 17 to 21 ft lb 23 to 28 3 17 to 21 ft lb 23 to 28 N m 35 to 43 48 to 58 N m Figure 18 1 Engine 5 Plate pin 2 used 9 Spring center coupling 2 Lock washer 6 Dowel 2 used 10 Lock washer 3 Cap screw 4 used 7 Coupling spacer 11 Cap screw 6 used 4 Pump adapter plate 8 Shoulder bolt 2 used 12 Cap screw 9 used Kubota Diesel Engine Rev A Page 3 16 Groundsmaster 4500 D 4700 D Disassembly 1 Hydraulic pump assembly needs to be removed from engine before coupling can be serviced see Pump sembly in Chapter 4 Hydraulic Systems 2 Remove pump adapter plate spring center coupling and coupling spacer from engine using Figure 18 as a guide Assembly 1 Position coupling spacer to engine and align mount ing holes Usetwo shoulder bolts and lockwashers in the positions shown in Figure 19 to secure the spacer to the half threaded holes in engine flywheel Torque shoulder bolts from 17 to 21 ft lb 23 to 28 N m 2 Install four cap screws and lockwashers to coupling spacer and flywheel Torque cap screws from 17 to 21 ft lb 23 to 28 3 Place
175. es see Bevel Gear Case Axle Case Assembly in this section of this manual IMPORTANT Donotinterchange right and left dif ferential shafts assemblies 2 Mark and pull the differential shaft assemblies from the axle support 3 Remove input shaft pinion gear assembly shims and O ring from the axle support Fig 30 4 Remove the axle support case screws Separate the axle support halves and remove the O ring 5 Remove the differential gear assembly bearings and adjusting shims from the axle case 6 Drive the spring pin from the differential case with a punch and hammer Discard the spring pin Fig 31 NOTE Mark and arrange all components so they can be reassembled in their original position 7 Remove the differential pinion shaft pinion gears and pinion washers Remove the differential side gears and side gear shims Remove the ring gear only if it will be replaced Fig 32 NOTE Replacement ring gears are only available in matched ring and pinion sets Axles Planetaries and Brakes Rev B Page 6 22 35 to 41 ft lb 47 to 56 N m 35 to 41 ft lb 47 to 56 N m Figure 30 Gear Case 5 Case screw Pinion Gear 6 Differential gear Axle support left Axle support right 7 O ring Figure 31 1 Differential case 2 Spring pin 22 to 25 ft lb 30 to 34 N m Thread locking Compound Figure 32 1 Differential pinion shaft 5 Side gear shims 2 Pini
176. evel gear case axle case assemblies IMPORTANT Do not interchange right and left bevel gear case axle case assemblies 3 Remove the axle cover mounting screws Remove the axle cover from the axle case as an assembly Fig 12 4 Remove the axle case support mounting screws the axle case support and the support shims Fig 13 Axles Planetaries and Brakes Rev B Page 6 14 35 to 41 ft lb 47 to 56 N m 35 to 41 ft lb 47 to 56 N m Figure 11 1 screw 5 2 Lock nut case assembly 3 Lock washer 6 O ring 4 Axle support 17 to 20 ft lb 23 to 27 N m Figure 12 3 Mounting screw 4 O ring 1 Axle case 2 Axle cover assembly Thread locking Compound 4 57 to 67 ft Ib 77 to 91 N m Figure 13 3 Mounting screw 4 Support shim 1 Axle case 2 Axle case support Groundsmaster 4500 D 4700 D 5 Remove the knuckle pin mounting screws and the knuckle pin Remove the gasket and any remaining gas ket material from either mating surface Fig 14 A 2 6 6 While holding the bevel gear case tap upper end 17 to 20 ft Ib 23 to 27 N m of the bevel gear shaft out of the upper bearing and up per bevel gear Thread locking 7 Pull the bevel gear case from the axle case and re Compound move the upper bevel gear and collar from the gear case 8 Remove the axle case cover screws cover and the O ring from the axle c
177. f i dd m do _ 10s C Y 571 di sq q 3siva 0 0 5 HINDI 0810 0022 jig 4 Q103INVW 1081 02 ASISSV 0112 81 ONY NMOG 33M0d Groundsmaster 4500 D 4700 D Hydraulic Flow Diagrams uonong Jo euinssejd eanssaJg GMP 006 IND Q 00Zv Q 00St 1e1seuispunoJt MES Q104INVA 1041039 OMZ OM ONV NMOG 33M0d JAWA 1081 02 83MOV 1411 Q104INVH 1081 02 9330 SAWA 1041 02 8331 5 11 E n E H
178. f full of new hydraulic oil Hydraulic System Rev A 2 Ga 0 This page is intentionally blank Hydraulic System Rev A Page 4 88 Groundsmaster 4500 D 4700 D Cutting Deck Motor The hydraulic motors used on all cutting decks are the same Removal 1 Park machine on a level surface lower cutting units stop engine engage parking brake and remove key from the ignition switch 2 Read the General Precautions for Removing and Installing Hydraulic System Components at the begin ning of the Service and Repairs section of this chapter NOTE Before disconnecting the hydraulic lines clean Figure 77 the port area of the deck motor 1 Socket head screw 2 Hydraulic motor 3 Disconnect hydraulic lines from deck motor Put caps or plugs on fittings and hoses to prevent contami nation Tag hydraulic lines for proper reassembly 4 Remove two socket head screws that secure hy draulic motor to cutting deck Fig 77 5 gt 5 Lift hydraulic motor from cutting deck Installation 1 Align splines on motor shaft and spindle shaft Posi tion hydraulic motor to the cutting unit 2 Secure motor to cutting deck with two socket head screws Fig 77 3 Remove caps or plugs from hydraulic fittings and hoses Connect hydraulic hoses to deck motor 4 After assembly is completed verify that hydraulic hoses and fittings are not contacted by moving compo nents
179. f the black wire The solenoid should engage making an audible click 5 Remove positive voltage from the pin of the white wire The solenoid should stay engaged 6 Remove positive voltage from the pin of the red wire The solenoid should release 7 Reinstall solenoid if removed from engine 8 Reconnect the harness wire connector to the sole noid Electrical System Rev A Page 5 18 Figure 27 1 Engine run solenoid 3 Injection pump 2 Solenoid connector Figure 28 1 Engine run solenoid 2 Red wire hold coil 3 White wire pull coil 4 Black wire common Groundsmaster 4500 D 4700 D Fuel Pump The fuel pump is attached to the frame near the fuel pre filter Fig 29 IMPORTANT When testing fuel pump make sure that pump is not operated without fuel Fuel Pump Capacity Test 1 Park machine on level surface lower cutting units stop engine and engage parking brake 2 Disconnect electrical connector from the engine run solenoid to prevent the engine from firing 3 Disconnectfuel pump discharge hose from the water separator 4 Make sure fuel hoses attached to the fuel pump are free of obstructions 5 Place disconnected pump discharge hose into a large graduated cylinder sufficient enough to collect 1 quart 0 95 liter 6 Collect fuel in the graduated cylinder by turning igni tion switch ON Allow pum
180. f the hydraulic lines and cartridge valves at each port location For solenoid and control valve service procedures see Hydraulic Control Manifold Service 2 Wheel 4 Wheel Drive Control in this section Refer to Figure 70 for car tridge valve installation torque Groundsmaster 4500 D 4700 D Zero leak plug 6 Page 4 79 9 Plug SAE 4 10 Zero leak plug 4 11 Expanding plug not serviced NOTE The Groundsmaster 4500 D deck drive man ifold uses several zero leak plugs These plugs have a tapered sealing surface on the plug head that is de signed to resist vibration induced plug loosening The zero leak plugs also have an o ring as a secondary seal If zero leak plug removal is necessary lightly rap the plug head using a pin punch and hammer before using an allen wrench to remove the plug the impact will allow plug removal with less chance of damage to the socket head of the plug Hydraulic System Rev A Hydraulic System Hydraulic Control Manifold Deck Drive GM 4700 D Figure 71 1 Hydraulic manifold decks 2 3 5 amp 7 7 90 hydraulic fitting 13 O ring 2 Hydraulic adapter 8 Quick fitting 14 O ring 3 90 hydraulic fitting 9 Dust cap 15 O ring 4 90 hydraulic fitting 10 O ring 16 Cap screw 5 Hydraulic manifold decks 1 4 amp 6 11 O ring 17 Flange nut 6 Straight hydraulic fitting 12 O ring 18 Plug Removal 3 Disconnect hydraulic lines from manifold and put NO
181. falling and being damaged 10 Install hydraulic pump assembly to engine see Pump Assembly in Chapter 4 Hydraulic Systems 11 Connect two wires to neutral switch on traction pump 12 Connect wires and or electrical connections to the following electrical components A The temperature sender and alternator Fig 12 B The engine run solenoid Fig 13 C The high temperature shutdown switch and glow plug connection Fig 14 D Battery frame and wire harness ground to the engine block Fig 15 E The electric starter Fig 15 F Fusible link harness connector and low oil pres sure switch located on alternator side of engine near electric starter Fig 16 Groundsmaster 4500 D 4700 D Page 3 15 13 Install air cleaner assembly to the engine see Air Cleaner Installation 14 Install exhaust system to machine see Muffler Installation 15 Connect coolant hoses to the radiator Make sure ra diator drain is shut Fill radiator and reservoir with cool ant 16 Check position of wires fuel lines hydraulic hoses and cables for proper clearance with rotating high tem perature and moving components 17 Position battery to machine Connect positive bat tery cable first and then negative battery cable Secure battery to machine with cover and strap 18 Check and adjust engine oil as needed see Traction Unit Operator s Manual 19 Check and adjust hydraulic oil as needed see Trac tion Unit Op
182. fication of components Example P1 is the gear pump connection port See Hydraulic Schematics to identify the function of the hydraulic lines and cartridge valves at each port 1 Read the General Precautions for Removing and Installing Hydraulic System Components at the begin ning of the Service and Repairs section of this chapter 2 Disconnect electrical connector from the solenoid valve Hydraulic System Rev A Page 4 78 caps or plugs on open hydraulic lines and fittings Label disconnected hydraulic lines for proper reassembly 4 Remove hydraulic manifold from the frame using Figure 69 as guide Installation 1 Install hydraulic manifold to the frame using Figure 69 as guide 2 Remove caps and plugs from fittings and hoses Properly connect hydraulic lines to manifold 3 Connect electrical connector to the solenoid valve Groundsmaster 4500 D 4700 D Hydraulic Control Manifold Service Deck Drive GM 4500 D 25 ft lb 33 9 N m gt 2 EN e 165 in Ib 18 6 N m 20 ft Ib a 271 N m 25 ft lb 4 lt 33 9 N m 8 198 in Ib 22 4 N m Figure 70 1 Manifold body 5 Relief valve RV8 2 Solenoid valve PRV2 6 Pilot piston 3 Solenoid coil 7 Nut 4 8 Logic cartridge LC1 NOTE The ports on the manifold are marked for easy identification of components Example P1 is the gear pump connection port See Hydraulic Schematics to identify the function o
183. for Removing and Installing Hydraulic System Components 52 Check Hydraulic Lines and Hoses 52 Groundsmaster 4500 D 4700 D Page 4 1 Chapter 4 Hydraulic System Flush Hydraulic System 53 Charge Hydraulic System 54 Gear PUMP ness Rene eden 56 Gear Pump 58 Piston Traction 62 Piston Traction Pump Service 64 Piston Pump Manual Servo Control Assembly 68 Hydraulic Control Manifolds 2 Wheel 4 Wheel Drive Filtration and Charge Power Down and Traction Assist 70 Hydraulic Control Manifold Service 2 Wheel 4 Wheel Drive Control 72 Hydraulic Control Manifold Service Filtration and Charge 74 Hydraulic Control Manifold Service Power Down and Traction Assist GM 4500 D 75 Hydraulic Control Manifold Service Power Down and Traction Assist GM 4700 D 76 Hydraulic Control Manifold Deck Drive GM 4500 D 78 Hydraulic Control Manifold Service Deck Drive GM 4500 0 79 Hydraulic Control Manifold Deck Drive GM 4700 D 80 Hydraulic Control Manifold Service Deck Drive GM 4700 D 81 Rear Axle Motor 82 Front Wheel Motors 84 Rear Axle
184. for approximately 10 minutes Make sure the hydraulic tank is full 2 machine on a level surface with the cutting units lowered and off Make sure engine is off and the parking brake is engaged Prevent personal injury and or damage to equip ment Read all WARNINGS CAUTIONS and Pre cautions for Hydraulic Testing at the beginning of this section 3 Raise seat to gain access to lift circuit test port lo cated on the front end of the gear pump Fig 39 Con nect a 5000 PSI gauge onto lift circuit test port Route gauge hose to allow seat to be safely lowered 4 Sit on seat and start the engine Move throttle to full speed 2800 50 RPM 5 While sitting on the seat pull lift lever back to raise the cutting units Momentarily hold the lever with the lift cylinder at full extension while looking at the gauge GAUGE READING TO BE 2000 to 2600 PSI 6 Stop the engine 7 If specification is not met adjust or clean relief valve located on the side of power down and traction assist control manifold under operator seat Fig 40 A If pressure is too high remove cap on relief valve Fig 41 Adjust relief valve by rotating adjustment Socket counterclockwise decreasing relief pres sure B If pressure is too low check for restriction in gear pump intake line Check the lift cylinders for internal leakage If pump intake line is not restricted and lift cylinders are not leaking remove cap on relief valve
185. g a hydraulic test Engine speed can affect the accuracy of the tester readings Check actual speed of the pump when performing flow testing 4 The inlet and the outlet hoses must be properly con nected and not reversed tester with pressure and flow capabilities to prevent damage to the hydraulic tester or components 5 When using hydraulic tester with pressure and flow capabilities open load valve completely in the tester to minimize the possibility of damaging components 6 Install fittings finger tight and far enough to make sure that they are not cross threaded before tightening them with a wrench 7 Position tester hoses to prevent rotating machine parts from contacting and damaging the hoses or tester 8 Check oil level in the hydraulic reservoir After con necting test equipment make sure tank is full 9 Check control linkages for improper adjustment binding or broken parts 10 All hydraulic tests should be made with the hydraulic oil at normal operating temperature 11 Before returning machine to use make sure that hy draulic reservoir has correct fluid level Hydraulic System Rev A 2 FE 0 TEST 1 Traction Circuit Charge Pressure Using Pressure Gauge CHARGE CIRCUIT amp 4WD 2WD CONTROL MANIFOLD TO TRACTI
186. g rod seal back up ring and dust seal with clean hydraulic oil A Install Uni ring and O ring to the piston B Install dust seal O ring back up ring and dust seal to the head IMPORTANT Do not clamp vise jaws against the shaft surface Protect shaft surface before mount ing in a vice 3 Mountshaft securely in a vise by clamping on the cle vis of the shaft A Coat shaft with clean hydraulic oil B If removed install collar onto shaft C Slide head and piston onto the shaft Secure pis ton to shaft with locknut 4 Lubricate head and piston with hydraulic oil Slide shaft assembly carefully into cylinder barrel 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 lift cylinder into a vise Install collar with a spanner wrench Hydraulic System Rev A 2 5 29 5 gt Steering Cylinder C 4859 SEQ V 0 57 100 to 125 ft Ib 135 to 169 N m Figure 98 2 o 5 o 6 25252 Eas 52 50 gt 5529545 a KNOTS rrrrr oo c c 5 7 Ona greece Oa00M o NM ogo 5 gt Deeces 0 0 5 0 5 4 1 2 3 4 5 Page 4 114 Groundsmaster 4500 D 4700 D Hydraulic System Rev A R
187. g nut 11 Flange head screw 17 O ring 6 Retaining ring 12 Hex plug 18 RH brake assembly Planetary Wheel Drive Removal 1 Park machine on a level surface lower cutting units A CAUTION stop engine engage parking brake and remove key When changing attachments tires or perform from the ignition switch ing other service use correct blocks hoists and jacks Make sure machine is parked on a solid level surface such as a concrete floor Prior to raising machine remove any attach 2 Drain oil from planetary wheel drive brake assembly see Traction Unit Operator s Manual ments that may interfere with the safe and proper raising of the machine Always chock or block wheels Use jack stands or solid wood blocks to support raised machine If the ma chine is not properly supported by blocks or jack stands the machine may move or fall which may result in personal injury Axles Planetaries and Brakes Rev B Page 6 8 Groundsmaster 4500 D 4700 D 3 Chock rear wheels and jack up front of machine see Jacking Instructions in Chapter 1 Safety Support ma chine with jack stands or solid wood blocks 4 Remove front wheel assembly 5 Remove flange head screws that secure brake as sembly to planetary assembly see Brake Assembly 6 Support planetary assembly to preventit from falling Loosen and remove flange head screws that secure planetary assembly to frame Remove planetary as sembly from machine P
188. gin ning of the Service and Repairs section of this chapter 2 If 2WD 4WD control manifold is being removed dis connect electrical connector from the solenoid valve 3 Disconnect hydraulic lines from manifold being re moved and put caps or plugs on open hydraulic lines and fittings Label disconnected hydraulic lines for prop er reassembly 4 Remove hydraulic manifold from the frame using Figure 64 as guide Groundsmaster 4500 D 4700 D Page 4 71 Installation 1 Install hydraulic manifold to the frame using Figure 64 as guide 2 Remove caps and plugs from fittings and hoses Properly connect hydraulic lines to manifold 3 If2WD AWD control manifold was removed connect electrical connector to the solenoid valve 4 Fill hydraulic reservoir with hydraulic fluid as re quired see Traction Unit Operator s Manual Hydraulic System Rev A 2 5 29 5 gt Hydraulic Control Manifold Service 2 Wheel 4 Wheel Drive Control 80 to 90 ft Ib 108 to 122 N m bs 0 6 IO Qo 9 2 60 to 70 ft lb gt 10 81 to 95 N m 35 to 40 ft Ib 47 to 54 N m 4 to 6 23 lt lt LS 9 OF y 80 to 90 ft Ib x 25 108 to 122 N m 9 PLUG TORQUE SAE 2 41 TO 49 4 6 to 5 6 N m SAE 4 6 to 10 ft lb 8 to 13 N m SAE 5 10 to 15 ft Ib 13 to 20 N m SAE 6 15 to 20 ft Ib 20 to 27 N m 25 to 30 ft Ib 34 to 41 N m 5 to 8 N m SAE
189. he bearing block with the pressure seal side down Careful ly install shaft into front flange 9 Lubricate the idler gear shaft with clean hydraulic oil Install idler gear shaft into the remaining position in the bearing block Apply light coating of clean hydraulic oil to gear faces 10 Noting the open and closed sides of the front bearing block install rear bearing block with pressure seal side up 11 Apply a light coating of petroleum jelly to new o rings and o ring grooves in the housing Install new o rings to the housing 12 Install locating dowel pins in housing Align scribe marks on the housing and front flange IMPORTANT Do not dislodge pressure seals from bearing blocks when installing housing to assem bly 13 Gently slide the housing onto the assembly Firm hand pressure should be sufficient to engage the dowel pins 14 Check to make sure that the surface of the rear bear ing block is slightly below the face of the housing If the bearing block is not below the housing check assembly for a shifted pressure seal backup seal or o ring Cor rect before proceeding 15 Apply alight coating of petroleum jelly to the exposed side of the rear cover 16 Place rear cover on assembly using marker or scribe mark for proper location Firm hand pressure should be sufficient to engage the dowel pins 17 Install the four cap screws and hand tighten IMPORTANT Avoid using excessive clamping pressure onthe mot
190. he General Precautions for Removing and Installing Hydraulic System Components at the begin ning of the Service and Repairs section of this chapter 3 Drain reservoir into a suitable container see Trac tion Unit Operator s Manual 4 Disconnect hydraulic hoses from reservoir 5 Remove hydraulic reservoir using Figure 100 as a guide Hydraulic System Rev A Page 4 118 1 Clean hydraulic reservoir and suction strainer with solvent 2 Inspect for leaks cracks or other damage Installation 1 Install reservoir using Figure 100 as a guide Torque mounting cap screws 15 from 30 to 60 in Ib 3 4 to 6 8 N m 2 Using a wrench tighten strainer into port to a torque from 80 to 87 ft lb 108 to 118 N m 3 Reconnect hydraulic hoses 4 Fill reservoir with hydraulic fluid as required see Traction Unit Operator s Manual Groundsmaster 4500 D 4700 D Hydraulic Cooler Removal The radiator and oil cooler may be hot To avoid possible burns allow the engine and cooling systems to cool before working on the oil cooler 1 Park machine on a level surface lower cutting units stop engine engage parking brake and remove key from the ignition switch 2 Read the General Precautions for Removing and Installing Hydraulic System Components at the begin ning of the Service and Repairs section of this chapter 3 Remove oil cooler using Figures 101 102 and 103 as guides Inspection 1 Back flu
