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Page 3 - Table Of Contents; Chapter 2 -- Product Records and Maintenance
Groundsmaster 4500--D/4700--D Table Of Contents Chapter 1 -- Safety General Safety Instructions 1 -- 2 . . . . . . . . . . . . . . . . . . Jacking Instructions 1 -- 5 . . . . . . . . . . . . . . . . . . . . . . . . . Safety and Instruction Decals 1 -- 6 . . . . . . . . . . . . . . . . Chapter 2 -- P...
Page 5 - Chapter 1; Safety; Table of Contents; Sa
Groundsmaster 4500--D/4700--D Page 1 -- 1 Safety Chapter 1 Safety Table of Contents GENERAL SAFETY INSTRUCTIONS 2 . . . . . . . . . . . . Before Operating 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . While Operating 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Maintenance a...
Page 6 - General Safety Instructions; To reduce the potential for injury or death,; Before Operating
Groundsmaster 4500--D/4700--D Page 1 -- 2 Safety General Safety Instructions The Groundsmaster 4500-D and 4700--D have been tested and certified by TORO for compliance with exist- ing safety standards and specifications. Although haz- ard control and accident prevention partially are dependent upon ...
Page 7 - While Operating
Groundsmaster 4500--D/4700--D Page 1 -- 3 Safety While Operating 1. Sit on 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, rel...
Page 8 - Maintenance and Service
Groundsmaster 4500--D/4700--D Page 1 -- 4 Safety Maintenance and Service 1. The Traction Unit and Cutting Deck Operator’s Manuals provide information regarding the operation, general maintenance and maintenance intervals for your Groundsmaster machine. Refer to these publica- tions for additional in...
Page 10 - Safety and Instruction Decals
Groundsmaster 4500--D/4700--D Page 1 -- 6 Safety Safety and Instruction Decals Numerous safety and instruction decals are affixed to the Groundsmaster 4500--D and 4700--D. If any decal becomes illegible or damaged, install a new decal. De- cal part numbers are listed in your Parts Catalog.
Page 11 - Chapter 2; Product Records and Maintenance
Groundsmaster 4500--D/4700--D Page 2 -- 1 Product Records and Maintenance Chapter 2 Product Records and Maintenance Table of Contents PRODUCT RECORDS 1 . . . . . . . . . . . . . . . . . . . . . . . . . MAINTENANCE 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EQUIVALENTS AND CONVERSI...
Page 12 - Equivalents and Conversions
0.09375 Groundsmaster 4500--D/4700--D Page 2 -- 2 Product Records and Maintenance Equivalents and Conversions
Page 13 - Torque Specifications; reduced by 25% for lubricated fasteners; Fastener Identification
Groundsmaster 4500--D/4700--D Page 2 -- 3 Product Records and Maintenance 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 clea...
Page 16 - Other Torque Specifications; Conversion Factors
Groundsmaster 4500--D/4700--D Page 2 -- 6 Product Records and Maintenance Other Torque Specifications SAE Grade 8 Steel Set Screws Thread Size Recommended Torque Square Head Hex Socket 1/4 -- 20 UNC 140 + 20 in--lb 73 + 12 in--lb 5/16 -- 18 UNC 215 + 35 in--lb 145 + 20 in--lb 3/8 -- 16 UNC 35 + 10 f...
Page 17 - Chapter 3; Yanmar Diesel Engine; Ya
Groundsmaster 4500--D/4700--D Page 3 -- 1 Yanmar Diesel Engine Chapter 3 Yanmar Diesel Engine Table of Contents SPECIFICATIONS 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Models 30873 and 30874 2 . . . . . . . . . . . . . . . . . . . . Models 30881 and 30882 3 . . . . . . . . . . . . ....
Page 20 - General Information; Operator’s Manuals; IMPORTANT: Before stopping the engine after
Groundsmaster 4500--D/4700--D Page 3 -- 4 Yanmar Diesel Engine General Information This Chapter gives information about specifications and repair of the diesel engine used in the Groundsmaster 4500--D and 4700--D. General maintenance procedures are described in your Traction Unit Operator’s Manual. ...