191. he cutting units lowered and off Make sure engine is off and the parking brake is engaged Prevent personal injury and or damage to equip ment Read all WARNINGS CAUTIONS and Pre cautions for Hydraulic Testing at the beginning of this section NOTE The deck motors are connected in series To isolate a faulty motor all motors in the circuit may have to be tested by starting with the first motor in the circuit see Hydraulic Schematic 3 Disconnect pressure return hose from the motor to be tested Fig 35 Install flow tester in series with the motor and the disconnected return hose Make sure the flow control valve on tester is fully open Fig 36 4 Disconnect the motor case drain hose small diame ter hose where it connects to bulkhead fitting at the frame rail not at the motor Put a steel cap on the bulk head fitting leave the case drain hose open Fig 36 Cutting unit blades will rotate when lowered with PTO switch in ON position Keep away from cut ting units during test to prevent personal injury from rotating blades Do not stand in front of the machine Groundsmaster 4500 D 4700 D Page 4 37 5 Siton seat and start the engine Move throttle to full speed 2800 50 RPM Move PTO switch to ON 6 While watching pressure gauge slowly close flow control valve on tester until a pressure of 1200 PSI is ob tained NOTE Use a graduated container special tool TOR4077 to measure case drain
192. he forward and reverse directions The wheels off the ground should rotate in the proper direction A If the wheels rotate in the wrong direction stop engine remove lines from bottom of piston traction pump and reverse the connections B If the wheels rotate in the proper direction stop engine 14 Adjust traction pedal to the neutral position see Traction Unit Operator s Manual 15 Check operation ofthe traction interlock switch see Traction Unit Operator s Manual 16 Remove blocks from frame and lower machine Re move chocks from remaining wheels 17 If the piston traction pump or a traction motor was replaced or rebuilt run the machine so all wheels turn slowly for 10 minutes 18 Operate machine by gradually increasing its work load to full over a 10 minute period 19 Stop the machine Check hydraulic reservoir and fill if necessary Check hydraulic components for leaks and tighten any loose connections Groundsmaster 4500 D 4700 D 2 FE 6 0 This page is intentionally blank Groundsmaster 4500 D 4700 D Page 4 55 Hydraulic System Rev A 85 to 95 ft lb 115 to 128 N m Figure 54 1 Flat washer 12 O ring 23 O ring 2 Cap screw 13 90 hydraulic fitting 24 O ring 3 90 hydraulic fitting 14 Suction hose 25 O ring 4 Hydraulic tee fitting 15 Suction hose 26 Gear pump assembly 5 O ring 16 O ring 27 Piston pump assembly 6 Quick fit
193. hined surfaces 1 Remove the seven cap screws from the steering valve assembly 2 Remove end cap geroter spacer geroter drive wear plate seal ring and o rings from housing Fig 89 3 Remove the plug and relief valve Hydraulic System Rev A Page 4 104 4 Slide the spool and sleeve assembly from the hous ing 5 Remove the thrust bearing and bearing races 2 6 Remove the quad seal 7 Use a small blade screwdriver to carefully pry the dust seal from the housing Be careful to not damage the dust seal seat in the housing 8 Remove the pin that holds the spool and sleeve to gether 9 Carefully slide the spool out of the sleeve The cen tering springs and spring retaining ring will stay with the spool as it is removed Groundsmaster 4500 D 4700 D The centering springs are under tension Re move the retaining ring carefully 10 Remove the spring retaining ring and centering springs from the spool Reassembly Check all mating surfaces Replace any parts with scratches or burrs that could cause leakage Wash all metal parts in clean solvent Blow them dry with pressur ized air Do not wipe parts dry with paper towels or cloth Lint in a hydraulic system will cause damage NOTE Always use new seals and o rings when reassembling the steering control unit IMPORTANT During reassembly lubricate the new seals with petroleum jelly Also lubricate machined surfaces and bearings with clean
194. ies Electrolyte Specific Gravity Fully charged 1 265 corrected to 80 F 26 7 C Discharged less than 1 240 Battery Specifications BCI Group Size 24 650 CCA at 0 F 17 8 C Reserve Capacity of 105 minutes at 80 F 26 7 C Dimensions including terminal posts and caps Length 11 inches 27 9 cm Width 6 76 inches 17 2 cm Height 9 2 inches 23 4 cm Removal and Installation Fig 43 See Traction Unit Operator s Manual for battery removal and installation information NOTE Before connecting the negative ground cable connect a digital multimeter set to amps between the negative battery post and the negative ground cable connector The reading should 0 amps If the reading is 0 1 amp or more this indicates a parasitic draw and the unit s electrical system should be tested and re paired Inspection Maintenance and Testing 1 Perform following inspections and maintenance A Replace battery if case is cracked or leaking B Check battery terminal posts for corrosion Use wire brush to clean corrosion from posts IMPORTANT Before cleaning the battery tape or block vent holes to the filler caps and make sure the caps are on tightly C Check for signs of wetness or leakage on the top ofthe battery which might indicate a loose or missing filler cap overcharging loose terminal post or over filling Also check battery case for dirt and oil Clean the battery with a solution of baking soda and
195. ion is controlled by a solenoid valve SV lo cated in the 4WD 2WD control manifold When in transport 2WD the solenoid valve SV is energized and directs charge pressure to shift control valves PD1 and PD2 The shifted valves block hydraulic flow to the rear axle motor in both forward and reverse directions when in transport 2WD 2 A pressure reducing valve PR1 in the 4WD 2WD control manifold lowers pressure to the rear axle motor when the machine is operated in reverse The lower pressure prevents rear tire scuffing and provides added pressure to the front wheels during reverse operation 3 An adjustable relief valve RV5 in the 4WD 2WD control manifold reduces rear axle motor pressure created in down hill dynamic braking conditions To enhance traction control the lift lower circuit is equipped with a counterbalance system An adjustable counterbalance valve RV1 located in the power down andtraction assist control manifold transfers cutting unit weight to the machine to improve traction Additionally the counterbalance system has a secondary relief valve RV2 that provides additional cutting unit weight trans fer when traction circuit pressure increase is sensed by directional valve PD3 located in the power down and traction assist control manifold Hydraulic System Rev A Rev D 2 zg E lt Jo einsse4g
196. is delivered to the two cir cuits through a proportional flow divider The gear pump takes its suction from the hydraulic reservoir Maximum lift lower circuit pressure 1500 PSI is limited by a relief valve in the power down and traction assist control man ifold RV7 Onthe Groundsmaster 4500 D a single lift lever is used to lift and lower the five cutting decks The Groundsmas ter 4700 D has three lift levers to control the cutting decks the center lever is for the five center decks the left lever controls the left rear deck and the right lever controls the right rear deck Pressure to the lift lower control valve can be monitored at a port on the end of the gear pump When the cutting units are in a stationary position flow from the gear pump is by passed through the lift lower control valve power down and traction assist control manifold oil filter and traction charge circuit To raise the center five cutting decks the lift lever on the lift lower control valve is pulled to allow valve shift in the lift lower control valve This valve change allows hy draulic pressure to the rod end of the lift cylinder and causes the shaft to retract raising the cutting units Oil from the piston end of the cylinder flows to the traction charge circuit When the lift lever is released the lift cyl inders are held in position To raise a side cutting unit on the Groundsmaster 4700 D deck 6 or 7 the appropriate outer lift leve
197. itting in the desired position unscrew it by the required amount but no more than one full turn Step 3 7 Hold the fitting in the desired position with a wrench and turn the jam nut with another wrench to the correct Flats From Finger Tight F F F T Step 4 Figure 3 ings instalation Torque 8 Figure 4 Lock Nut D Back up Washer O Ring Figure 5 Size F F F T 4 1 4 in nominal hose or tubing 1 00 0 25 6 3 8 in 1 50 0 25 8 1 2 in 1 50 0 25 10 5 8 1 50 0 25 Figure 6 12 3 4 in 1 50 0 25 16 1 in 1 50 0 25 Hydraulic System Rev 4 4 Groundsmaster 4500 D 4700 D Towing Traction Unit IMPORTANT If towing limits are exceeded severe damage to the piston pump may occur If it becomes necessary to tow or push the machine tow or push in a forward direction only at a speed below 3 mph 4 8 kph and for a distance less than 1 4 mile 0 4 km The piston traction pump is equipped with a by pass valve that needs to be turned 90 for tow ing See Traction Unit Operator s Manual for additional tow ing procedures Figure 7 1 By pass valve location Check Hydraulic Fluid The Groundsmaster 4500 D and 4700 D hydraulic systems are designed to operate on anti wear hydraulic fluid The reservoir holds about 7 5 gallons 28 4 liters of hydraulic fluid Check level of hydraulic fluid daily See Traction
198. l WARNINGS CAUTIONS and Pre cautions for Hydraulic Testing at the beginning of this section 3 Locate gear pump section to be tested P1 or P2 Disconnect appropriate hydraulic hose from 90 hy draulic fitting in gear pump Fig 31 4 Install hydraulic flow meter in series with the discon nected hose and fitting in gear pump section 5 Make sure the flow control valve on the tester is fully open 6 Start engine and move throttle to full speed 2800 50 RPM Do not engage the cutting units IMPORTANT Do not fully restrict oil flow through tester In this test the flow tester is positioned be fore the relief valve Pump damage can occur if the oil flow is fully restricted 7 Watch pressure gauge carefully while slowly closing the flow control valve until 2000 PSI is obtained Verify with a phototac that the engine speed is 2800 50 RPM Groundsmaster 4500 D 4700 D Page 4 33 8 Flow indication should be approximately 11 5 GPM 9 Shut off engine 10 Disconnect flow tester from hydraulic hose and fit ting Reconnect hose to the fitting 11 If flow was less than 11 5 GPM or a pressure of 2000 PSI cannot be obtained check for restriction in the pump intake line including oil filter and oil cooler If line is not restricted remove gear pump and repair or replace as necessary Figure 31 1 Gear pump 2 90 hydraulic fitting 3 Pump section P1 hose 4 Pump section P2 hose Hydraulic Syst
199. l shaft seal 1 and install over drive shaft carefully so that rubber sealing lips are not cut 19 Place 1 3 8 O D sleeve over shaft and press in shaft seal 200 5 08mm below surface of front plate 20 Install plug 7 and o ring 9 into rear adapter plate 21 11 removed install plug 28 with o ring into back plate and torque from 21 to 24 ft Ib 29 to 33 N m 22 Install proportional valve 6 into backplate Torque plug from 21 to 24 ft Ib 29 to 33 N m Groundsmaster 4500 D 4700 D 2 FE 6 0 This page is intentionally blank Groundsmaster 4500 D 4700 D Page 4 61 Hydraulic System Rev A Piston Traction Pump 85 to 95 ft lb 115 to 128 N m LN gt 90 Q EN HE Figure 56 1 Flat washer 14 Suction hose 26 Gear pump assembly 2 Cap screw 15 Suction hose 27 Piston pump assembly 3 90 hydraulic fitting 16 Wire harness 28 Coupler 4 Hydraulic tee fitting 17 Hydraulic hose 29 Cap screw 5 O ring 18 Hydraulic hose 30 Washer 6 Quick fitting 19 Hydraulic hose 31 O ring 7 Dust 20 Hydraulic hose 32 Spacer 8 90 hydraulic fitting 21 O ring 33 O ring 9 Clamp 22 Hydraulic fitting 34 O ring 10 90 hydraulic fitting 23 O ring 35 O ring 11 Hydraulic fitting 24 O ring 36 O ring 12 Hydraulic tee fitting 25 O ring 37 O ring 13 90 hydraulic fitting Hydraulic System Rev A Page 4 62 Groundsmaster 4500 D 4700 D
200. lanetary Wheel Drive Installation 6 2 1 Brake housing 3 Drain plug 1 Position planetary assembly to machine Install 2 Check plug flange head screws that secure planetary assembly Torque screws from 75 to 85 ft Ib 101 to 115 N m 2 Install brake assembly to planetary see Brake As sembly Failure to maintain proper wheel lug nut torque could result in failure or loss of wheel and may result in personal injury 3 Install wheel assembly Torque lug nuts from 85 to 100 ft Ib 115 to 135 N m 4 Lower machine from jack stands 5 Make sure drain plug is installed in bottom of brake assembly Fig 6 Fill planetary wheel drive brake as sembly with SAE 85W 140 gear lube see Traction Unit Operator s Manual Capacity is approximately 16 oz 47 1 per wheel and Brakes 5 o c S 9 x 6 Check and adjust brake cables for proper brake eration see Traction Unit Operator s Manual Groundsmaster 4500 D 4700 D Page 6 9 Axles Planetaries and Brakes Rev B Planetary Wheel Drive Service 4 ad 28 S N 118 144 in Ib A 13 3 to 16 3 N m Figure 7 1 Spindle 11 Bearing cup 21 Thrust plug 2 Boot seal 12 Bearing cone 22 Thrust washer 3 Oil seal 13 O ring 23 Retaining ring 4 Bearing cone 14 Bearing shim 24 Primary gear 5 Bearing cup 15 Snap ring 25 Drive shaft 6 Wheel stud 16 Ring gear 26 Primary carrier 7 Socket hea
201. le plate should be aligned to front of deck 2 Install cutting blade anti scalp cup and bolt see Cutting Unit Operator s Manual Tighten blade bolt from 85 to 110 ft lb 115 to 149 N m 3 Position O ring to top of spindle housing Install hy draulic motor to the cutting unit with two socket head screws 2 5 Groundsmaster 4500 D 4700 D Page 8 9 Cutting Units Rev B Blade Spindle Service Disassembly 1 Remove blade spindle from cutting deck see Blade Spindle Removal 2 Loosen and remove spindle nut from top of spindle shaft 3 Press the spindle shaft out of the spindle housing us ing an arbor press The shaft spacer remains on the spindle shaft as the shaft is being removed 4 Remove seals from spindle housing 5 Allow the bearings inside spacer and spacer ring to drop out of the spindle housing 6 Using a punch and hammer drive both of the bearing cups out of the spindle housing Also remove the large spacer from the housing 7 The large snap ring can remain inside the spindle housing Removal of large snap ring is very difficult Assembly IMPORTANT If new bearings will be installed into a used spindle housing that has the original large snap ring installed discard the snap ring that comes with the new bearings because it is not nec essary to replace the original snap ring If a spindle housing is being replaced new bearings with their matched spacer set and
202. ler tube 3 Inner seal tool 2 Inner seal RERE R D Figure 14 4 5 1001 1 Roller tube 2 Inner seal 3 Bearing Groundsmaster 4500 D 4700 D 3 From the roller tube end with only the inner seal installed carefully install the roller shaft into the roller tube Make sure that seals are not damaged as shaft is installed 4 Install new bearing and outer seals into second end of roller tube A Position a second new bearing to roller shaft and tube Position washer see Special Tools on bearing to allow pressing on both inner and outer bearing races simultaneously B Use washer and bearing outer seal tool see Special Tools with a soft face hammer to fully seat bearing Fig 16 After bearing installation make sure that shaft freely rotates and that no binding is detected If necessary lightly tap bearing and or shaft ends to align shaft and bearings Remove washer from roller C Apply a small amount of grease around the lip of both outer seals 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 and soft face hammer to lightly seat seal Fig 17 Make sure that shaft and bearings still freely ro tate after seal installation E Using the same process install second outer
203. lid object is struck by the cutting deck the blade plane of the deck should be inspected Blade Plane Inspection 1 Remove cutting unit to be inspected see Cutting Unit Operator s Manual 2 Use hoist or minimum of two people and place cut ting deck on flat table 3 Mark one end of blade with paint pen or marker Use this end of blade to check all heights 4 Position cutting edge of marked end of blade at 12 o clock straight ahead in direction of mowing Measure height from table to cutting edge of blade 5 Rotate marked end of blade to the 3 and 9 o clock positions and measure heights 6 Compare 12 o clock measured height to the height of cut setting It should be within 090 inch 2 3 mm The 3 and 9 o clock heights should be 150 090 inch 3 8 2 3 mm higher than the 12 o clock setting and within 090 inch 2 3 mm of each other If any of these measurements are not within specification proceed to Adjusting Blade Plane Adjusting Blade Plane Start with front bracket adjustment and change one height of cut bracket at a time 1 Remove height of cut bracket front left or right from deck frame 2 Position 060 inch 1 5 mm and or 030 inch 8 mm shims between the deck frame and bracket to achieve the desired blade height setting 3 Install height of cut bracket to deck frame with re maining shims assembled below the height of cut bracket NOTE Socket head bolt and spacer for f
204. ling Hydraulic System Components at the begin ning of the Service and Repairs section of this chapter NOTE To ease reassembly tag the hydraulic hoses to show their correct position on the lift cylinder Also clean hydraulic fittings and hose ends prior to disconnecting the hoses 3 Disconnect hydraulic hoses from lift cylinder 4 Remove lock nuts 9 that secure link assembly 5 Remove rear link 8 from link assembly Pull link assem bly from support frame lift links 4 and cylinder shaft clevis which will free lift cylinder from lift arm Locate and remove plastic rollers 7 positioned on both sides of cyl inder clevis 5 Remove one retaining ring that secures the cylinder pin 2 to the support frame Pull pin from frame and cyl inder barrel clevis 6 Remove lift cylinder from machine Installation Fig 95 1 Position cylinder barrel clevis to support frame and insert cylinder pin 2 into frame and clevis Secure pin with retaining ring 2 Position plastic rollers 7 to cylinder shaft clevis In sert link assembly 5 through support frame lift links 4 plastic rollers and cylinder shaft clevis Install rear link to link assembly and secure assembly with lock nuts 3 Attach hydraulic hoses to lift cylinder 4 Fill reservoir with hydraulic fluid as required see Traction Unit Operator s Manual 5 After assembly is completed operate lift cylinder to verify that hydraulic hoses and fittings are
205. ll front adapter plate 23 in place on front body 10 Check positioning marks for correct orientation 9 Install middle body 19 onto front adapter plate 23 Place wear plate 12 into the gear pocket with the pres sure seal and backup gasket against the front adapter plate Hydraulic System Rev A Page 4 60 10 Install key 17 in slot of drive gear shaft Dip slip fit gear 18 inclean hydraulic oil and slide on shaft and into gear pocket of middle body 19 Check key for proper alignment 11 Dip idler gear 21 in clean hydraulic oil and install in gear pocket of middle body 12 Install rear adapter plate 24 in place on middle body 19 Check positioning mark on all sections of pump 13 Position rear body 26 onto rear adapter plate 24 Place wear plate 12 into the gear pocket with the pres sure seal and backup gasket against the rear adapter plate 14 Install key 22 in slot of drive gear shaft Dip slip fit gear 20 in clean hydraulic oil and slide on shaft and into gear pocket of rear body 26 Check key for proper alignment 15 Dip rear idler gear 25 in clean hydraulic oil and install in gear pocket of rear body 16 Position backplate 27 over shafts until dowel pins in body are engaged 17 pump components with cap screws 3 Torque cap screws evenly in a crisscross pattern from 25 to 28 ft lb 34 to 38 N m 18 Place washer 2 over drive shaft into housing Liber ally oi
206. ll lower bearing and seal into bottom of spindle housing Note The bottom seal must have the lip facing out down Fig 7 6 Slide spacer ring and inside spacer into spindle housing then install upper bearing and seal into top of housing Note The upper seal must have the lip facing out up Fig 7 7 Inspect the spindle shaft to make sure it is free of burrs or nicks that could possibly damage the seals Lu bricate the shaft with grease 8 Install spindle spacer onto shaft Carefully slide spindle shaft through spindle housing The bottom seal and spindle spacer fit together when the spindle is installed fully 9 Thread spindle nut onto shaft and tighten nut from Figure 7 130 to 160 ft lb 177 to 216 N m 1 Bottom seal installation 2 Upper seal installation 10 Install spindle plug to top of spindle housing Attach a hand pump grease gun to either grease fitting and fill housing cavity with grease until grease starts to come out of lower seal Note Pneumatic grease guns can produce air pockets when filling large cavities 11 Install blade spindle to cutting deck see Blade Spindle Installation 2 5 Groundsmaster 4500 D 4700 D Page 8 11 Cutting Units Rev B Rear Roller Three types of rear rollers have been used on the Groundsmaster 4500 D and 4700 D One roller design has sealed bearings with no grease fittings on the roller shaft The second design has grease fitti
207. ll the two new seal sub assemblies 37 into the servo piston cavity of pump housing 19 4 Screw the cover plate 10 onto the servo piston as sembly 7 Install new cover plate gasket 33 in place on pump housing Install servo piston assembly 7 and cover plate 10 into servo piston bore in right side of housing Fig 61 Retain cover plate with four washers 31 and socket head screws 5 Torque screws from 40 to 48 in Ib 4 5 to 5 4 N m To obtain neutral centering the servo piston assembly is required Measure in from the left side and set servo piston 500 12 7 mm from surface of housing servo bore as shown in Figure 61 NOTE Re adjustment may be required for neutral at unit start up Hydraulic System Rev A Page 4 66 Figure 60 1 Piston assemblies 4 Piston block 2 Spider 5 Retainer 3 Spider pivot 500 inch 12 7 mm Left Side Front flange Drive shaft end of pump Adjust to center piston Install servo piston in this direction Figure 61 5 Install new seal washer 4 washer 29 and jam nut 1 to servo piston bolt Holding servo piston bolt with hex key wrench torque jam from 150 to 160 in Ib 17 to 18 N m Check the centering of servo piston assem bly 7 Install new cover plate gasket 33 and cover plate 9 to open side of servo piston and retain with four washers 31 and socket head screws 5 Torque screws from 40 to 48 in Ib 4 5 to 5 4 N m 6 Press do
208. low is routed to the oil filter and then to the traction charge circuit Figure 9 LIFT LOWER CONTROL VALVE POWER DOWN AND TRACTION ASSIST 2200 CONTROL MANIFOLD TH PSI 7 GM 4700 D LOWER DECK 6 SHOWN amp a gt FROM TRACTION CIRCUIT Figure 10 Groundsmaster 4500 D 4700 D Page 4 11 Hydraulic System Rev A 2 FE 6 uonong Jo lt nss iqg eanssaJg BUOM umoys q oosr suun siey 00 00 1 lt Q103INVW 1081407 ONY NOllVdlllJ 2a gt 31002 110 lt 154 08
209. lug until there is no end play in the valve spool with input shaft held stationary Secure plug in place with set screw 24 Torque set screw from 17 to 26 in Ib 2 to N m Disassembly Neutral Switch 1 Loosen 8 17 in adapter and remove neutral switch from adapter 2 Remove adapter from control housing 3 Remove pin ball and o rings 11 amp 16 from adapt er Reassembly Neutral Switch 1 Install new o ring 11 onto adapter and new o ring 16 onto pin 2 Install ball and pin into adapter Lubricate with petro leum jelly to hold in place during installation 3 Install adapter into control housing Torque from 44 to 52 ft Ib 60 to 70 N m 4 Apply Loctite 2222 or equivalentto threads of neutral switch and install switch into adapter The adjustment procedure for the switch are as follows A Install switch while moving link back and forth until detent action is detected Back out the switch until the detent action is very slight B Attach leads from a test light to the switch ter minals Note A multimeter could be used instead of a test light C Move the link out of the detent position The test light will go on Screw in the switch until the light goes off Mark this as position A Fig 63 Move the link to the detent position and the test light should come back on D Leaving the link in the detent position the light will remain on Screw in the switch un
210. main in cage move freely and setting at the dimension shown in Figure 59 bearing removal is not required Flange end of housing Numbered end 070 inch 1 78 mm Figure 59 Hydraulic System Rev A 2 FE Ga Oo 3 Inspect camplate assembly A The finish on the piston shoe surfaces ofthe cam plate 11 should show no signs of scoring B Inspect camplate 11 bushing surface for wear Also inspect surface for coating transfer from bush ing 4 Inspect bushing 44 for contamination embedment within coating of bushing surface coming in contact with camplate 11 5 Inspect rotating kit Fig 60 A The pistons should move freely in the rotating kit piston block bore If they are sticky in the bore ex amine the bore for scoring or contamination B Examine the O D of the pistons for finish condi tion They should not show wear or deep scratches Inspect the shoes for a snug fit on the ball end of the pistons and a flat smooth surface that comes in con tact with the camplate Do not lap piston shoes C Examine the spider for wear in the pivot area D Examine the spider pivot to insure smoothness and no signs of wear Reassembly 1 All parts should be cleaned and internal pump parts lubricated with clean hydraulic oil before reassembly 2 If necessary press new bearing into pump housing to dimension shown in Figure 59 with the numbered end of bearing outward 3 Insta
211. me and cylinder barrel clevis 6 Remove lift cylinder from machine Installation Fig 93 1 Position cylinder barrel clevis to frame and insert inder pin 8 with one retaining ring installed through the frame and cylinder clevis Secure pin with second re taining ring 2 Insertcylinder pin 2 through the lift arm and cylinder shaft clevis Secure pin to lift arm with flange head screw and flange nut 3 Attach hydraulic hoses to lift cylinder 4 Fill reservoir with hydraulic fluid as required see Traction Unit Operator s Manual 5 After assembly is completed operate lift cylinder to verify that hydraulic hoses and fittings are not contacted by anything Groundsmaster 4500 D 4700 D Page 4 109 gt EN VY CUTTING DECK LOCATIONS Figure 94 5 i gt Hydraulic System Rev Lift Cylinders Decks 6 and 7 4700 D Figure 95 1 Retaining ring 7 Plastic roller 12 O ring 2 Cylinder pin 8 Rear link 13 Grease fitting 3 Thrust washer 9 Locknut 14 O ring 4 Liftlink 10 90 hydraulic fitting 15 Support frame 5 Linkassembly 11 Lift cylinder 16 Lift arm deck 46 shown 6 Bushing Hydraulic System Rev A Page 4 110 Groundsmaster 4500 D 4700 D Removal Fig 95 1 Park machine on level surface lower cutting units stop engine engage parking brake and remove key from the ignition switch 2 Read the General Precautions for Removing and Instal
212. mperature shutdown switch terminal 3 Engine should stop running indicating that the switch circuit is functioning correctly If the engine continues running with the grounded jumper wire the switch circuit needs repair Shutdown Switch Test A CAUTION Make sure engine is cool before removing the temperature switch 1 Lower coolant level in the engine and remove the temperature shutdown switch 2 Put switch in a container of oil with a thermometer and slowly heat the oil Fig 37 CAUTION Handle the hot oil with extreme care to prevent personal injury or fire 3 Check continuity of the switch with a multimeter ohms setting The temperature switch is normally open and should close between 225 to 235 F 107 to 113 C 4 Allow oil to cool while observing temperature The temperature switch should open at about 219 F 104 C 5 Replace switch if necessary Groundsmaster 4500 D 4700 D Page 5 23 Figure 36 1 High temperature shutdown switch 2 Glow plug connection 6 Install switch to the water flange A Clean threads of cylinder head and switch thor oughly Apply thread sealant to the threads of the Switch B Screw switch into the cylinder head and tighten C Connect blue white wire to switch 7 Fill engine cooling system see Traction Unit Opera tor s Manual Electrical System Rev A SE o0 Traction Neutral Switch The tractio
213. ms ELECTRICAL SYSTEM QUICK CHECKS Battery Test Open Circuit Check Operation of Interlock Switches COMPONENT TESTING Ignition Switch Fuses Indicator Lights PTO and Hi Lo Speed Control Switches Seat Switch Parking Brake Switch Cutting Deck Position Switch Cutting Deck Lift Lower Switch Ramp up Module Groundsmaster 4500 D 4700 D Chapter 5 Electrical System Hour Meter 15 2 Glow Relay eels 15 2 Start Neutral Seat Cutting Deck Parking Brake and High Temperature Relays 16 Hydraulic Valve Solenoids 17 24 Engine Run Solenoid 18 PUMP 19 6 Glow Controller 20 6 Temperature 21 6 Temperature Gauge 22 7 High Temperature Shutdown Switch 23 7 Traction Neutral Switch 24 8 Diode Assemblies 24 9 Diode Circuit 25 10 Standard Control Module 26 11 SERVICE AND REPAIRS 27 11 Battery Storage 27 12 Battery 27 13 Battery Service 28 14 Page 5 1 Electrical System Rev A 2 o gt Electrical Schematics and Electrical Harness and Connector
214. n 3 2 mm Tire pressure front and rear 20 psi 1 4 bar Planetary gear drive lubricant SAE 85W 140 wt gear lube Planetary gear lube capacity each wheel 16fl oz 47 1 Rear axle lubricant SAE 85W 140 wt gear lube Rear axle gear lube capacity 80 fl oz 2 37 Axles Planetaries and Brakes Rev B Page 6 2 Groundsmaster 4500 D 4700 D Adjustments See Traction Unit Operator s Manual for adjustment procedures for Groundsmaster 4500 D and Ground smaster 4700 D axles planetaries and brakes and Brakes 5 S 9 x Groundsmaster 4500 D 4700 D Page 6 3 Axles Planetaries and Brakes Rev B Service and Repairs Brake Assembly FRONT 75 to 85 ft lb 101 to 115 N m 85 to 100 ft Ib 115 to 135 N m Figure 1 1 Flange head screw 8 Compression spring 14 Flat washer 2 Splined brake shaft 9 Jam nut 15 Cap screw 3 Planetary assembly 10 LH Brake assembly 16 O ring 4 Tire and wheel assembly 11 Flange head screw 17 O ring 5 Lug nut 12 Hex plug 18 RH brake assembly 6 Retaining ring 13 Piston motor 19 Brake cable 7 Spring plate Axles Planetaries and Brakes Rev B Page 6 4 Groundsmaster 4500 D 4700 D Remove Brake Assembly Fig 1 1 Park machine on a level surface and raise cutting units to allow easier access to front brake assembly Stop engine engage parking brake and remove key from the ignition switch 2 Drain oil from planetary
215. n end of housing up clamping housing on the outer portion of the flange 12 Install gasket 32 onto housing 13 necessary press new bearing 45 and roll pin 38 in backplate 20 to dimension shown in Figure 58 Note Bearing should be installed with the numbered end out ward Roll pin should be installed with split oriented away from bearing NOTE Forward and reverse relief valves are identical 14 Install new o ring on relief valves 16 amp 26 Install relief valve in the cavity in backplate and torque from 100 to 110 ft Ib 136 to 149 N m 15 Install new o ring on bypass valve 14 Install by pass valve 14 into backplate 20 Note Make sure paddle of bypass valve is perpendicular to relief valve axis prior to installing or damage could result Groundsmaster 4500 D 4700 D Page 4 67 16 Apply a small amount of petroleum jelly to the steel side of valve plate 18 to hold in place for installation Aligning the index pin place the valve plate 18 in posi tion onto the backplate 20 with steel side against backplate 17 Install backplate assembly 20 onto housing assem bly 19 Make sure ports are positioned correctly and that valve plate 18 and gasket 32 stay in place 18 Retain backplate 20 with four cap screws 15 Torque cap screws from 27 to 31 ft lb 37 to 42 N m 19 Install control housing gasket 34 onto housing Install orifices 30 into servo control assembly 28 and retain
216. n neutral switch is closed when the traction pedal is inthe neutral position and opens when the pedal is depressed in either direction The switch is located on the right side of the piston traction pump Test the switch by disconnecting the wires from the switch terminals and connecting a continuity tester across the two switch terminals With the engine turned off slowly push the traction pedal in a forward or reverse direction while watching the continuity tester There should be indications that the traction neutral switch is opening and closing Allow the traction pedal to return to the neutral position There should be continuity across the switch terminals when the traction pedal is in the neutral position Figure 38 1 Piston traction pump 2 Neutral switch See Piston Pump Control Assembly in Chapter 4 Hy draulic Systems for disassembly and reassembly proce dures for the neutral switch Diode Assemblies Diode D8 provide logic for the interlock switches Diodes D2 D3 D4 GM 4700 D only and D5 GM 4700 D only are used for circuit protection from voltage spikes when relays and hydraulic valve solenoids are de ener gized The diodes plug into the wiring harness at various locations see Wire Harness Drawings in Chapter 9 Electrical Diagrams Diode Test The diodes Fig 39 can be individually tested using a digital multimeter diode test or ohms setting and the Figure 39
217. nd clean the fuel tank if the fuel system becomes contaminated or if the machine is to be stored for an ex tended period To clean fuel tank flush tank out with clean diesel fuel Make sure tank is free of contaminates and debris Groundsmaster 4500 D 4700 D Fuel Tank Removal Fuel Tank Installation 1 Park machine on level surface lower cutting units 1 Install fuel tank to frame using Figure 7 as a guide stop engine engage parking brake and remove key from the ignition switch 2 Connect fuel hoses to the suction and return fittings in top of tank 2 Disconnect fuel hoses from the suction and return fit tings in top of tank 3 Make sure that draincock is closed 3 Use draincock to empty fuel tank into a suitable con 4 Fill fuel tank see Traction Unit Operator s Manual tainer 4 Remove fuel tank using Figure 7 as a guide 8 Groundsmaster 4500 D 4700 D Page 3 9 Kubota Diesel Engine Rev A Radiator Hydraulic fitting Oil cooler Flange nut Radiator bracket Bulb seal Air cleaner hose Hood seal bracket Radiator Reservoir hose Hose clamp Radiator cap Radiator fan shroud Clamp Radiator hose Kubota Diesel Engine Rev Figure 8 Flange nut Tank bracket Flat washer Fla
218. nd put throttle at full engine speed 2800 50 RPM with no load on the hydraulic system 5 gt GAUGE READING TO BE 230 to 300 PSI 5 lf there is no pressure or pressure is low check for restriction in pump intake line Also inspect charge relief valve located in filter manifold and charge check valve gt system relief valve in hydrostat If necessary check for Figure 25 internal damage or worn parts in gear pump 1 Charge pressure port 2 Filter manifold 6 Also with the pressure gauge still connected to the charge pressure test port monitor the gauge reading while operating the machine in forward and reverse Start the engine and put throttle at full engine speed 2800 50 RPM Apply the brakes and push the trac tion pedal forward then reverse GAUGE READING TO BE 230 to 300 PSI 7 If pressure is good under no load but drops below specification when under traction load the piston trac tion pump front wheel motors and or rear axle motor should be suspected of wear and inefficiency When the pump and or traction motor s are worn or damaged the charge pump 15 not able to keep up with internal leakage in traction circuit components Groundsmaster 4500 D 4700 D Page 4 27 Hydraulic System Rev A Rev D TEST 2 Traction Circuit Relief Pressure Using Pressure Gauge CHARGE CIRCUIT NOTE FORWARD DIRECTION TEST SHOWN
219. nd rear for proper re assembly 8 Carefully remove rear bearing block idler gear drive gear and front bearing block from the front flange 9 Remove and discard pressure seals from bearing blocks 10 Turn front flange over with seal side up IMPORTANT Make sure not to damage the counter bore when removing the shaft seals and retaining ring from the front flange 11 Remove outer shaft seal retaining ring and inner shaft seal from the front flange Discard seals Inspection 1 Remove any nicks and burrs from all parts with caution emery cloth Use eye protection such as goggles when using compressed air 2 Clean all parts with solvent Dry all parts with com pressed air 3 Inspect drive gears and idler gears for the following Fig 80 A Drive gear shaft spline should be free of twisted or broken teeth B Gear shafts should be free of rough surfaces and excessive wear at bushing points and sealing areas Scoring rough surfaces or wear on gear shafts indi cates need for replacement C Gear teeth should be free of excessive scoring and wear Any broken or nicked gear teeth must be replaced D Inspect gear face edge for sharpness Sharp edges of gears will mill into bearing blocks and thus must be replaced Groundsmaster 4500 D 4700 D Page 4 91 4 Inspect bearing blocks for the following A Bearing areas should not have excessive wear or scoring B Face of bearing block
220. nd red area 105 C 3 Turn off the voltage source Disconnect voltage source gauge and variable resistance Temperature Gauge Check The following procedure can be used to check the tem perature gauge and the gauge circuit 1 Disconnect wire from temperature sender on engine Fig 35 Turn ignition key to ON do not start engine 2 Temperature gauge needle should remain in the cold temp range 3 Ground the wire that was disconnected from the tem perature sender The gauge needle should move toward the high temp position 4 Reconnect wire to temperature sender Electrical System Rev A Page 5 22 VARIABLE RESISTANCE 14 VDC 0 01 VDC Figure 34 3 Edge of glass cover 4 Cold temp position 1 Middle position 2 High temp position Figure 35 2 Alternator 1 Temperature sender Groundsmaster 4500 D 4700 D High Temperature Shutdown Switch The high temperature shutdown switch is located near the glow plug connection on the engine cylinder head Fig 36 There is a blue white wire attached to the switch The high temperature shutdown switch is designed to shut the engine off when engine coolant temperature reaches an unsafe level If problems with the switch sys tem are encountered the following procedure can be used to determine if the problem is related to the switch or the switch circuit 1 Start engine 2 Use a jumper wire to ground the high te
221. nd terminals 1B and 2B 3 Both indicator lights should light Engine Oil Pressure Light The oil pressure light should come on when the ignition switch is in the ON position with the engine not running Also it should light with the engine running if the engine oil pressure drops below 7 PSI 0 5 kg cm2 To testthe oil pressure light and circuit wiring ground the green wire attached to oil pressure switch located on right side of engine near the starter motor Turn ignition switch to ON the oil pressure light should come on indi cating correct operation of the electrical wiring to the oil pressure switch High Temperature Shutdown Light Figure 8 If the engine coolant temperature rises to 230 F 1 Charge indicator 3 High temp shutdown 2 Engine oil pressure 4 Glow plug indicator 110 C the high temperature light should come on as the high temperature shutdown switch stops the engine To test the high temperature shutdown light and circuit wiring start the engine and ground the blue white wire attached to high temperature shutdown switch on fly wheel end of engine see High Temperature Shutdown Switch in this Chapter Warning light should illuminate and engine should stop running 26 4 Glow Plug Indicator Light The glow plug light should come on when the ignition switch is placed in ON prior to placing the ignition switch in START The light should stay lit for 7 to 10 secon