Page 24 - Service and Repairs; Air Cleaner System; MODELS
Groundsmaster 4500--D/4700--D Page 3 -- 8 Yanmar Diesel Engine Service and Repairs Air Cleaner System Figure 6 FRONT RIGHT 1. Air cleaner assembly 2. Air cleaner mount 3. Indicator 4. Adapter 5. Air cleaner strap 6. Socket head screw (2 used) 7. Flat washer (2 used) 8. Flat washer (2 used) 9. Lock n...
Page 26 - Fuel System
Groundsmaster 4500--D/4700--D Page 3 -- 10 Yanmar Diesel Engine Fuel System Figure 9 1. Fuel suction tube 2. Fuel gauge 3. Fuel hose (supply) 4. Return fitting 5. Fuel hose (return) 6. Fuel tank cap 7. Bushing (2 used) 8. Hose clamp (6 used) 9. Fuel tank 10. Cap screw (2 used) 11. Clamp (2 used) 12....
Page 27 - DANGER
Groundsmaster 4500--D/4700--D Page 3 -- 11 Yanmar Diesel Engine DANGER 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 ...
Page 28 - Radiator and Oil Cooler Assembly
Groundsmaster 4500--D/4700--D Page 3 -- 12 Yanmar Diesel Engine Radiator and Oil Cooler Assembly 1. Radiator/oil cooler assembly 2. Cap screw (4 used) 3. Washer (4 used) 4. Fan 5. Plenum assembly 6. Cap screw (6 used) 7. Flange nut (6 used) 8. Air intake hose 9. Hose 10. Hose clamp (4 used) 11. Uppe...
Page 29 - CAUTION; Do not open radiator cap or drain coolant if the
Groundsmaster 4500--D/4700--D Page 3 -- 13 Yanmar Diesel Engine Removal (Fig. 11) 1. Park machine on a level surface, lower cutting decks, stop engine, engage parking brake and remove key from the ignition switch. 2. Remove hood from the machine (see Hood Removal in the Service and Repairs section o...
Page 32 - Engine
Groundsmaster 4500--D/4700--D Page 3 -- 16 Yanmar Diesel Engine Engine Figure 14 1. LH front engine mount bracket 2. RH front engine mount bracket 3. LH rear engine mount bracket 4. RH rear engine mount bracket 5. Lock washer (16 used) 6. Cap screw (16 used) 7. Engine mount (4 used) 8. Flange head s...
Page 36 - Pump Adapter Plate
Groundsmaster 4500--D/4700--D Page 3 -- 20 Yanmar Diesel Engine Pump Adapter Plate Figure 17 1. Flywheel plate 2. Hardened washer (8 used) 3. Spring coupler 4. Cap screw (8 used) 5. Cap screw with patchlock (8 used) 6. Hardened washer (8 used) 7. Engine assembly FRONT RIGHT 1 3 5 2 4 6 7 29 to 33 ft...
Page 39 - The muffler and exhaust pipe may be hot. To
Groundsmaster 4500--D/4700--D Page 3 -- 23 Yanmar Diesel Engine Groundsmaster models that are powered by a diesel en- gine that complies with EPA Tier 4 emission regulations are equipped with an exhaust system that includes a diesel oxidation catalyst (DOC) and a diesel particulate filter (DPF). The...
Page 41 - Chapter 4; Hydraulic System; Hydrauli
Groundsmaster 4500--D/4700--D Hydraulic System Page 4 -- 1 Chapter 4 Hydraulic System Table of Contents SPECIFICATIONS 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . GENERAL INFORMATION 3 . . . . . . . . . . . . . . . . . . . . . Operator’s Manual 3 . . . . . . . . . . . . . . . . . . . ....
Page 42 - Specifications
Groundsmaster 4500--D/4700--D Hydraulic System Page 4 -- 2 Specifications Item Description Piston (Traction) Pump Sauer--Danfoss Variable Displacement Axial Piston Pump Maximum Displacement (per revolution) 2.75 in 3 (45 cc) System Relief Pressure: Forward 4350 PSI (300 bar) System Relief Pressure: ...
Page 43 - Operator’s Manual
Groundsmaster 4500--D/4700--D Hydraulic System Page 4 -- 3 General Information Operator’s Manual The Operator’s Manual provides information regarding the operation, general maintenance and maintenance intervals for your Groundsmaster machine. Refer to that publication for additional information when...
Page 44 - Towing Traction Unit
Groundsmaster 4500--D/4700--D Hydraulic System Page 4 -- 4 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...