222. neral Run and Transport Problems Engine continues to run but should not when the ignition switch is turned off Engine continues to run but should not when the traction pedal is engaged with no operator in the seat The engine stops during operation but is able to restart The engine kills when the traction pedal is depressed Battery does not charge Electrical System Rev A Page Possible Causes Engine is not cranking fast enough Engine run solenoid circuit wiring or fuel pump is faulty The problem is not electrical see Chapter 3 Kubota Engines The traction neutral switch is out of adjustment The traction neutral switch or circuit wiring is faulty The engine fuel stop solenoid is stuck open Ignition switch or circuit wiring is faulty The seat switch or circuit wiring is faulty Traction neutral switch or circuit wiring is faulty The operator is lifting off the seat The seat switch or circuit wiring is faulty The engine shutdown delay is faulty The ignition switch or circuit wiring is faulty The operator is lifting off the seat switch The parking brake is on The seat switch seat relay or circuit wiring is faulty The parking brake switch relay or circuit wiring is faulty Loose corroded or broken wire s The fusible link to the battery is faulty Faulty alternator or dead battery Charge indicator lamp is faulty or burned out Charge indicator lamp wiring loose c
223. ng A Forthe Tyco Electronics relay VF4 65F 11 re sistance should be from 71 to 88 ohms B For the Hella Electronics relay 766211 resist ance should be from 70 to 80 ohms 2 Connectmultimeter ohms setting leads to relay ter minals 30 and 87 Ground terminal 86 and apply 12 VDC to terminal 85 The relay should make and break continuity between terminals 30 and 87 as 12 VDC is applied and removed from terminal 85 3 Disconnect voltage from terminal 85 and multimeter lead from terminal 87 4 Connectmultimeter ohms setting leads to relay ter minals 30 and 87A Apply 12 VDC to terminal 85 The relay should make and break continuity between termi 30 and 87A as 12 VDC is applied and removed from terminal 85 5 Disconnect voltage and multimeter leads from the relay terminals Electrical System Rev A Page 5 16 Figure 23 Control panel 6 K2relay decks 1 5 K8 relay seat 7 high temp K9 relay neutral behind 8 K5 relay start K7 relay parking brake 9 Kirelay GM4700 deck 6 K3 relay GM4700 deck 7 Figure 24 Groundsmaster 4500 D 4700 D Hydraulic Valve Solenoids The Groundsmaster 4500 D has three hydraulic valve solenoids one on each cutting deck manifold and one on the traction manifold The Groundsmaster 4700 D has five solenoids two on each cutting deck manifold and one on the traction manifold Testing of these sole noids can be
224. ng LH shown 6 Hitch pin 11 Rotating actuator 2 Seal 7 Stationary disc 12 Extension spring 3 Pull rod 8 Rotating disc 13 Ball 4 Clevis pin 9 Retaining ring 14 Plug 5 Link 10 Gasket 15 O ring Brake Inspection and Repair Fig 4 6 Remove seal 2 from brake housing 1 Scrape gasket material 10 from brake housing and 7 Wash parts in cleaning solvent Inspect components planetary wheel drive mounting surfaces for wear or damage 2 Remove retaining ring 9 8 Reverse steps 2 6 to assemble brakes installing new parts as necessary Install a new seal 2 3 Remove stationary discs 7 and rotating discs 8 9 Useanew gasket 10 when installing brake assem 4 Remove extension springs 12 bly to machine 5 Remove actuator assembly 3 4 5 6 and 11 and balls 13 Axles Planetaries and Brakes Rev B Page 6 6 Groundsmaster 4500 D 4700 D This page is intentionally blank and Brakes 5 S 9 x Groundsmaster 4500 D 4700 D Page 6 7 Axles Planetaries and Brakes Rev B Planetary Wheel Drive Assembly 75 to 85 ft lb 101 to 115 N m RIGHT FRONT 75 to 85 ft lb 101 to 115 N m 85 to 100 ft Ib 115 to 135 N m Figure 5 1 Flange head screw 7 Spring plate 13 Piston motor 2 Splined brake shaft 8 Compression spring 14 Flat washer 3 Planetary assembly 9 Jam nut 15 Cap screw 4 Tire and wheel assembly 10 LH Brake assembly 16 O ring 5 Lu
225. nge head screw Coolant reservoir Reservoir cap Flange head screw Flange nut Bulb seal Bottom cover Flange head screw Washer head screw Spacer Page 3 10 O ring O ring Oil cooler mount plate Oil cooler clamp Flat washer Cap screw Wire form clamp Cap screw Washer cooler bracket top Bulb seal Foam seal Foam seal Groundsmaster 4500 D 4700 D Removal 1 Park machine on level surface lower cutting units stop engine engage parking brake and remove key from the ignition switch 2 Remove hood from the machine see Traction Unit Operator s Manual Do not open radiator cap or drain coolant if the radiator or engine is hot Pressurized hot cool ant can escape and cause burns Ethylene glycol antifreeze is poisonous Dis pose of coolant properly or store it in a properly labeled container away from children and pets 3 Remove radiator cap Drain radiator into a suitable container using the coolant draincock The coolant draincock and hose is attached to the engine oil filter housing Figures 9 and 10 4 Disconnect hoses upper and lower from the radia tor 5 Remove air cleaner hose 6 Disconnect reservoir hose from the vent tube 7 Detach radiator fan shroud from the radiator by re moving four flange head screws and flat washers Posi tion shroud away from radiator 8 Pivot rear
226. ngers 2 and 16 7 Remove plug 21 8 Remove detent plugs 18 discs 19 detent springs 20 and detent plungers 17 9 Remove all O rings and back up rings from all plugs and seats Inspection 1 Remove all nicks and burns from parts and inspect for excessive wear 2 Inspect all plungers and poppet seats for burrs or roughness 3 Inspect spool springs 15 lockout springs 9 and detent springs 20 for breakage 4 If spools 4 have excessive wear the control valve becomes non serviceable as the spools and spool bores are matched Damaged spools cannot be re placed Groundsmaster 4500 D 4700 D Page 4 101 Assembly 1 Thoroughly clean and dry all parts Apply a light coat ing of clean hydraulic oil to parts prior to assembly NOTE All O rings back up washers wiper seals and nylon poppets should be replaced as new items 2 Install new O rings 12 in proper grooves in spool bores 3 Install plugs 6 with new back up washers 29 and O rings 28 Torque plugs from 30 to 35 ft Ib 41 to 48 4 Lubricate plungers 2 and 16 with clean hydraulic oil and install them into their correct position in valve body IMPORTANT Check location and positioning of plungers during installation 5 Install new O rings 25 on seats 5 Install new back up washers 23 and O rings 24 on plugs 7 6 Lubricate seats 5 with clean hydraulic oil Install seats 5 new poppets 1 and se
227. ngs in the roller shaft ends The third design has grease fittings incorpo rated into the roller fasteners Removal and installation of the rear roller from the cutting deck is the same re gardless of roller type Removal Fig 8 1 Park machine on level surface lower cutting units stop engine engage parking brake and remove key from the ignition switch 2 If cutting deck is equipped with a roller scraper re move fasteners securing left and right scraper rod brackets to roller mounts Remove scraper rod assem bly 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 Loosen fasteners securing each end of roller to roller mounts Remove mounts from roller Installation Fig 8 1 Place roller assembly into roller mounts 2 Install roller and roller mount assembly into rear of deck frame Secure assembly to deck frame with flange head screws IMPORTANT If roller design includes grease fittings in roller fasteners items 9 and 10 in Fig 8 make sure the grease groove in each roller mount aligns with the grease hole in each end of the roller shaft To help align the groove and hole there is also an alignment mark on one end of the roller shaft 3 Tighten fasteners that secure each end of roller to roller mounts 4 If removed install scraper rod assembly to roller mounts Adjust scraper rod see Cutting Unit Ope
228. no load 1300 50 RPM High Idle no load 2800 50 RPM Direction of Rotation Counterclockwise Viewed from Flywheel Compression Ratio 22 0 1 Injection Nozzle Bosch Throttle Type Engine Oil SAE 10W30 or 10W40 Detergent API CD or higher Oil Pump Trochoid Type Crankcase Oil Capacity liters U S quarts 7 6 8 0 with Filter Starter 12 VDC 1 4 kW Alternator Regulator 12 VDC 40 AMP Coolant Capacity liters U S quarts 10 4 11 with 0 9 1 0 Reservoir Engine Dry Weight kilograms U S pounds 184 406 Groundsmaster 4500 D 4700 D Page 3 3 Kubota Diesel Engine Rev A 8 Adjustments Engine Run Solenoid 1 When ignition switch is in the RUN position the en gine run solenoid should energize and position the fuel stop lever to within 1 16 1 6 mm of stop on the injec tion pump 2 If adjustment is needed loosen lock nut and rotate the threaded end of the swivel until the lever is properly positioned 3 Tighten lock nut Recheck adjustment Figure 1 1 Run solenoid ON 3 Swivel 2 Lever 4 Lock nut Figure 2 1 Run solenoid OFF 3 Injection pump stop 2 Solenoid lever Kubota Diesel Engine Rev A 3 4 Groundsmaster 4500 D 4700 D Service and Repairs Air Filter System 8
229. not lap valve plate bronze surface Replace valve plate if any wear exists 3 Inspect the piston block surface that makes contact with valve plate This surface should be smooth and free of deep scratches Do not lap piston block 4 The pistons should move freely in the piston block bore If they are sticky in the bore examine the bore for scoring or contamination 5 Examine the O D of the pistons for finish condition They should not show wear or deep scratches Inspect the shoes for a snug fit on the ball end of the pistons and aflat smooth surface that comes in contact with the cam plate Do not lap piston shoes 6 Examine the spider for wear in the pivot area 7 Examine the spider pivot to insure smoothness and no signs of wear 8 The polished finish on the shoe surface of the cam plate insert 5 should show no signs of scoring 9 Inspect the shaft for wear in the seal bearing and spline areas 10 Inspect thrust bearing 13 and races 10 for wear 11 Check the condition of the needle bearing 17 in housing and replace if necessary Reassembly 1 Clean all parts in suitable solvent and lubricate all in ternal parts with clean hydraulic oil before reassembly Groundsmaster 4500 D 4700 D Page 4 87 2 If necessary install new needle bearing 17 in hous ing 3 with numbered end of the bearing outward 3 Install retaining ring 9 on shaft Install thrust race 10 thrust bearing 13 and se
230. ntrol valve is pushedto allow valve shift in the lift lower control This valve change allows a passage for oil flow from the rod end of the lift cylinders The weight of the cutting decks causes the lift cylinders to extend lowering the cutting units An orifice positioned in the lift lower control valve restricts oil flow from the lift cylinders to control deck drop speed Oil from the rod end of the cylinders is allowed to return to the traction charge cir cuit The piston end of the cylinders are replenished by the charge circuit When the lift lever is released the lift cylinders are held in position To lower a side cutting unit on the Groundsmaster 4700 D deck 6 or 7 the appropriate lift lever on the lift lower control valve is pushedto allow valve shift inthe lift lower control This valve change causes a shift in the sequence valve located in the power down and traction assist manifold and also allows a passage for oil flow from the rod end ofthe lift cylinder Cil flow to the piston end of the lift cylinder causes the cylinder shaft to ex tend and lowers the cutting unit Oil from the rod end of the cylinders returns to the traction charge circuit When the lift lever is released the lift cylinder is held in posi tion An adjustable counterbalance valve RV1 maintains back pressure on the deck lift cylinders This counterbal ance pressure transfers cutting unit weight to the ma chine to improve traction Excess circuit f
231. o tor from falling during removal 4 Remove wheel motor using Figure 74 as a guide Groundsmaster 4500 D 4700 D Page 4 85 Installation 1 Position wheel motor to brake assembly making sure that arrows on the side of motor case point upward 2 Align splines on motor shaft and splined brake shaft Slide motor into brake assembly 3 Secure motor to brake assembly with cap screws and flat washers Tighten cap screws from 75 to 85 ft Ib 101 to 115 N m 4 Remove plugs from motor ports Attach hydraulic hoses and tubes to wheel motor 5 Fill reservoir with hydraulic fluid as required see Traction Unit Operator s Manual Hydraulic System Rev A 2 FE 6 Oo Rear Axle Front Wheel Motor Service FRONT WHEEL MOTOR SHOWN 15 to 18 20 to 24 N m Figure 75 1 Drive shaft 8 Shaft seal front motor only 15 Roll pin 2 Backplate 9 Retaining ring 16 Bearing 3 Housing assembly 10 Thrust race 17 Bearing 4 Rotating assembly 11 O ring 18 Washer 5 Cam plate insert 12 Valve plate 19 Plug 6 Retaining ring 13 Thrust bearing 20 O ring 7 Cap screw 14 Roll pin NOTE The front wheel motors shown in Figure 75 are identical The rear axle motor is similar to the front wheel motors Service ofthe front and rear motors requires the same procedure NOTE Therear axle motor does not have a shaft seal The case drain from the rear axle motor provides lu brication for the inp
232. oil seal Cutting Units Rev B Page 8 14 Groundsmaster 4500 D 4700 D Rev D Roller Disassembly Fig 11 1 Remove retaining ring from both ends of roller 2 Hit end of roller shaft with a soft face hammer to re move seals and bearing from one end of roller Hit other end of roller shaft to remove seals and bearing from oth er end of roller Be careful not to drop roller shaft 3 Discard seals and bearings Roller Assembly Fig 11 NOTE Asoftface hammer can be used with the special tools listed see Special Tools to assemble the roller however use of a press is recommended 1 Useinstallation tool TOR4065 and handle TOR4073 to install inner oil seal into each end of roller tube 2 Install ball bearings NOTE Ball bearings have a press fit into the roller tube and a slip fit onto the roller shaft IMPORTANT If ball bearing has a seal on one side install bearing with seal orientated toward the out side of the roller A Use tool TOR4066 and handle TOR4073 to install ball bearing into one end of roller tube B Install roller shaft from opposite end of roller Be careful not to damage the inner oil seals C Put roller in a vertical position and support shaft and bearing with tool TOR4067 D Use tool TOR4067 to install second ball bearing Groundsmaster 4500 D 4700 D Page 8 15 3 Use tool TOR4068 to install inner seal 4 Use tool TOR4069 to install outer seal 5 Install retaining ring so that
233. on gear 6 Ring gear 3 Pinion washer 7 Differential case 4 Side gear Groundsmaster 4500 D 4700 D Inspection 1 Measure the differential side gear O D and the dif ferential case 1 0 to determine the side gear to case clearance Fig 33 Replace components as necessary SIDE GEAR TO CASE CLEARANCE 0 002 to 0 012 in 0 05 to 0 30 mm SIDE GEAR O D Factory Spec 1 335 to 1 337 in 33 91 to 33 95 mm DIFFERENTIAL CASE 1 0 Factory Spec 1 339 to 1 341 in 34 00 to 34 06 mm 2 Measure the differential pinion shaft O D and the pinion gear to determine the pinion shaft to pinion gear clearance Fig 34 Replace components as nec essary PINION SHAFT TO PINION GEAR CLEARANCE 0 001 to 0 010 in 0 03 to 0 25 mm PINION SHAFT O D Factory Spec 0 550 to 0 551 in 13 97 to 13 10 mm Figure 33 1 Side gear 2 Differential case PINION GEAR 1 0 Factory Spec 0 551 to 0 552 in 13 10 to 14 02 mm 3 Inspect all gears shafts bearings cases and cov ers for damage and wear Replace components as nec essary and Brakes o 5 o S S 2 x Figure 34 1 Pinion shaft 2 Pinion gear Groundsmaster 4500 D 4700 D Page 6 23 Axles Planetaries and Brakes Rev B Installation 1 If the ring gear was removed from the differential case use medium strength Loctite thread locker and tighten the mounting screws from 22 to 25 ft lb 30 to 34 N m 2 Apply molyb
234. on motor Cutting Deck Motors Gear motor Hydraulic Filters In line Suction Strainer 2 Micron nominal spin on cartridge type 100 mesh in reservoir Hydraulic Reservoir 7 5 gal 28 4 Hydraulic Oil See Traction Unit Operator s Manual Hydraulic System Rev A Page 4 2 Groundsmaster 4500 D 4700 D General Information Hydraulic Hoses Hydraulic hoses are subject to extreme conditions such as pressure differentials during operation and exposure to weather sun chemicals very warm storage condi tions or mishandling during operation and mainte nance These conditions can cause damage or premature deterioration Some hoses are more suscep tible to these conditions than others Inspect the hoses frequently for signs of deterioration or damage When replacing a hydraulic hose be sure that the hose is straight not twisted before tightening the fittings This can be done by observing the imprint on the hose Use two wrenches hold the hose straight with one wrench and tighten the hose swivel nut onto the fitting with the other wrench Hydraulic Fitting Installation O Ring Face Seal 1 Make sure both threads and sealing surfaces are free of burrs nicks scratches or any foreign material 2 Make sure the O ring is installed and properly seated in the groove It is recommended that the O ring be replaced any time the connection is opened 3 Lubricate the O ring with a light
235. operation of hood latches and dust seals Figure 12 1 Hood lock pin 2 Lanyard Groundsmaster 4500 D 4700 D Page 7 11 Chassis This is intentionally blank Chassis Page 7 12 Groundsmaster 4500 D 4700 D TORO Table of Contents SPECIFICATIONS TROUBLESHOOTING Factors That Can Affect Quality of Cut SPECIAL TOOLS ADJUSTMENTS Blade Stopping Time Blade Plane Inspection and Adjustment Groundsmaster 4500 D 4700 D Chapter 8 Cutting Units 2 SERVICE AND REPAIRS 8 3 Blade Spindle Assembly 8 3 Blade Spindle Service 10 4 Rear Rollet sare ee PLE rate ected 12 5 Rear Roller Service Non Greasable Bearings 13 5 Rear Roller Service Greasable Bearings with 6 Retaining Ring 14 Rear Roller Service Greasable Bearings with Bearing Nut 16 Front Roller Service 18 Cutting Deck Carrier 20 Page 8 1 Cutting Units Rev B Rev D 2 5 Specifications MOUNTING All cutting units are supported by indepen dent lift arms and are interchangeable to any cutting unit positions The Groundsmaster 4700 D shown above uses 7 cutting units The Groundsmaster 4500 D uses 5 cutting units CONSTRUCTION Deck chamber is welded 7 10 and 12 gauge steel Deck frame is welded 1 1 2 inch square tubing
236. or housing to prevent distorting the housing 18 Place front flange of the motor into a vise and alter nately torque the cap screws from 38 to 43 ft Ib 51 to 58 N m 19 Remove motor from vise 20 Place a small amount of clean hydraulic oil in the inlet of the motor and rotate the drive shaft one revolution Fig 82 If any binding is noted disassemble the motor and check for assembly problems Hydraulic System Rev A Page 4 92 Figure 81 1 Inner shaft seal 3 Outer shaft seal 2 Retaining ring Rotation Direction Figure 82 1 Pressure IN 3 Case drain 2 Pressure OUT Groundsmaster 4500 D 4700 D Relief Valve Service IMPORTANT Do not remove the relief valve as sembly unless testing shows it to be faulty 1 When removing or installing the relief valve motor should be removed from deck and positioned horizon tally with the relief valve pointed down Fig 83 This process will prevent the relief valve from falling into mo tor passages NOTE The relief valve seat is difficult to remove be cause it has a thin hex head and has sealant applied to the threads Inspect the seat carefully and remove it only if damage or wear is identified 2 Remove plug with o ring spring and relief valve from the rear cover 3 Clean and inspect removed parts Visually inspect relief valve seat and plug threads in the rear co