Page 45 - Relieving Hydraulic System Pressure
Groundsmaster 4500--D/4700--D Hydraulic System Page 4 -- 5 Relieving Hydraulic System Pressure Before disconnecting or performing any work on the hy- draulic system, all pressure in the hydraulic system must be relieved. Park machine on a level surface, make sure that PTO switch is OFF, lower cuttin...
Page 46 - Hydraulic Hoses; WARNING
Groundsmaster 4500--D/4700--D Hydraulic System Page 4 -- 6 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 maintenance. These ...
Page 50 - Hydraulic Schematics; Hydr
Groundsmaster 4500--D/4700--D Hydraulic System Page 4 -- 10 Hydraulic Schematics Hydr aulic Sc hem atic G rou nd sm aster 45 00 --D A ll solenoid s are sho w n as de --ene rg iz ed NOTE :A larger hydraulic schematic is in clud ed in Ch ap te r 9 -- F old ou tD ra wing s 0.630” RO D 105 0 16 00 PSI 6...
Page 52 - Hydraulic Flow Diagrams
Groundsmaster 4500--D/4700--D Hydraulic System Page 4 -- 12 Hydraulic Flow Diagrams Tr action C irc u it: L OW Spe ed (GM 45 00 --D For wa rd Shown) W ork in g P res su re Low P ressu re (C ha rg e) Retu rn or Suction Flow Gr ou ndsma ste r 450 0- -D /4 700 --D 0.630” RO D 10 50 16 00 P S I 6. 2 G P...
Page 53 - Forward Direction
Groundsmaster 4500--D/4700--D Hydraulic System Page 4 -- 13 Traction Circuit: LOW Speed (Mow) The traction circuit piston pump is a variable displace- ment pump that is directly coupled to the engine fly- wheel. This pump utilizes an integral electro--hydraulic servo piston assembly that controls th...
Page 65 - Mow Circuit; PTO Disengaged
Groundsmaster 4500--D/4700--D Hydraulic System Page 4 -- 25 Mow Circuit Hydraulic flow for the mow circuit is supplied by the first two (2) sections of the gear pump. The first gear pump section P1 supplies hydraulic flow to decks 5, 3 and 2 (also deck 7 on the GM 4700--D), while the second gear pum...
Page 66 - Cutting Deck Blade Braking
Groundsmaster 4500--D/4700--D Hydraulic System Page 4 -- 26 Cutting Deck Blade Braking When the operator turns the PTO switch OFF (or if the decks are raised), deck manifold solenoid valves (PRV1, PRV2, SV1 and SV2) are de--energized. The valves will shift to direct oil away from the deck motors and...
Page 69 - Steering Circuit; Right Turn
Groundsmaster 4500--D/4700--D Hydraulic System Page 4 -- 29 Steering Circuit A four section gear pump is coupled to the piston (trac- tion) pump. The third gear pump section supplies hy- draulic flow to the steering control valve and the lift/lower control valve. Pump hydraulic flow is delivered to ...
Page 71 - Engine Cooling Fan Circuit; Forward Direction Fan Operation
Groundsmaster 4500--D/4700--D Hydraulic System Page 4 -- 31 Engine Cooling Fan Circuit A four section gear pump is coupled to the piston (trac- tion) pump. The final gear pump section (farthest from the piston pump) supplies hydraulic flow for the hydrau- lic engine cooling fan motor. The fan contro...
Page 72 - Special Tools; Hydraulic Pressure Test Kit
Groundsmaster 4500--D/4700--D Hydraulic System Page 4 -- 32 Special Tools Order these special tools from your Toro Distributor. Hydraulic Pressure Test Kit Use to take various pressure readings for diagnostic tests. Quick disconnect fittings provided attach directly to mating fittings on machine tes...
Page 73 - 0 GPM Hydraulic Tester (Pressure and Flow); Hydraulic Hose Kit
Groundsmaster 4500--D/4700--D Hydraulic System Page 4 -- 33 40 GPM Hydraulic Tester (Pressure and Flow) Use to test hydraulic circuits and components for flow and pressure capacities as recommended in the Testing section of this chapter. This tester includes the following: 1. LOAD VALVE: A simulated...
Page 74 - High Flow Hydraulic Filter Kit
Groundsmaster 4500--D/4700--D Hydraulic System Page 4 -- 34 High Flow Hydraulic Filter Kit The high flow hydraulic filter kit is designed with large flow (40 GPM/150 LPM) and high pressure (5000 PSI/345 bar) capabilities. This kit provides for bi--direc- tional filtration which prevents filtered deb...
Page 75 - Hydraulic Test Fitting Kit
Groundsmaster 4500--D/4700--D Hydraulic System Page 4 -- 35 Hydraulic Test Fitting Kit This kit includes a variety of O--ring Face Seal fittings to enable you to connect test gauges into the system. The kit includes: tee’s, unions, reducers, plugs, caps and male test fittings. Toro Part Number: TOR4...
Page 76 - Remote Starter Switch; IMPORTANT: When using a remote starter switch, it
Groundsmaster 4500--D/4700--D Hydraulic System Page 4 -- 36 Remote Starter Switch After flushing the hydraulic system or replacing a hy- draulic component (e.g. gear pump, piston pump, wheel motor), it is necessary to prime the hydraulic pumps. A remote starter switch (Fig. 35) can be used for this ...
Page 77 - Troubleshooting; General Hydraulic System Problems; Problem
Groundsmaster 4500--D/4700--D Hydraulic System Page 4 -- 37 Troubleshooting The charts that follow contain information to assist in hy- draulic system troubleshooting. There may possibly be more than one cause for a machine malfunction. Refer to the Testing section of this Chapter for precau- tions ...
Page 78 - Traction Circuit Problems
Groundsmaster 4500--D/4700--D Hydraulic System Page 4 -- 38 Traction Circuit Problems NOTE: When troubleshooting traction circuit problems, if a problem exists in both low (mow) and high (transport) speeds, consider a faulty component that affects the en- tire traction circuit (e.g. charge circuit, ...
Page 79 - Mow Circuit Problems
Groundsmaster 4500--D/4700--D Hydraulic System Page 4 -- 39 Mow Circuit Problems Problem Possible Cause None of the cutting decks will oper- ate. NOTE: To engage the mow circuit, the seat must be occupied, the cut- ting deck(s) must be fully lowered, the traction speed must be in the LOW (mow) posit...
Page 80 - Steering Circuit Problems
Groundsmaster 4500--D/4700--D Hydraulic System Page 4 -- 40 Mow Circuit Problems (Continued) Problem Possible Cause All cutting decks operate slowly. Engine RPM is low. Deck motor is damaged. First and second gear pump sections are worn or damaged. Cutting deck stops under load. Relief valve in deck...
Page 81 - Lift/Lower Circuit Problems
Groundsmaster 4500--D/4700--D Hydraulic System Page 4 -- 41 Lift/Lower Circuit Problems Problem Possible Cause Cutting decks will not raise. NOTE: Operator must be in seat in order to raise the cutting decks. Operator seat is unoccupied. Hydraulic oil level in reservoir is low. Electrical problem ex...
Page 82 - Engine Cooling Fan Circuit Problems
Groundsmaster 4500--D/4700--D Hydraulic System Page 4 -- 42 Engine Cooling Fan Circuit Problems Problem Possible Cause Cooling fan runs only in forward di- rection (fan does not run in reverse direction). Fan control manifold solenoid cartridge valve (S1) is faulty. Electrical problem exists that pr...
Page 86 - Traction Circuit Charge Pressure (Using Pressure Gauge); PRESSURE
Groundsmaster 4500--D/4700--D Hydraulic System Page 4 -- 46 Traction Circuit Charge Pressure (Using Pressure Gauge) PRESSURE GAUGE 105 0 16 00 P S I 6. 2 G P M 11 .4 G P M 3500 PS I 3500 PSI 15 00 PSI 150 0 PS I P1 P2 T1 G1 PR V1 PR V2 LC 1 LC 2 M1 M2 M3 M4 T RV 09 PR V S1 CV FD P2 P1 ST L M1 M2 PE ...
Page 87 - Prevent personal injury and/or damage to equip-
Groundsmaster 4500--D/4700--D Hydraulic System Page 4 -- 47 NOTE: The traction charge circuit is designed to re- place loss of hydraulic fluid from the closed loop traction circuit. Procedure for Traction Circuit Charge Pressure Test CAUTION Prevent personal injury and/or damage to equip- ment. Read...