237. orage If the machine will be stored for more than 30 days 1 Remove the battery and charge it fully see Battery Service 2 Either store battery on a shelf or on the machine 3 Leave cables disconnected if the battery is stored on the machine Battery Care 1 Battery electrolyte level must be properly main tained The top of the battery must be kept clean If the machine is stored in a location where temperatures are extremely high the battery will run down more rapidly than ifthe machine is stored in a location where temper atures are cool Wear safety goggles and rubber gloves when working with electrolyte Charge battery in a well ventilated place so gasses produced while charging can dissipate Since the gases are explosive keep open flames and electrical sparks away from the battery do not smoke Nausea may result if the gases are inhaled Un plug charger from electrical outlet before con necting or disconnecting charger leads to or from battery posts IMPORTANT Do not remove fill caps while clean ing 2 Check battery condition weekly or after every 50 hours of operation Keep terminals and entire battery case clean because a dirty battery will discharge slowly A Clean battery by washing entire case with a solu tion of baking soda and water Rinse with clear water B Coat battery posts and cable connectors with skin over grease Toro Part No 505 165 or petro leum jelly to prevent corrosion
238. orroded or damaged 5 4 Groundsmaster 4500 D 4700 D Cutting Unit Operating Problems Cutting units run but should not when raised Units The cutting deck position switch or circuit wiring is shut off with PTO switch faulty The cutting deck lift lower switch or circuit wiring is faulty Cutting units run but should not when raised Units do The deck position switch cutting deck lift lower switch not shut off with the PTO switch or circuit wiring and PTO switch or circuit wiring are faulty A hydraulic problem exists see Troubleshooting Section of Chapter 4 Hydraulic System Cutting units run but should not when lowered with The PTO switch or circuit wiring is faulty PTO switch in the OFF disengage position Cutting deck s do not operate The cutting deck position switch or circuit wiring to the affected decks is faulty The cutting deck lift lower switch or circuit wiring to the affected decks is faulty The PTO relay or circuit wiring to the affected decks is faulty The Ramp up module or circuit wiring is faulty Hydraulic valve solenoid s or circuit wiring to the affected decks is faulty A hydraulic problem exists see Troubleshooting section of Chapter 4 Hydraulic System All cutting decks do not operate The cutting decks are raised Fuse 2 PTO is faulty The ignition switch or circuit wiring is faulty The PTO switch or circuit wiring is faulty The 2WD 4WD switch or circuit wiring is
239. osition o rings and spacer to gear pump Align gear teeth and slide gear pump input shaft into coupler Secure gear pump to piston pump with two 2 cap screws and washers 4 Remove caps and plugs from hydraulic lines and fit tings Install lines to gear pump 5 Replace hydraulic filter and fill hydraulic reservoir with new hydraulic oil 6 Disconnect engine run solenoid electrical connector to prevent engine from starting Prime the hydraulic pump by turning the ignition key switch to start and crank the engine for 10 seconds Repeat cranking procedure again 7 Connect engine run solenoid electrical connector start the engine and check for proper operation 8 Properly fill hydraulic system see Charge Hydraulic System 9 Stop engine and check for hydraulic oil leaks Check hydraulic reservoir oil level Hydraulic System Rev A 2 6 Gear Pump Service 21 to 24 ft Ib 29 to 33 N m 21 to 24 ft Ib 29 to 33 N m Disassembly Work in a clean area as cleanliness is extremely impor tant when repairing hydraulic pumps Thoroughly clean the outside of pump After cleaning remove port plugs and drain oil from pump 1 Scribe a line at an angle across front plate 15 bo dies 10 19 26 adapter plates 23 24 and backplate 27 This will assure proper reassembly Hydraulic System Rev A Page 4 58 25 to 28 ft lb 34 to 38 N m Figure 55 1 Shaft s
240. ould be continuity across the switch terminals 5 Raise the cutting unit There should be no continuity across the switch terminals 6 Replace switch as needed Reconnect switch Switch Adjustment 1 Adjust switch to have 1 16 in 1 6 mm clearance be tween switch and sensing plate on the lift arm Electrical System Rev A Page 5 12 Figure 14 1 Position switch 3 Lift arm 5 shown 2 Switch connector CUTTING DECK LOCATIONS Figure 15 Groundsmaster 4500 D 4700 D Cutting Deck Lift Lower Switch The lift lower switch is a normally open proximity switch that is closed when a lift lever is in the neutral position When a lift lever is moved to raise the lift lower switch opens Each lift lever is equipped with a cutting deck lift lower switch When the machine operator engages the cutting decks PTO switch ON and decks lowered the cutting deck lift lower switch and circuit board diode D1 C provide a latching circuit to keep the PTO relay energized Fig 18 Operating the machine on uneven ground could cause a Cutting deck to raise enough to open a deck position switch The cutting deck lift lower switch is de signed to keep the PTO relay energized in this situation to maintain cutting deck operation Figure 16 1 Lift lower switch location GM4700 shown 2 Switch connector 3 Switch plate screw Switch Testing and Adjustment 1 Park machine on a level surface lower cutting units stop engine
241. ower Cutting 10 Raise Cutting Units 12 Mow Circuit eee ee 14 Cutting Deck Blade Braking 16 Steering Circuit 18 SPECIAL TOOLS 20 Hydraulic Pressure Test Kit 20 Hydraulic Tester Pressure and Flow 20 Hydraulic Test Fitting 21 Measuring Container 21 TROUBLESHOOTING 22 TESTING ni gad Rmo MEL 25 Test No 1 Traction Circuit Charge Pressure 26 Test No 2 Traction Circuit Relief Pressure 28 Test No 3 Cutting Deck Circuit Pressure 30 Test No 4 Cutting Deck Gear Pump Flow 32 Test No 5 Cutting Deck Manifold Relief 34 Test No 6 Cutting Deck Motor Case Drain Leakage 36 Test No 7 Steering Circuit Relief Pressure 38 Test No 8 Lift Lower Circuit Relief Pressure 40 Test No 9 Steering and Lift Lower Gear Pump Flow 42 Test No 10 Counterbalance RV1 Pressure 44 Test No 11 Rear Traction Circuit RV5 Relief Pressure dice ete ud ebbe as 46 Test No 11 Traction Circuit Reducing Valve PR1 Pressure 48 Test No 13 Traction Assist RV2 Pressure 50 SERVICE AND REPAIRS 52 General Precautions
242. p engine area free of excessive grease grass leaves and dirt Clean protective screen on machine frequently 9 must be running to perform maintenance or an adjustment keep hands feet clothing and other parts of the body away from cutting units and other mov ing parts Keep bystanders away Groundsmaster 4500 D 4700 D Page 1 3 10 Do not overspeed the engine by changing governor setting To assure safety and accuracy check maximum engine speed 11 Shut engine off before checking or adding oil to the crankcase 12 Disconnect battery before servicing the machine Disconnect negative battery cable first and positive cable last If battery voltage is required for troubleshoot ing or test procedures temporarily connect the battery Reconnect positive cable first and negative cable last 13 Battery acid is poisonous and can cause burns Awoid contact with skin eyes and clothing Protect your face eyes and clothing when working with a battery 14 Battery gases can explode Keep cigarettes sparks and flames away from the battery 15 At the time of manufacture the machine conformed to the safety standards for riding mowers To assure op timum 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
243. p to run for 30 seconds then release ignition switch to OFF 7 The amount of fuel collected in the graduated cylin der should be approximately 11 75 floz 350 ml after 30 seconds 8 Replace fuel pump as necessary Install fuel hose to the water separator 9 Reconnect electrical connector to the engine run so lenoid 10 Bleed the fuel system see Traction Unit Operator s Manual Groundsmaster 4500 D 4700 D Page 5 19 Rev D Figure 29 1 Fuel pump 3 Pump discharge hose 2 Fuel pre filter Fuel Pump Specifications Pump Capacity 23 5 fl oz min 695 ml min 3 3 psi 22 8 kPa Max Current 0 9 amp Draw Electrical System Rev A 26 Glow Controller The glow controller is located under the console cover NOTE Refer to Chapter 9 Electrical Schematics and Diagrams when troubleshooting the controller Controller Operation 1 When the ignition switch is placed in the ON position the controller energizes the glow plugs and lights up the glow lamp for 7 to 10 seconds 2 When the ignition switch is held in the START posi tion the glow plugs will energize and the glow lamp will not light 3 When the ignition switch is released from START to ON the glow plugs will deenergize and the glow lamp will remain off Controller Checks 1 Make sure there is power from the battery 2 Disconnect electrical connector to the run solenoid to prevent the engine
244. 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 trans port maintenance and storage of the machine Improp er use or maintenance of the machine can result in injury Before Operating 1 Read and understand the contents of the Operator s Manual before starting and operating the machine Be come familiar with the controls and know how to stop the machine and engine quickly A replacement Operator s Manual is available on the Internet at www Toro com or by sending the complete model and serial number to The Toro Company Attn Technical Publications 8111 Lyndale Avenue South Bloomington Minnesota 55420 1196 2 Keep all shields safety devices and decals in place If a shield safety device or decal is defective illegible or damaged repair or replace it before operating the machine Also tighten any loose nuts bolts or screws to ensure machine is in safe operating condition While Operating 1 Siton the seat when starting and operating the ma chine 2 Before starting the engine A Engage the parking brake B Make sure traction pedal is in neutral and the PTO switch is OFF disengaged C After engine is started release parking brake and keep foot off traction pedal Machine must not move If movement is evident the traction pedal linkage is adjusted incorrectly
245. pump IMPORTANT Support hydraulic pump assembly to prevent it from falling and being damaged 12 Remove hydraulic pump assembly from engine see Pump Assembly in Chapter 4 Hydraulic Systems 13 Make sure all cable ties securing the wiring harness fuel lines or hydraulic hoses to the engine are removed 14 Connect hoist or liftto the front Fig 11 and rear Fig 14 lift tabs on engine 15 Remove flange head nuts rebound washers and cap screws securing the engine mounts to the rubber engine supports One person should operate lift or hoist while the other person guides the engine out of the ma chine IMPORTANT Make sure not to damage the engine fuel lines hydraulic lines electrical harness or oth er parts while removing the engine 16 Slowly remove engine from the machine 17 necessary remove engine mounts from the engine using Figure 11 as a guide Engine Installation 1 Ifremoved install engine mounts to the engine using Figure 11 as a guide 2 Connecthoist the front Fig 11 and rear Fig 14 lift tabs on engine 3 Position fan shroud around the engine fan Kubota Diesel Engine Rev A Page 3 14 7
246. r onthe lift lower control valve is pulled to allow valve shift in the lift lower control This valve change allows hy draulic pressure to the rod end of the cylinder and causes the lift cylinder shaftto retract raising the cutting unit Oil from the piston end ofthe cylinder returns to the traction charge circuit Whenthe lift lever is released the lift cylinder is held in position An adjustable counterbalance valve RV1 in the power down and traction assist control manifold maintains back pressure on the lift cylinders This counterbalance pressure transfers cutting unit weight to the machine to improve traction Excess circuit flow is routed to the oil filter and then to the traction charge circuit Figure 11 LIFT LOWER LoweR CONTROL VALVE POWER DOWN TRACTION ASSIST CONTROL MANIFOLD 4g pli GM 4700 0 RAISE DECK 6 SHOWN amp a 2 5 gt o 7 FROM TRACTION CIRCUIT CHARGE CIRCUI Figure 12 Groundsmaster 4500 D 4700 D Page 4 13 Hydraulic System Rev A 2
247. r 5 Electrical System for information on cutting deck switch operation 5 OPTIONAL FUSE BLOCK 8 _J 1127 0 lt 5 DECK UP TE T 5 6 1 1 1 R a ON lt lt e GN i T R BK K w CENTER 1 EGET 7 1 PEE ru A eae BU 4 RUN 1 i FRONT tet Tal pr A e PR i ME ne iu el dL ________ 5052 3 5 BK 51 d FRONTDECK FRONT DECK Bh lt gt 8 POSITION POSITION BK m OFF RUN START Y 5 DECK LOWERED DECK LOWERED e SENS cse s DECKS 1 4 F IS A g 4 GN GN Wiese fe 5795 NEUTRAL SWITCH NOT IN NEUTRAL VIO F 2 I0 A 17 ye ee ee ep POWER POINT 9 12 Rev 0 Groundsmaster 4500 D 4700 D Run Mow Circuit Power Current Control Current Indicator Gauge Current This page is intentionally blank Page 9 13 Rev D oil WARNING LIGHTS P1 alt L GLOW RELAY INTERCONNECT TO ENGINE over temp WARNING LI
248. r Bearna install roller that has greasable bearings and a bearing lock nut used to retain the bearings 115 0852 Inner Seal Tool 115 0853 Bearing Outer Seal Tool 107 8133 Bearing Installation Washer N M 2 Inner Seal Bearing Outer Seal Tool Tool Figure 3 Cutting Units Rev B Page 8 4 Groundsmaster 4500 D 4700 D Rev D Adjustments Never install or work on the cutting units or lift arms with the engine running Always stop en gine and remove key first See the Cutting Unit Operator s Manual for adjustment procedures for cutting units on the Groundsmaster 4500 D and Groundsmaster 4700 D Blade Stopping Time The blades of the cutting deck are to come to acomplete stop in approximately 5 seconds after the cutting deck engagement switch is shut down NOTE Make sure the decks are lowered onto a clean section of turf or hard surface to avoid dust and debris To verify this stopping time have a second person stand back from the deck at least 20 feet and watch the blades on one of the cutting decks Have the machine operator shut the cutting decks down and record the time it takes for the blades to come to a complete stop If this time is greater than 7 seconds the braking valve RV in the deck control manifold needs adjustment 2 5 Groundsmaster 4500 D 4700 D 8 5 Cutting Units Rev Blade Plane Inspection and Adjustment If a so
249. r flange and sender thor oughly Apply thread sealant to the threads of the sender B Screw sender into the water flange Torque send er from 16 to 20 1 21 7 to 27 1 N m C Reconnect gray wire to sender Apply skin over grease Toro Part No 505 47 to sender terminal 5 Fill engine cooling system see Traction Unit Opera tor s Manual Groundsmaster 4500 D 4700 D Page 5 21 Electrical System Rev A Temperature Gauge The temperature gauge can be tested using a new gauge as a substitute or by the use of a DC voltage source and a variable resistance box Temperature Gauge Test A CAUTION Make sure the voltage source is turned OFF be fore connecting it to the electrical circuit to avoid electrical shock and prevent damaging the gauge 1 Connect temperature gauge to the variable resis tance and DC voltage source Fig 33 NOTE When reading the gauge test point there are two white dots on the gauge face below the edge of the glass cover for the each test point For each variable re sistance setting the needle must be pointed between the two white dots 2 Take test point readings Fig 33 IMPORTANT Allow circuit to warm up for at least 5 minutes before taking test readings A Set variable resistance to 71 ohms Apply a 14 0 01 VDC to the circuit The needle should point to the middle of the green area 80 C B Set variable resistance to 38 ohms The needle should point between the green a
250. rator s Manual Figure 8 Deck frame 6 Cap screw Rear roller assembly 7 Scraper plate Flange head screw 8 Roller scraper Flange head screw 9 Cap screw if equipped Roller mount 10 Grease fitting Cutting Units Rev Page 8 12 Groundsmaster 4500 D 4700 D Rev D Rear Roller Service Non Greasable Bearings Seal Removal Fig 9 1 Using a 1 4 inch thick 3 X 3 square piece of steel make a seal removal tool as shown in Figure 10 2 Slide seal removal tool over roller shaft 3 Using the tool as a template locate mark and drill two 7 64 inch 109 inch diameter holes in outer face of seal 4 Screw two 8 164 inch diameter by 3 4 inch long self tapping screws into outer face of seal 5 Install two 1 4 20 by 1 inch long cap screws into seal removal tool 6 Alternately tighten cap screws to pull seal out of roller assembly NOTE Seals will be destroyed when servicing the rear roller Do not re use seals that have been removed Bearing Removal Fig 9 NOTE The bearings are pressed onto the roller shaft and loose fit into the roller 1 Remove seals from roller Remove retaining rings from roller shaft catch ring removal notch with pick and pull ring from shaft 2 Loosely secure roller assembly in bench vise and lightly tap one end of roller shaft until free from bearing and housing 3 Remove second bearing from shaft by supporting bearing on inner race
251. rator s Manual 6 After assembly is completed verify that hydraulic hoses and fittings do not contact anything Hydraulic System Rev A 2 6 Front Wheel Motors 101 to 115 N m Arrows side of motor case point up d Figure 74 1 Flange head screw 10 O ring 18 O ring 2 Splined brake shaft 11 Piston wheel motor 19 O ring 3 Planetary assembly 12 Flat washer 20 RH brake assembly 4 Wheel assembly 13 Cap screw 21 Hydraulic tee fitting 5 Lugnut 14 O ring 22 45 hydraulic fitting 6 Retaining ring 15 90 hydraulic fitting 23 O ring 7 LH brake assembly 16 O ring 24 Hydraulic fitting 8 Flange head screw 17 90 hydraulic elbow 25 O ring 9 Plug Hydraulic System Rev A Page 4 84 Groundsmaster 4500 D 4700 D Removal 1 Park machine on level surface lower cutting units stop engine engage parking brake and remove key from the ignition switch 2 Read the General Precautions for Removing and Installing Hydraulic System Components at the begin ning of the Service and Repairs section of this chapter NOTE To ease reassembly tag the hydraulic hoses to show their correct position on the wheel motor Also clean the port area of the motor before disconnecting the hydraulic lines 3 Disconnect hydraulic hoses and tubes from wheel motor Put caps or plugs on motor ports to prevent con tamination IMPORTANT Support wheel motor to prevent m
252. raulic GAUGE READING TO BE 600 to 640 PSI NOTE Counterbalance pressure setting toward the higher specification 640 PSI will improve traction on slopes Counterbalance pressure setting toward the lower specification 600 PSI improves quality of cut 5 Adjustment of the counterbalance valve can be per formed as follows Figure 45 1 GM 4500 D traction assist manifold NOTE Do not remove the valve from the hydraulic 2 GM 4700 D traction assist manifold manifold for adjustment 3 Counterbalance valve RV1 A To increase pressure setting turn the adjusting dial on the counterbalance valve in a clockwise di rection A 1 8 turn on the dial will make a measurable change in counterbalance pressure Fig 45 B To decrease pressure setting turn the adjusting dial on the counterbalance valve in a counterclock wise direction A 1 8 turn on the dial will make a mea surable change in counterbalance pressure Fig 45 C Recheck counterbalance pressure and readjust as needed Groundsmaster 4500 D 4700 D Page 4 45 Hydraulic System Rev A ing Pressure Gauge f Pressure Us t 5 Reli ircui TEST NO 11 Rear Traction C Working Pressure Low Pressure Return or Suction 209 ld EU 154 08 Q103INVW 1081N02 JOYVHI ONY NOIIV31TIJ FROM PTO MOW CIRCUIT FROM STEERING CONTROL FROM
253. re muffler bracket to en gine 3 Adjust tailpipe so it has equal clearance between frame and engine before tightening muffler clamp Groundsmaster 4500 D 4700 D Page 3 7 Kubota Diesel Engine Rev A Fuel System Figure 7 1 Suction fitting 7 Bushing 13 Cap screw 4 used 2 Fuel line clamp 8 Fuel level gauge 14 Hose clamp 3 Fuel hose 9 Grommet 15 Draincock 4 Return fitting 10 Fuel tank 16 Hose clamp 5 Fuel hose 11 Tank mount grommet 4 used 17 Frame 6 Fuel tank cap 12 Flat washer 4 used Because diesel fuel is highly flammable use cau tion 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 start ing the engine Store fuel in a clean safety ap proved container and keep cap in place Use die sel fuel for the engine only not for any other purpose Kubota Diesel Engine Rev A Page 3 8 Check Fuel Lines and Connections Check fuel lines and connections periodically as recom mended in the Traction Unit Operator s Manual Check lines for deterioration damage leaking or loose con nections Replace hoses clamps and connections as necessary Drain and Clean Fuel Tank Drain and clean the fuel tank periodically as recom mended in the Traction Unit Operator s Manual Also drain a
254. red or temporarily stopped 6 Three hours prior to the end of the charging mea sure the specific gravity of a battery cell once per hour The battery is fully charged when the cells are gassing freely at a low charging rate and there is less than a 0 003 change in specific gravity for three consecutive readings Groundsmaster 4500 D 4700 D TORO Table of Contents SPECIFICATIONS ADJUSTMENTS SERVICE AND REPAIRS Brake Assembly Brake Inspection and Repair Planetary Wheel Drive Assembly Planetary Wheel Drive Service Groundsmaster 4500 D 4700 D Page 6 1 Chapter 6 Axles Planetaries and Brakes Rear Axle Assembly 12 Bevel Gear Case and Axle Case 14 Differential Shafts 18 AX e Shaf DSL RE 19 Input Shaft Pinion Gear 20 Differential Gear 22 Pinion Gear to Ring Gear Engagement 25 Axles Planetaries and Brakes Rev B T 5 S 9 x and Brakes Specifications Item Specification Wheel lug nut torque front and rear 85 to 100 ft Ib 115 to 135 N m Steering cylinder bolt torque 100 to 125 ft lb 135 to 169 N m Planetary brake housing and wheel motor 75 to 85 ft lb 101 to 115 N m mounting screw torque Rear wheel toe in 125 i
255. rfaces damaged threads and contami nation Groundsmaster 4500 D 4700 D 5 Visually inspect cartridge for damaged sealing surfaces and contamination A Contamination may cause valves to stick or hang up Contamination can become lodged in small valve orifices or seal areas causing malfunction If valve sealing surfaces appear pitted or dam aged the hydraulic system may be overheating or there may be water in the system A CAUTION Use eye protection such as goggles when using compressed air 6 Clean cartridge valve using clean mineral spirits Submerge valve in clean mineral spirits to flush out con tamination Particles as fine as talcum powder can affect the operation of high pressure hydraulic valves If car tridge design allows use a wood or plastic probe to push the internal spool in and out 20 to 30 times to flush out contamination Be extremely careful not to damage car tridge Use compressed air for cleaning Groundsmaster 4500 D 4700 D Page 4 73 7 Reinstall the cartridge valve A Lubricate new seal kit components with clean hy draulic oil and install on valve The o rings sealing rings and backup rings must be arranged properly on the cartridge valve for proper operation and seal ing IMPORTANT Use care when handling the valve car tridge Slight bending or distortion of the stem tube can cause binding and malfunction B Thread cartridge valve carefully into manifold port
256. ring cone 12 onto spindle and secure with bearing shim 14 and snap ring 15 7 Install o ring 13 then secure ring gear 16 to housing 9 with socket head screws 7 and lock wash ers 8 Torque screws from 118 to 144 in Ib 13 3 to 16 3 N m Groundsmaster 4500 D 4700 D Page 6 11 8 Install secondary carrier 28 secondary gear 27 and primary carrier 26 9 Install drive shaft 25 and primary gear 24 Secure gear with retaining ring 23 10 Install thrust washer 22 and thrust plug 21 11 Install o ring 20 and end cap 19 Secure end cap with retaining ring 17 12 Check operation of planetary wheel drive before installing assembly on the machine With a constant turning force applied rotation of the planetary should be consistent If there is more drag at certain points gears are not rolling freely and the planetary should be ex amined for improper assembly or damaged compo nents Axles Planetaries and Brakes Rev B 5 S 9 x and Brakes Rear Axle Assembly 85 to 100 ft Ib 115 to 135 N m Figure 8 1 Steering cylinder 9 Cap screw 17 Tire and wheel assembly 2 Needle bearing 10 Flat washer 18 Lug nut 3 External snap ring 11 Piston motor 19 Hex plug 4 External snap ring 12 O ring 20 O ring 5 Thrust washer 13 Pinion gear 21 Drive axle assembly 6 Flat washer 14 Gear 22 Axle pivot pin 7 Lock nut 15 Cap screw 23 Stop pin
257. rminal of a12 VDC source to the positive terminal of the hour meter 2 Connect the negative terminal of the voltage source to the other terminal of the hour meter 3 The hour meter should move a 1 10 of an hour in six minutes 4 Disconnect voltage source from the hour meter Glow Relay The glow relay is attached to the battery support brack et When energized the glow relay allows electrical cur rent to the engine glow plugs Two styles of glow relays have been used on the Groundsmaster 4500 D 4700 D On machines with se rial numbers below 260000600 two of the four relay connections are secured with screws Fig 21 On ma chines with serial numbers above 260000600 the relay is attached to the wire harness with a four wire connector Fig 22 NOTE Prior to taking small resistance readings with a digital multi meter short the meter test leads together The meter will display a small resistance value usually 0 5 ohms or less This resistance is due to the internal resistance ofthe meter and test leads Subtract this val ue from from the measured value of the component you are testing 1 Verify coil resistance between terminals 86 and 85 with a multimeter ohms setting A On machines with serial numbers below 260000600 resistance should be from 41 to 51 ohms B On machines with serial numbers above 260000600 resistance should be approximately 72 ohms 2 Connectmultimeter ohms setting leads to
258. ront bracket are held together with Loctite to prevent spacer from fal ling inside the deck frame 4 Secure front height of cut bracket to deck frame with socket head bolt spacer and flange nut 5 Verify 12 o clock height Re adjust if needed Cutting Units Rev B Page 8 6 6 Determine if one or both RH and LH height of cut brackets need to be adjusted If the 3 or 9 o clock side is 150 090 inch 3 8 2 3 mm higher than the new front height then no adjustment is needed for that side Adjust other side if needed to within 090 inch 2 3 mm of correct side Adjust right and or left height of cut brackets by re peating steps 1 thru 3 8 Secure right and or left height of cut brackets with carriage bolts and flange nuts 9 Verify 12 3 and 9 o clock heights 10 Reinstall cutting unit see Cutting Unit Operator s Manual FRONT OF DECK 12 o clock 9 o clock 3 o clock A SLY 6 o clock REAR OF DECK Figure 1 Figure 2 1 Height of cut bracket 2 Shims Groundsmaster 4500 D 4700 D This page is intentionally blank 2 5 Groundsmaster 4500 D 4700 D 8 7 Cutting Units Rev Service and Repairs Never install or work on the cutting units or lift arms with the engine running Always stop en gine and remove key first Blade Spindle Assembly Figure 3 1 Flange nut 6 Spindle assembly 2 Socket head screw
259. rs section of Chapter 4 Hydraulic System 7 Install hydraulic hoses to steering cylinder and input gear case Failure to maintain proper wheel lug nut torque could result in failure or loss of wheel and may result in personal injury 8 Install wheels to axle Torque wheel lug nuts from 85 to 100 ft Ib 115 to 135 N m Lower machine to ground Groundsmaster 4500 D 4700 D Page 6 13 9 Fill axle with SAE 85W 140 weight gear lube see Traction Unit Operator s Manual 10 Check rear wheel toe in and adjustif necessary see Traction Unit Operator s Manual 11 Check steering stop bolt adjustment When the steering cylinder is fully extended right turn a gap of 1 16 1 6 mm should exist between bevel gear case casting and stop bolt on left axle case Figure 10 shows stop bolt location Figure 9 1 rod 4 Castle nut 2 Dust cover 5 Tie rod end 3 Cotter pin 6 Steering arm LH gt Figure 10 1 Steering stop bolt 2 Bevel gear case LH Axles Planetaries and Brakes Rev B 5 s 9 x and Brakes The following procedures assume the rear axle assem bly has been removed from the machine Removal 1 Remove the mounting screws nuts and lock wash ers Remove the bevel gear case axle case assembly and O ring from the axle support Fig 11 2 Mark both right and left b
260. rvoir and add correct amount of oil if necessary 14 Operate machine for 2 hours under normal operating conditions 15 Check condition of hydraulic oil If the new fluid shows any signs of contamination repeat steps 1 through 14 again until oil is clean If changing to biode gradable fluid repeat steps 1 through 14 again at least once and until the oil is clean 16 Assume normal operation and follow recommended maintenance intervals Hydraulic System Rev A 2 Ga 0 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 and its components to reduce the chance of damage IMPORTANT Change hydraulic oil filter whenever hydraulic components are repaired or replaced 1 Park machine on alevel surface Lower cutting units stop engine and engage parking brake Remove key from the ignition switch 2 Make sure all hydraulic connections lines and com ponents are secured tightly Ifcomponentfailure was severe or the system is con taminated flush and refill hydraulic system and tank see Flush Hydraulic System 4 Make sure hydraulic reservoir is full Add correct hy draulic oil if necessary see Traction Unit Operator s Manual 5 Disconnect engine run solenoid lead to prevent the engine from star
261. s Drawings The electrical schematics and other electrical drawings for the Groundsmaster 4500 D and Groundsmaster 4700 D are located in Chapter 9 Electrical Diagrams Special Tools Order special tools from your Toro distributor Some tools may also be available from a local supplier Multimeter The multimeter can test electrical components and cir cuits for current resistance or voltage NOTE Toro recommends the use of a DIGITAL Volt Ohm Amp multimeter when testing electrical circuits The high impedance internal resistance of a digital me ter in the voltage mode will make sure that excess cur rent is not allowed through the meter This excess current can cause damage to circuits not designed to carry it Skin Over Grease Special non conductive grease Toro Part No 505 165 which forms a light protective skin to help wa terproof electrical switches and contacts Electrical System Rev A Page5 2 Rev D Figure 1 Figure 2 Groundsmaster 4500 D 4700 D Troubleshooting For effective troubleshooting and repairs you must have a good understanding of the electrical circuits and A CAUTION components used on this machine Chapter 9 Electrical Diagrams Remove all jewelry especially rings and watches before doing any electrical trouble If the machine has any interlock switches by passed shooting or testing Disconnect the battery reconnect the switches for proper troubleshooting and cables unle
262. s an assembly Fig 23 2 Useabearing puller to remove the bearing and bevel gear as shown Fig 24 3 Remove the shims spacer and retaining ring Drive the axle out of the bearing and cover Remove and dis card the axle shaft seal 4 Inspect all gears shafts bearings spacers and cases for damage and wear Replace components as necessary Installation 1 Coat new axle shaft seal with grease and install in axle cover as shown Fig 25 2 Press the axle cover and bearing assembly onto the axle shaft Press only on the inner race of the cover bearing Fig 25 3 Install retaining ring spacer and correct combina tion of bearing shims Install bevel gear and bearing 4 Coat a new O ring with grease and install the axle cover assembly Tighten axle cover screws from 17 to 20 ft lb 23 to 27 N m Groundsmaster 4500 D 4700 D Page 6 19 17 to 20 ft Ib 23 to 27 N m Figure 23 3 Mounting screw 4 O ring 1 Axle case 2 Axle cover assembly Figure 24 1 Bearing 4 Spacer 2 Bevel gear 5 Retaining ring 3 Shims Figure 25 1 Axle shaft seal 3 Bearing 2 Axle cover 4 Axle shaft Axles Planetaries and Brakes Rev B o 5 S 9 x and Brakes Input Shaft Pinion Gear 35 to 41 ft lb 47 to 56 N m 35 to 41 ft lb 47 to 56 N m Figure 26 1 Nut 7 O ring 13 Shim 2 Lockwasher 8 Seal collar 14 Screw 3 Stud 9 Bearing 15 Gear case
263. s that are in contact with gears should be free of wear roughness or scoring C Thickness of bearing blocks should be equal 5 Inspect front flange and rear cover for damage or wear Figure 80 3 Gear teeth 1 Gear shaft spline 2 Gear shaft 4 Gear face edge Reassembly Fig 78 NOTE When reassembling the motor check the mark er or scribe marks on each part to make sure the parts are properly aligned during reassembly 1 Lubricate o rings pressure seals and bearing block grooves with a thin coat of petroleum jelly Lubricate all other internal parts freely with clean hydraulic oil 2 Install inner shaft seal into front flange with seal lip facing in Fig 81 Seal should be pressed into place un til it reaches the bottom of the bore 3 Install retaining ring into the groove of the front flange 4 Install outer shaft seal in front flange with seal lip fac ing out Fig 81 Seal should be pressed into place until it reaches the bottom of the bore 5 Place front flange shaft seal side down flat sur face 6 Install the pressure seals into the grooves in the bearing blocks 7 Apply alight coating of petroleum jelly to the exposed side of the front flange Hydraulic System Rev A gt LU gt 8 Lubricate the drive gear shaft with clean hydraulic oil Noting the open and closed sides of the front bearing block insert the drive end of the drive shaft through t
264. se block is located under the operator s control panel Machines with serial numbers below 220999999 have four 4 fuses Fig 5 Machines with serial num bers above 230000000 have six 6 fuses Fig 6 Identification Function and Wiring The fuses are held in the fuse block Use Figure 7 to identify each individual fuse and its correct amperage Each fuse holder has the following functions and wire connected to it Fuse 1 15 Amp A Supplies power to ignition switch terminal B Fuse 2 10 Amp A Supplies power to the PTO circuit Fuse 3 10 Amp A Supplies power to the power point outlet Fuse 4 10 Amp A Supplies power from ignition switch terminal Fuse 5 2 Amp Only on machines with Serial Number above 230000000 A Supplies power from ignition switch terminal to Standard Control Module Fuse 6 10 Amp Only on machines with Serial Number above 230000000 A Supplies power from ignition switch terminal S Testing Remove fuses from the fuse block for testing Fuse should have continuity between fuse terminals Electrical System Rev A 5 8 lee Figure 5 1 Control panel 2 Fuse block Figure 6 1 Control panel 2 Fuse block Figure 7 Groundsmaster 4500 D 4700 D Indicator Lights Testing Indicator Lights 1 Apply 12 VDC to terminals 1A and 2A 2 Grou
265. sembly onto frame aligning splined brake shaft with input shaft on planetary wheel drive Groundsmaster 4500 D 4700 D 6 5 3 Install flange head screws 11 to secure brake as sembly to frame Tighten screws in a crossing pattern to a torque from 75 to 85 ft Ib 101 to 115 N m 4 Install brake cable to pull rod on brake assembly Brake cable end should be completely threaded onto pull rod 5 Install new o ring on hydraulic wheel motor Install wheel motor and torque capscrews from 75 to 85 ft lb 101 to 115 N m Failure to maintain proper torque could result in failure or loss of wheel and may result in personal injury 6 Install wheel assembly Torque lug nuts from 85 to 100 ft Ib 115 to 135 N m 7 Lower machine to ground 8 Make sure drain plug is installed in bottom of brake assembly Fig 3 Fill planetary wheel drive brake as sembly with SAE 85W 140 gear lube see Traction Unit Operator s Manual 9 Check and adjust brake cables for proper brake op eration see Traction Unit Operator s Manual Figure 2 1 Splined brake shaft step 2 Hydraulic motor end 3 Planetary assembly end Figure 3 1 Brake housing 3 Drain plug 2 Check plug Axles Planetaries and Brakes Rev B o 5 o S 9 x and Brakes Brake Inspection and Repair Figure 4 1 Brake housi
266. sh oil cooler with cleaning solvent After cool er is clean make sure all solvent is drained from the cooler A CAUTION Use eye protection such as goggles when using compressed air 2 Dry inside of oil cooler using compressed air in the opposite direction of the oil flow 3 Plug both ends of oil cooler Clean exterior of cooler Make sure fins are clear of dirt and debris 4 The oil cooler should be free of corrosion cracked tubes and excessive pitting of tubes Installation 1 Install oil cooler using Figures 101 102 and 103 as guides 2 Fill reservoir with hydraulic fluid as required see Traction Unit Operator s Manual Groundsmaster 4500 D 4700 D Page 4 1 Figure 101 1 Oil cooler latch 3 Hose from oil cooler 2 Hose to oil cooler 5 gt 2 Figure 102 1 Oil cooler latch 2 Oil cooler Figure 103 1 Oil cooler 6 Clamp 2 Washer 7 Flat washer 3 Flange head screw 8 Cap screw 4 Flange nut 9 Wire form latch 5 Mount plate 10 Cap screw 19 Hydraulic System Rev A This page is intentionally blank Hydraulic System Rev A Page 4 120 Groundsmaster 4500 D 4700 D TORO Table of Contents ELECTRICAL SCHEMATICS AND ELECTRICAL HARNESS AND CONNECTORS DRAWINGS SPECIAL TOOLS TROUBLESHOOTING Starting Problems General Run amp Transport Problems Cutting Unit Operating Proble
267. smaster 4500 0 4700 0 5 13 Electrical System Rev The ramp up module is located under the console cover Fig 19 The ramp up module is used to prevent hydraulic spikes that could affect cutting system hydraulic compo nents As the PTO relay for decks 1 to 5 is energized the ramp up module provides a gradual increasing cur rent flow to the cutting deck solenoid valves Solenoid ramp up time occurs in 1 75 seconds The Ramp up module has no affect on operation of decks 6 and 7 on the GM 4700 D The ramp up module can be monitored by the three LED s located onthe module below the harness connec tion 1 All module LED s will be off when the PTO switch is Figure 19 OFF 1 Ramp up module 2 Harness connection 2 When the PTO switch is turned ON and interlock switches allow cutting deck operation seat occupied decks lowered etc the Power LED will illuminate im mediately The 51 and S2 LED s will gradually illumi nate during the 1 75 second ramp up time 3 After initial PTO startup all LED s will be illuminated fully while PTO is ON 4 All LED s will out immediately with the interruption of PTO operation e g PTO switch turned off or cutting deck raised Electrical System Rev A Page 5 14 Groundsmaster 4500 D 4700 D The meter is located on the control console next to the operator seat 1 Connectthe positive te
268. ss the test requires battery voltage safety Starting Problems All electrical power is dead including gauges The battery charge is low Fuse 1 to the ignition switch is open failed Bad ground connection on machine The ignition switch or circuit wiring is faulty The fusible link from the battery is faulty Starter solenoid clicks but starter will not crank Low battery charge NOTE Ifthe solenoid clicks the problem is not in the in es Loose or corroded battery cables terlock circuit Loose or corroded ground Faulty wiring at the starter System Faulty starter solenoid Faulty starter Nothing happens when start attempt is made Control The traction pedal is not in neutral position or the panel lights and gauges operate with the ignition neutral switch or circuit wiring is faulty switch in ON The cutting units are engaged Faulty ignition switch or circuit wiring Start relay or circuit wiring is faulty Starter solenoid or starter motor is faulty Engine starts but stops when the ignition switch is The engine run solenoid is out of adjustment or circuit released from the START position wiring is faulty High temperature shutdown switch or circuit wiring is faulty Groundsmaster 4500 D 4700 D Page 5 Electrical System Rev Starting Problems continued Engine cranks but does not start Starter cranks but should not when the traction pedal is depressed Ge
269. stable 1 Make sure both threads and sealing surfaces are free of burrs nicks scratches or any foreign material 2 Always replace the O ring seal when this type of fit ting shows signs of leakage 3 Lubricate the O ring with a light coating of oil 4 Install the fitting into the port and tighten it down full length until finger tight 5 Tighten the fitting to the correct Flats From Finger Tight F F F T Size F F F T 4 1 4 in nominal hose or tubing 1 00 0 25 6 3 8 in 1 50 0 25 8 1 2 in 1 50 0 25 10 5 8 in 1 50 0 25 12 3 4 in 1 50 0 25 16 1 in 1 50 0 25 NOTE Installation torque values for non adjustable fit tings are listed in Figure 4 These torque values should only be used when a fitting can be accessed with a socket Use of an offset wrench e g crowfoot wrench will affect torque wrench accuracy and should not be used SAE Straight Thread O Ring Port Adjustable 1 Make sure both threads and sealing surfaces are free of burrs nicks scratches or any foreign material 2 Always replace the O ring seal when this type of fit ting shows signs of leakage 3 Lubricate the O ring with a light coating of oil 4 Turn back the jam nut as far as possible Make sure the back up washer is not loose and is pushed up as far as possible Step 1 5 Install the fitting into the port and tighten finger tight until the washer contacts the face of the port Step 2 6 Toputthe f
270. stem Rev A Steering Circuit Athree section gear pump is coupled to the piston trac tion pump The gear pump section P3 supplies hy draulic 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 The gear pump takes its suction from the hydraulic reservoir Steering circuit pressure is limited by a relief valve lo cated in the steering control Pressure to the steering control valve can be monitored at a port on the end of the gear pump With the steering wheel in the neutral position rear wheels positioned straight ahead and the engine run ning flow enters the steering control valve at the P port and goes through the steering control spool valve by passing the rotary meter V1 and steering cylinder Flow leaves the control valve through the PB port to the oil filter and traction charge circuit Left Turn When a left turn is made with the engine running the turning of the steering wheel positions the spool valve so that flow goes through the top of the spool Flow entering the steering control valve at the P port goes through the spool and is routed to two places First most of the flow through the valve is by passed out the PB port back to the oil filter and traction charge circuit Second the re mainder of the flow is drawn through the rotary meter V1 and out the L port Pressure contracts the piston for STEE
271. t e g Loctite degree of lubrication on the fastener presence of a prevailing torque feature hardness ofthe surface underneath the fastener s head or similar condition which affects the installation Fastener Identification Grade 1 Grade 5 Inch Series Bolts and Screws Figure 1 Groundsmaster 4500 D 4700 D 2 3 As noted in the following tables torque values should be reduced by 25 for lubricated fasteners to achieve the similar stress as a dry fastener Torque values may also have to be reduced when the fastener is threaded into aluminum or brass The specific torque value should be determined based on the aluminum or brass material strength fastener size length of thread en gagement etc The standard method of verifying torque shall be per formed by marking a line on the fastener head or nut and mating part then back off fastener 1 4 of a turn Measure the torque required to tighten the fastener until the lines match up D Class 8 8 Class 10 9 Metric Bolts and Screws Figure 2 Product Records and Maintenance Product Records 2 Standard Torque for Dry Zinc Plated and Steel Fasteners Inch Series Grade 1 5 amp SAE Grade 1 Bolts Screws Studs amp SAE Grade 5 Bolts Screws Studs amp SAE Grade 8 Bolts Screws Studs 8 Thread Size 8 with Thin Sems with Regular Height Nuts Sems with Regular Height Nuts Sems with Regular H
272. t Summary in this section of this manual Example If the pinion gear to ring gear backlash is set m Figure 39 correctly to specifications and the bearing case shim is 1 Inputshaft pinion gear 4 Differential bearing changed to adjust tooth contact it may be necessary to 2 Bearing case shims shims readjust backlash to the correct specification before 3 Differential gear case checking the contact pattern Groundsmaster 4500 D 4700 D Page 6 25 Axles Planetaries and Brakes Rev B Gear Pattern Movement Summary Heel Contact Base Contact Every gear has acharacteristic pattern The illustrations show typical patterns only and explain how patterns shift as gear location is changed 1 If contact is toward the heel or base of the gear Fig 40 A Install thicker or additional bearing case shim s to move pinion shaft toward ring gear Figure 40 B Install thinner or remove differential bearing shim s to move ring gear backward m Toe Contact Tip Contact C Repeat until proper tooth contact and pinion gear to ring gear backlash are correct Ss Ss 2 If contact is toward the toe or tip of the gear Fig 41 A Install thinner or remove bearing case shim s to move pinion shaft away from ring gear B Install thicker or additional differential bearing shim s to move ring gear forward Figure 41 C Repeat until proper tooth contact and pinion gear to ring gear backlash are correct Axles Plane
273. t be on the pressure side of the pump The side of the wear plate with mid section cut out must be on suction side of pump Suction side of backplate or adapter plate is always the side with larger port boss 1 Replace the wear plates pressure seals backup gaskets shaft seal and o rings as new parts During re assembly check the scribe mark on each part to make sure the parts are properly aligned 2 Install o rings 4 in groove of front plate 15 adapt er plates 23 and 24 and backplate 27 using a small amount of petroleum jelly to hold in place 3 Install new pressure seals 13 and backup gaskets 14 into new wear plates 12 The flat section in the middle of the backup gasket must face away from the wear plate inside the seal 4 Place plug 8 into pocket of front plate 15 5 Apply athin coatof petroleum jelly to both milled gear pockets of front body 10 Position body onto front plate 15 with half moon port cavities in body facing away from front plate NOTE The small half moon port cavity must be on the pressure side of pump 6 Place wear plate 12 into the gear pocket with the pressure seal and backup gasket againstthe front plate The side with the mid section cut away must be on suc tion side of pump 7 Dip drive gear assembly 11 and idler gear assem bly 16 into clean hydraulic oil Slip both gear assem blies into gear pocket of front body 10 and into front plate bushings 8 Insta
274. taries and Brakes Rev B Page 6 26 Groundsmaster 4500 D 4700 D 7 TORO Table of Contents GENERAL INFORMATION 1 Lift Arms For Cutting Decks 2 3 6 Cutting Deck Identification 1 Lift Arms For Cutting Decks 6 and 7 SERVICE AND REPAIRS 2 Groundsmaster 4700 D only 8 Steering 2 HOGA ET MP HIE 10 Lift Arms For Cutting Decks 1 4 and 5 4 General Information Cutting Deck Identification Cutting decks on the Groundsmaster 4500 D and 4700 D are identified as shown in Figure 1 CUTTING DECK LOCATIONS Figure 1 Groundsmaster 4500 D 4700 D Page 7 1 Chassis Service and Repairs Steering Tower Steering wheel cover Hex nut Steering wheel Parking brake knob Dust cover Flange head screw Friction disc Spring pin Cotter pin 10 Cable 11 Flat washer 12 Lock nut 13 Spring washer 14 Tube 15 Lever bracket 16 Steering column Chassis Figure 2 Steering valve Warning lamp temp glow plug Warning lamp oil pressure charge Speed control knob Speed control lever Instrument plate Steering column bracket Flange head screw Compression spring Flange head screw Lock washer Flat washer Cotter pin Parking brake rod Ignition switch Tower cover Page 7 2 Rev D
275. te continuity across the switch terminals 5 Apply the parking brake There should be no continu ity across the switch terminals 6 Replace switch as needed Reconnect switch Switch Adjustment 1 Adjust switch to have 1 16 in 1 6 mm clearance be tween switch and sensing plate on the brake rod when the parking brake is released Groundsmaster 4500 D 4700 D Page 5 11 Electrical System Rev A Cutting Deck Switch The cutting deck position switch is a normally open prox imity switch that is located on the traction unit frame Fig 14 The sensing plate is located on the cutting deck lift arm The GM 4500 D uses two cutting deck position switches for decks 4 and 5 There are four deck position switches on the GM 4700 D for decks 4 5 6 and 7 When the cutting deck is raised the sensing plate is moved away from the position switch and the switch opens This open switch prevents current flow to the PTOrelay andthe cutting deck hydraulic solenoid valve keeping the cutting decks from operating Switch Testing 1 Park machine on a level surface lower cutting units stop engine engage parking brake and remove key from the ignition switch 2 Disconnect deck position switch that requirestesting from machine wiring harness 3 Check the continuity of the switch by connecting a multimeter ohms setting across the switch connector terminals 4 With the cutting unit in the lowered position there sh
276. ted by anything Hydraulic System Rev A 2 FE 6 Oo Steering Cylinder Service Figure 99 1 Butt and tube assembly 5 Lock nut 9 O ring 2 Shaft 6 O ring 10 U cup 3 Piston rod assembly 7 PTFE seal 11 Wiper 4 Gland 8 O ring Hydraulic System Rev A Page 4 116 Rev C Groundsmaster 4500 D 4700 D Disassembly IMPORTANT To prevent damage when clamping cylinder barrel or rod vise clamp only on pivotal ends 1 Pump oil out of cylinder into a drain pan by SLOWLY moving rod and piston in and out of cylinder bore Plug ports and clean outside of cylinder 2 Mount cylinder in a vise so piston rod end of cylinder is tilted up slightly Do not close vise so firmly that cylin der tube could become distorted Loosen gland with spanner wrench 3 Grasp end of piston rod and use a twisting and pull ing motion to carefully extract piston piston rod and gland from cylinder tube IMPORTANT Do not clamp vise jaws against smooth piston rod surface the piston rod will be come damaged 4 Securely mount piston piston rod and gland into vise and remove lock nut Remove piston and gland from rod 5 Remove all seals and O rings 6 Wash parts in clean solvent Dry parts with com pressed air Do not wipe parts dry with paper towels or cloth Lint in a hydraulic system will cause damage 7 Carefully inspect internal surface of barrel for dam age deep scratches out of round etc R
277. tely seated There should be no input shaft pinion gear end play 3 Coata new oil seal with grease and install as shown Fig 27 The seal should be installed with the garter spring towards the hydraulic motor 4 Coat new O ring with grease Install O ring in the oil seal collar and install the collar 5 Install a new stake washer Install the lock nut finger tight Groundsmaster 4500 D 4700 D 6 Setthe bearing preload by securing the bearing case in a vise Thread a M12 x 1 5 hex head cap screw into the splined end ofthe input shaft pinion gear and slowly tighten the locknut until 4 to 6 in Ib 0 4 to 0 7 N m of force is required to rotate the input shaft pinion gear in the bearing case 7 Secure the lock nut with the stake washer 8 Useadepth gauge to measure the distance from the end face of the input shaft pinion gear to the mating sur face of the bearing case Subtract the Design Cone Center Distance from this distance to determine initial shim thickness Fig 28 DESIGN CONE CENTER DISTANCE distance from mating surface of axle support to end face of pinion gear 1 870 0 002 in 47 5 0 05 mm NOTE Bearing case shims are available in 0 004 in 0 1 mm and 0 008 in 0 2 mm thickness 9 Coatnew O rings with grease and install the bearing case in the gear case Place shims on the gear case and temporarily install gear case assembly into axle case Tighten mounting nuts and screws from 35 to 41 ft Ib 4
278. the highest and lowest cell specific gravity is 0 050 or greater or the lowest cell specific gravity is less than 1 225 charge the bat tery Charge at the recommended rate and time giv en in Charging or until all cells specific gravity is 1 225 or greater with the difference in specific gravity between the highest and lowest cell less than 0 050 If these charging conditions can not be met replace the battery 3 Perform a high discharge test with an adjustable load tester This is one of the most reliable means of testing a battery as it simulates the cold cranking test Acommercial bat tery load tester is required to perform this test A CAUTION Follow the manufacturer s instructions when us ing a battery tester A Check the voltage across the battery terminals prior to testing the battery If the voltage is less than 12 4 VDC recharge the battery B Ifthe battery has been charged apply a 150 amp load for 15 seconds to remove the surface charge Use a battery load tester following the manufactur er s instructions C Make sure battery terminals are free of corrosion D Measure the temperature of the center cell E Connect a battery load tester to the battery termi nals following the manufacturer s instructions Connect a digital multimeter to the battery terminals F Apply atest load of one half the Cranking Perfor mance see Battery Specifications rating of the bat tery for 15 seconds G Take
279. the machine and the other should read and record test results Operate all hydraulic controls to relieve system pressure and avoid injury from pressurized hy draulic oil Controls must be operated with the ignition switch in OFF Remove key from the igni tion switch WARNING Keep body and hands away from pin hole leaks or nozzles that eject hydraulic fluid under high pressure Do not use hands to search for leaks use paper or cardboard Hydraulic fluid escaping under pressure can have sufficient force to penetrate the skin and cause serious injury If fluid is injected into the skin it must be surgically removed within a few hours by a doctor familiar with this type of injury Gan grene may result from such an injury Groundsmaster 4500 D 4700 D Page 4 25 Before disconnecting or performing any work on the hydraulic system all pressure in the system must be relieved and all rotating ma chine parts must be stopped Stop engine lower or support attachments 1 Clean machine thoroughly before disconnecting or disassembling any hydraulic components Always keep in mind the need for cleanliness when working on hy draulic equipment Contamination will cause excessive wear of components 2 Put metal caps or plugs on any hydraulic lines left open or exposed during testing or removal of compo nents 3 Theengine must be in good operating condition Use a phototac to determine engine speed when performin
280. the same height of cut Adjust cutting units as specified in the Cutting Unit Operator s Manual Adjust height of cut setting to remove only 1 inch 2 5 cm or 1 3 of the grass blade when cutting 7 Cutting unit alignment and ground following Check lift arms and cutting unit pivot linkages for wear damage or binding Also inspect for bent or damaged pivot shafts 8 Roller condition rollers should rotate freely Replace bearings if worn or damaged 9 Grass Conditions Mow when grass is dry for best cutting results 2 5 Groundsmaster 4500 D 4700 D Page 8 Cutting Units Rev B Special Tools Order these special tools from your Toro Distributor Cutting Unit Tool Kit TOR4070 This tool kit includes special tools used to assemble the cutting unit rear roller that has greasable bearings with a grease fitting on the ends of the roller shaft TOR4064 Spanner Wrench TOR4065 Inner Oil Seal Installer TOR4066 Bearing Installer TOR4067 Shaft Support Tool TOR4068 Inner Seal Installer TOR4869 Outer Seal Installer TOR4071 Outer Oil Seal Installer TOR4072 Shaft Seal Protector TOR4073 Handle TOR4074 Spline Insert Tool Figure 1 Rear Roller Grease Nozzle 107 1998 This tool is used to grease the cutting unit rear roller bearings when equipped with greasable bearings Figure 2 Rear Roller Bearing and Seal Installation Tools These tools are used to assemble the cutting unit rea
281. til the light goes off Mark this position B E Unscrew the switch one third of the distance be tween and Install and tighten the set screw 17 in one of the upper quadrants of the hex of the switch adapter Fig 63 Torque set screw from 28 to 34 3 2 to 3 8 Groundsmaster 4500 D 4700 D Page 4 69 5 Test the switch by moving the control arm to the det ent position the light should be on Move the control arm out of detent the light should go off 6 Remove test light and put servo control assembly into operation Reassembly Step 4 C Reassembly Step 4 D Reassembly Step 4 E Figure 63 Hydraulic System Rev A 2 5 29 gt Hydraulic Control Manifolds 2 Wheel 4 Wheel Drive Filtration and Charge Power Down and Traction Assist Figure 64 1 Power down traction assist manifold 4 Flange head screw 4 used 6 Cap screw 2 used 2 Flange head screw 3 used 5 2WD AWD manifold 7 Flange nut 2 used 3 Filtration charge manifold Hydraulic System Rev A Page 4 70 Groundsmaster 4500 D 4700 D Removal NOTE The ports on the manifolds are marked for easy identification of components Refer to the Hydraulic Schematics to identify the function of the hydraulic lines and cartridge valves at each port 1 Read the General Precautions for Removing and Installing Hydraulic System Components at the be
282. ting 6 Check control rod to the piston traction pump for proper adjustment binding or broken parts 7 Make sure traction pedal and lift control lever are in the neutral position Turn ignition key switch engage starter for fifteen 15 seconds to prime the traction and gear pumps 8 Reconnect engine run solenoid lead Before jacking up the machine review and follow Jacking Instructions in Chapter 1 Safety 9 Raise one front and one rear wheel off the ground and place support blocks under the frame Chock re maining wheels to prevent movement of the machine 10 Make sure traction pedal and lift control lever are in neutral Start engine and run it at low idle 1300 rpm The charge pump should pick up oil and fill the hydraulic system If there is no indication offill in 30 seconds stop the engine and determine the cause Hydraulic System Rev A Page 4 54 11 After the hydraulic system starts to show signs of fill actuate lift control lever until the lift cylinder rod moves in and out several times If the cylinder rod does not move after 10 to 15 seconds or the pump emits abnor mal sounds shut the engine off immediately and deter mine cause or problem Inspect for the following A Loose filter or suction lines B Blocked suction line C Faulty charge relief valve D Faulty gear pump 12 If cylinder does move in 10 to 15 seconds proceed to step 13 13 the traction pedal in t
283. ting 17 Hydraulic hose 28 Coupler 7 Dust cap 18 Hydraulic hose 29 Cap screw 8 90 hydraulic fitting 19 Hydraulic hose 30 Washer 9 Clamp 20 Hydraulic hose 31 O ring 10 90 hydraulic fitting 21 O ring 32 Spacer 11 O ring 22 Hydraulic fitting Hydraulic System Rev A Page 4 56 Groundsmaster 4500 D 4700 D Removal 1 Park machine on level surface lower cutting units stop engine engage parking brake and remove key from the ignition switch 2 Raise seat and secure it with prop rod to gain access to gear pump 3 Drain the hydraulic reservoir see Traction Unit Op erator s Manual 4 To prevent contamination of hydraulic system during removal thoroughly clean exterior of pump and fittings 5 Read the General Precautions for Removing and Installing Hydraulic System Components at the begin ning of the Service and Repairs section of this chapter 6 Disconnect hydraulic lines from gear pump and put caps or plugs on open hydraulic lines and fittings Label disconnected hydraulic lines for proper reassembly 7 Support gear pump assembly to prevent it from fal ling 8 Remove two 2 cap screws and washers securing gear pump to piston pump Remove gear pump cou pler spacer and o rings from machine Groundsmaster 4500 D 4700 D Page 4 57 Installation 1 Lubricate new o rings with clean hydraulic oil and position on gear pump 2 Slide coupler onto the piston pump output shaft 3 P
284. to ful ly seat seals against roller shoulder Fig 13 Apply a small amount of grease aroundthe lip of both inner seals after installation IMPORTANT During assembly process frequently check that bearings rotate freely and do not bind If any binding is detected consider component re moval and reinstallation 2 Install new bearing and outer seals into one end of roller tube A Position a new bearing into one end of roller tube Use bearing outer seal tool see Special Tools with a soft face hammer to fully seat bearing against roller shoulder Fig 14 After bearing installation make sure that it rotates freely with no binding B Apply a small amount of grease around the lip of both outer seals 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 and soft face hammer to lightly seat seal against roller shoulder Fig 15 Make sure that bearing still freely rotates after seal installation D Using the same process install second outer seal making sureto not crush the installed outer seal Again make sure that bearing still freely rotates Cutting Units Rev B 50 to 60 ft Ib 68 to 81 N m Figure 12 1 Roller tube 5 Outer seal 2 Roller shaft 6 Bearing lock nut 3 Inner seal 7 Setscrew 4 Bearing Page 8 16 Rev D S Figure 13 Rol
285. top engine engage parking brake and remove key from the ignition switch gt EN VY 2 Remove cutting deck from lift arm see Cutting Unit Operator s Manual 3 Remove lift cylinder pin that secures lift cylinder to lift arm 4 Loosen and remove lock nut from pivot pin 5 Support lift arm and pull lift arm pivot pin from lift arm and frame Locate and remove thrust washer from rear of lift arm during pivot pin removal 6 Remove lift arm from machine CUTTING DECK LOCATIONS 7 Clean lift arm and pivot pin Inspect lift arm flange Figure 7 bushings and pivot pin for damage or wear Installation 1 Position lift arm to frame Fig 6 Fit thrust washer between rear of lift arm and frame Slide pivot pin into frame and lift arm Align roll pin in pivot pin with slot in frame flange 2 Install andtighten lock nutto secure lift arm pivot pin 3 Install lift cylinder to lift arm with cylinder pin Secure cylinder pin to lift arm with flange head screw and flange nut NOTE Install thrust washer on deck pivot shaft before installing cutting deck on pivot shaft 4 Position and install cutting deck to lift arm see Cut ting Unit Operator s Manual NOTE The lift arms for cutting decks 2 and are fitted with a lift arm rotation stop block 27 This stop is to keep the deck stable while raised To adjust rotation stop loosen set screws and fully raise cutting deck to position the stop Apply medium str
286. trol Manifold Service 2 Wheel 4 Wheel Drive Con trol in this section Refer to Figure 66 for cartridge valve installation torque Hydraulic System Rev A Page 4 74 Groundsmaster 4500 D 4700 D Hydraulic Control Manifold Service Power Down and Traction Assist GM 4500 D 25 ft Ib 33 9 N m 2 5 i gt Figure 67 1 Manifold body 4 Expanding plug not serviced 6 Traction pressure sensing valve 2 Traction assist valve RV2 port 2 5 Lift relief RV7 port 7 PD3 port 5 3 Counterbalance valve RV1 port 4 NOTE The ports on the manifold are marked for easy identification of components Example CB is the con nection port from the lift lower control valve and CHG is the charge circuit connection See Hydraulic Schemat ics to identify the function of the hydraulic lines and car tridge valves at each port For cartridge valve service procedures see Hydraulic Control Manifold Service 2 Wheel 4 Wheel Drive Con trol in this section Refer to Figure 67 for cartridge valve installation torque Groundsmaster 4500 D 4700 D Page 4 75 Hydraulic System Rev A Hydraulic Control Manifold Service Power Down and Traction Assist GM 4700 D 25 ft Ib 3 33 9 N m 7 2 27 1 N m 25 ft Ib 33 9 N m 3 20 ft lb 27 1 N m 5 7 20 ft Ib 27 1 N m Figure 68 1 Manifold body 4 Counterbalance valve
287. ty switch plate Removal 3 If lift arm for either deck 4 or 5 Fig 4 is to be re moved tag and remove hydraulic hoses from the deck 1 Park machine on a level surface lower cutting units motor Fig 5 Slide hoses out of the hose retaining loop stop engine engage parking brake and remove key on the lift arm from the ignition switch 4 Removelift cylinder pin that secures lift cylinder to lift 2 Remove cutting deck from lift arm see Cutting Unit arm Operator s Manual 5 Loosen and remove lock nut from lift arm pivot pin Chassis 7 4 Groundsmaster 4500 D 4700 D 6 Support lift arm and pull lift arm pivot pin from lift arm and frame Locate and remove thrust washer from rear of lift arm during pivot pin removal 7 Remove lift arm from machine 8 Clean lift arm and pivot pin Inspect lift arm flange bushings and pivot pin for damage or wear Installation 1 Position lift arm to frame Fig 3 Fit thrust washer between rear of lift arm and frame Slide pivot pin into frame and lift arm Align roll pin in pivot pin with slot in frame flange 2 Install and tighten lock nut to secure lift arm pivot pin 3 Install lift cylinder to lift arm with cylinder pin Secure cylinder pin to lift arm with flange head screw and flange nut NOTE Install thrust washer on deck pivot shaft before installing cutting deck on pivot shaft 4 Position and install cutting deck to lift arm see Cut ting Unit Operator
288. urface with the cutting units lowered and off Make sure engine is off and the parking brake is engaged Prevent personal injury and or damage to equip ment Read all WARNINGS CAUTIONS and Pre cautions for Hydraulic Testing at the beginning of this section Raise seat to gain access to steering circuit test port located on the front end of the gear pump Fig 37 Con nect a 5000 PSI gauge onto steering circuit test port Route gauge hose to allow seat to be safely lowered 4 Start the engine and move throttle to full engine speed 2800 50 RPM IMPORTANT Hold steering wheel at full lock only long enough to get a system pressure reading Holding the steering wheel against the stop for an extended period will damage the steering motor 5 Turn steering all the way in one direction and mo mentarily hold the steering wheel against resistance GAUGE READING TO BE 1150 TO 1500 PSI 6 Stop the engine 7 If pressure is incorrect inspect steering relief valve located in the steering control valve Fig 38 If relief valve is operating properly and iflift lower problems also exist gear pump should be suspected of wear and ineffi ciency If steering wheel continues to turn at end of cylin der travel with lower than normal effort steering cylinder or steering control valve should be suspected of wear or damage Figure 37 1 Steering circuit test port 2 Gear pump 5 gt Figure
289. ut gear case of the rear axle Cleanliness is extremely important when repairing hy draulic motors Work in a clean area Before disconnect ing the lines clean port area of motor Thoroughly clean the outside of the motor After cleaning remove port plugs and drain oil from motor Hydraulic System Rev A Page 4 86 Disassembly 1 Clampthe drive shaftend ofthe piston motor in a pro tected jaw vise with the cap screws up Remove the six cap screws 7 from the motor assembly 2 Use a soft face hammer and tap the backplate 2 to loosen and remove from housing 3 Remove valve plate 12 and O ring 11 from back plate It is not necessary to remove roll pins 14 and 15 in backplate Groundsmaster 4500 D 4700 D 4 Remove motor from vise and remove rotating as sembly 4 from motor housing 5 Remove the camplate insert 5 from housing Use caution not to mar the finish that makes contact with pis tons 6 Remove retaining ring 6 from housing Press shaft from housing and remove shaft seal 8 and washer 18 7 Remove retaining rings 9 from shaft and remove thrust races 10 and thrust bearing 13 8 Discard the shaft seal and o ring and replace with new items upon reassembly Inspection 1 Check the condition of the needle bearing 16 in backplate 2 and replace if necessary 2 Inspectvalve plate 12 on the bronze side next to the piston block for wear A smooth surface is required Do
290. uts from the neutral parking brake PTO start igni tion and high temperature switches are monitored by the Module Output to the PTO deck drive solenoids fuel pump and engine run solenoid are controlled based on the inputs received by the Module The Standard Control Module does not connect to an external computer or hand held device can not be re programmed and does not record intermittent fault data The Standard Control Module can be used to check op eration of machine switches by monitoring the LED s of the module Module LED does not illuminate e g the in seat input LED does not illuminate with the seat occu pied and the ignition switch in the run position testing of the switch and circuit wiring would be required Refer to the Operator s Manual for operation and trou bleshooting of the Standard Control Module Electrical System Rev A Page 5 26 1 2 Start input LED Start output LED PTO output LED Figure 41 Control panel Standard control module Figure 42 6 Neutral input LED 7 Park brake off input LED Engine run output LED 8 PTO switch input LED 9 In seat input LED 10 High temp input LED 11 Backlap input not used Groundsmaster 4500 D 4700 D Service and Repairs NOTE For more component repair information see the Kubota Workshop Manual Diesel Engine V2003 T Series at the end of Chapter 3 Kubota Diesel Engines Battery St
291. ve Percent of Fully Charged Capacity nt 80 less 3 8hrs 7 5 hrs 11 3hrs 15 hrs 3 amps 3 amps 3 amps 3 amps 81 to 125 5 3 hrs 4 amps 10 5 hrs 15 8 hrs 21 hrs 4 amps 4amps 4 amps 126 to 5 5 hrs 11 hrs 16 5 hrs 22 hrs 170 5 amps 5 amps 5 amps 5 amps 171 to 5 8 hrs 11 5 hrs 17 3hrs 23 hrs 250 6 amps amps amps amps above 6 hrs 12 hrs 18 hrs 24 hrs 250 10 amps 10 amps 10 amps 10 amps A CAUTION Do not charge a frozen battery because it can ex plode and cause injury Let the battery warm to 60 F 15 5 C before connecting to a charger Charge the battery in a well ventilated place to dissipate gases produced from charging These gases are explosive keep open flame and elec trical spark away from the battery Do not smoke Nausea may result if the gases are inhaled Un plug the charger from the electrical outlet before connecting or disconnecting the charger leads from the battery posts Electrical System Rev A Page 5 30 3 Following the manufacturer s instructions con nectthe charger cables to the battery Make sure a good connection is made 4 Charge the battery following the manufacturer s instructions 5 Occasionally check the temperature of the battery electrolyte If the temperature exceeds 125 F 51 6 C or the electrolyte is violently gassing or spewing the charging rate must be lowe
292. ver 4 If relief valve seat was removed apply medium strength thread locking compound e g Loctite 242 to seat and install in rear cover Torque seat from 4 to 6ft Ib 5 4 to 8 1 N m 5 Apply hydraulic oil to relief valve components Re place the relief valve assembly install relief valve spring and plug with o ring into the rear cover Torque plug from 30 to 35 ft Ib 41 to 47 6 Install motor on cutting deck RELIEF VALVE KIT 1 Plug 2 O ring 3 Spring Groundsmaster 4500 D 4700 D Page 4 93 Figure 83 4 Relief valve 5 Relief valve seat Hydraulic System Rev A 2 5 3 gt Lift Lower Control Valve GM 4500 0 Figure 84 1 Control valve assembly 1 spool 10 Lift lever 18 Insert nut 2 O ring 11 Control knob 19 Flange nut 3 Hydraulic adapter 12 Curved washer 20 Extension spring 4 O ring 13 Cotter pin 21 Cap screw 5 Hydraulic fitting 14 Thread forming screw 22 Valve support 6 Orifice port B 15 Proximity switch 23 Link 7 screw 16 Flange head screw 24 Lock nut 8 Spacer 17 Switch plate 25 O ring 9 Spacer tube Hydraulic System Rev A Page 4 94 Groundsmaster 4500 D 4700 D Removal Installation 1 Park machine on level surface lower cutting units 1 Install control valve using Figure 86 as a guide stop engine engage parking brake and remove key from the ignition switch 2 Make sure hydraulic tank is full Add correct oil if nec
293. wel bushings 40 into cradle and secure bushing 44 onto cradle with button head cap screw 43 Torque button head cap screw from 14 to 16 in Ib 1 6 to 1 8 N m 7 Place cradle sub assembly 41 into housing 19 making sure dowel bushings 40 and cradle 41 are completely seated into housing Retain cradle sub as sembly with two cap screws 42 after applying Loctite 277 or equivalent to the end of threads Torque cap screws from 25 to 28 ft lb 34 to 38 N m Groundsmaster 4500 D 4700 D 8 Place exterior retaining ring 3 thrust 12 thrust bearing 13 second thrust race 12 and second retaining ring 3 onto drive shaft 21 Position washer 24 and shaft seal 25 onto shaft 9 Install shaft assembly into front of housing Seat seal 25 into position with seal driver and retain with interior retaining ring 2 10 Install servo piston follower 8 onto camplate dowel pin Install camplate 11 carefully onto bushing 44 coat bushing surface with hydraulic oil aligning servo piston follower 8 with slot in servo piston assembly 7 11 Position housing in a horizontal position Holding camplate 11 in position with screw driver through con troller linkage passageway at the top of housing place rotating kit assembly 6 over shaft and into housing until pistons are against camplate 11 Make sure all parts are in housing completely and are properly positioned Return the pump to the vise with ope
294. wheel drive brake assembly see Traction Unit Operator s Manual When changing attachments tires or perform ing other service use correct blocks hoists and jacks Make sure machine is parked on a solid level surface such as a concrete floor Prior to raising machine remove any attach ments that may interfere with the safe and proper raising of the machine Always chock or block wheels Use jack stands or solid wood blocks to support the raised machine If the ma chine is not properly supported by blocks or jack stands the machine may move or fall which may result in personal injury 3 Chock rear wheels and jack up front of machine see Jacking Instructions in Chapter 1 Safety Support ma chine with jack stands or solid wood blocks 4 Remove wheel assembly 5 Remove hydraulic wheel motor see Front Wheel Motors in Service and Repairs section of Chapter 4 Hydraulic System 6 Disconnect brake cable from pull rod on brake NOTE Be careful not to drop splined brake shaft as brake assembly is removed 7 Support brake assembly and remove flange head capscrews 11 securing brake assembly to frame Re move brake assembly 8 Remove splined brake shaft 9 Complete brake inspection and repair Install Brake Assembly Fig 1 NOTE The stepped end of the splined brake shaft must be aligned toward the hydraulic wheel motor Fig 2 1 Install splined brake shaft into brake assembly 2 Install brake as
295. when the solenoid valves are de energized as the PTO switch is turned OFF On the Groundsmaster 4700 D hydraulic flow from the two pump sections is controlled by two hydraulic man ifolds each equipped with a solenoid controlled propor tional relief valve PRV1 PRV2 asolenoid valve SV2 two logic cartridges LC1 and LC2 and two brake relief cartridges RV8 and RV9 When the PTO switch is OFF or if decks are raised the deck solenoid valves SV2 and PRV1 PRV2 are not energized allowing hydraulic flow to by pass the deck motors through the manifold When the PTO switch is turned ON with the decks low ered the solenoid valves SV2 and PRV1 PRV2 ener gize causing a shift of the logic cartridges LC1 and LC2 and allowing hydraulic flow to the deck motors Brake relief cartridges RV8 and RV9 control the FROM GEAR PUMP P1 DECK CONTROL MANIFOLD TO HYDRAULIC RESERVOIR stopping rate of the blade when the solenoid valves are de energized as the PTO switch is turned OFF Decks 6 and 7 are controlled by solenoid valve SV2 logic cartridge LC2 and brake relief cartridge 9 Return oil from the deck motors is directed to the oil cool er and oil filter Deck motor case drain leakage returns to the hydraulic reservoir Maximum mow circuit pressure is limited
296. witch in OFF Remove key from the igni tion switch IMPORTANT Make sure to clean around any hy draulic connections that will be disconnected for draining 2 Drain hydraulic reservoir see Traction Unit Opera tor s Manual 3 Drain hydraulic system Drain all hoses tubes and components while the system is warm 4 Change and replace both hydraulic oil filters see Traction Unit Operator s Manual 5 Inspect and clean hydraulic reservoir see Hydraulic Reservoir Inspection Groundsmaster 4500 D 4700 D Page 4 53 6 Reconnect all hydraulic hoses lines and compo nents that were disconnected while draining system NOTE Use only hydraulic fluids specified in the Trac tion Unit Operator s Manual Other fluids may cause system damage 7 Fill hydraulic reservoir with new hydraulic fluid see Traction Unit Operator s Manual 8 Disconnect electrical connector from engine run so lenoid 9 Turn ignition key switch engage starter for 10 se conds to prime pump Repeat this step again 10 Connect electrical connector to engine run solenoid 11 Start engine and let it idle at low speed 1300 RPM for a minimum of 2 minutes Increase engine speed to high idle 2800 50 RPM for minimum of 1 minute un der no load 12 Raise and lower cutting units several times Turn steering wheel fully left and right several times 13 Shut off engine and check for hydraulic oil leaks Check oil level in hydraulic rese
297. y a proportional valve to provide flow to the steering circuit and the lift circuit To test gear pump flow testing of both circuits is required Total gear pump flow is the combined flow from the two circuits 1 Make sure hydraulic oil is at normal operating tem perature by operating the machine for approximately 10 minutes Make sure the hydraulic tank is full 2 Park machine on alevel surface with the cutting units lowered and off Make sure engine is off and the parking brake is engaged Prevent personal injury and or damage to equip ment Read all WARNINGS CAUTIONS and Pre cautions for Hydraulic Testing at the beginning of this section IMPORTANT Make sure that the oil flow indicator arrow on the flow gauge is showing that the oil will flow from the pump through the tester and into the hydraulic hose 3 With the engine off and cutting units lowered install tester in series between the last gear pump section and one of the circuit hoses Fig 42 Make sure the tester flow control valve is OPEN IMPORTANT The pump is a positive displacement type If pump flow is completely restricted or stopped damage to the pump tester or other com ponents could occur 4 Startthe engine and move throttle to full speed 2800 50 RPM DO NOT engage the cutting units 5 While watching pressure gauges slowly close flow control valve until 1000 PSI is obtained on gauge Verify engine speed continues to be correct 2800 50
298. ystem Quick Checks Component Testing Service and Repairs Chapter 6 Axles Planetaries and Brakes Specifications Adjustments Service and Repairs Chapter 7 Chassis General Information Service and Repairs Chapter 8 Cutting Units Specifications Troubleshooting Special Tools Adjustments Service and Repairs Chapter 9 Electrical Diagrams Electrical Schematics Circuit Diagrams Wire Harness Drawings Product Records and Maintenance Kubota Diesel Engine Electrical System o 5 a o 9 Cutting Units Electrical Hydraulic System o o x 6 a 75 Diagrams This is intentionally blank Groundsmaster 4500 D 4700 D 1 TORO Safety Table of Contents GENERAL SAFETY INSTRUCTIONS 2 JACKING INSTRUCTIONS 4 Before Operating 2 SAFETY AND INSTRUCTION DECALS 5 While 0 2 Maintenance and Service Groundsmaster 4500 D 4700 D Page 1 1 Safety General Safety Instructions The GROUNDSMASTER 4500 D 4700 D was tested and certified by TORO for compliance with the B71 4 1999 specifications of the American National Standards Institute Although hazard control and acci dent prevention

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