Page 88 - Traction Circuit Relief Pressure (Using Pressure Gauge); FORWARD DIRECTION
Groundsmaster 4500--D/4700--D Hydraulic System Page 4 -- 48 Traction Circuit Relief Pressure (Using Pressure Gauge) FORWARD DIRECTION TEST SHOWN PRESSURE GAUGE 10 50 16 00 PSI 6.2 G P M 11 .4 G P M 35 00 PSI 35 00 PSI 150 0 PS I 15 00 PSI P1 P2 T1 G1 PR V 1 PR V 2 LC1 LC 2 M1 M2 M3 M4 T RV 09 PR V S...
Page 89 - Move machine to an open area, away from people
Groundsmaster 4500--D/4700--D Hydraulic System Page 4 -- 49 Procedure for Traction Circuit Relief Pressure Test CAUTION Prevent personal injury and/or damage to equip- ment. Read all WARNINGS, CAUTIONS and Pre- cautions for Hydraulic Testing at the beginning of this section. 1. Make sure hydraulic o...
Page 96 - Cutting Deck Circuit Pressure (Using Pressure Gauge); DECKS 1 AND 4 SHOWN
Groundsmaster 4500--D/4700--D Hydraulic System Page 4 -- 56 Cutting Deck Circuit Pressure (Using Pressure Gauge) DECKS 1 AND 4 SHOWN TEST FOR GM4500--D PRESSURE GAUGE 6.2 G P M 11 .4 G P M 350 0 PS I 35 00 PS I 15 00 PSI 15 00 PS I P1 P2 T1 G1 PR V 1 PR V2 LC1 LC 2 M1 M2 M3 M4 RV 09 T2 FR O N T LEF ...
Page 102 - Steering Circuit Relief Pressure (Using Pressure Gauge); (STEERING WHEEL TURNED
Groundsmaster 4500--D/4700--D Hydraulic System Page 4 -- 62 Steering Circuit Relief Pressure (Using Pressure Gauge) (STEERING WHEEL TURNED TEST FOR GM4500--D SHOWN FOR RIGHT TURN) CAP STEEL PRESSURE GAUGE 105 0 160 0 P S I 6. 2 G PM 11 .4 G P M 35 00 PSI 35 00 PSI 15 00 PSI 150 0 PS I P1 P2 T1 G1 PR...
Page 104 - Steering Cylinder Internal Leakage
Groundsmaster 4500--D/4700--D Hydraulic System Page 4 -- 64 Steering Cylinder Internal Leakage 1050 P E T R STEERING CYLINDER 6.1 CIR L CONTROL VALVE STEERING PSI FROM COMBINATION MANIFOLD TO GEAR CYLINDER FULLY EXTENDED LOOK FOR LEAKAGE STEEL CAP STEERING WHEEL TURNED FOR RIGHT TURN PUMP INLET TO T...
Page 108 - Engine Cooling Fan Circuit (Using Pressure Gauge and Phototac); SURE
Groundsmaster 4500--D/4700--D Hydraulic System Page 4 -- 68 Engine Cooling Fan Circuit (Using Pressure Gauge and Phototac) GM 4500--D SHOWN P R ES SURE GAUGE 10 50 16 00 PSI 6.2 G P M 11 .4 G P M 3500 PS I 3500 PSI 150 0 PS I 15 00 PSI P1 P2 T1 G1 PR V1 PR V2 LC 1 LC 2 M1 M2 M3 M4 T RV 09 PR V S1 CV...
Page 110 - Gear Pump Flow (Using Tester with Pressure Gauge & Flow Meter); SECOND GEAR; FLOW TEST SHOWN
Groundsmaster 4500--D/4700--D Hydraulic System Page 4 -- 70 Gear Pump Flow (Using Tester with Pressure Gauge & Flow Meter) SECOND GEAR PUMP SECTION TESTER 4350 PSI 250 PSI 500 0 PSI EU -- 260 0 /1200 RPM 0.5 6 CI D 0.5 6 CI D 1.0 3 CI D 1. 03 CI D 2. 75 CID 50 PSI ENG IN E T 4 -- 27 00 /120 0 R ...
Page 112 - Adjustments; Adjust Control Manifold Relief Valves; increase
Groundsmaster 4500--D/4700--D Hydraulic System Page 4 -- 72 Adjustments Adjust Control Manifold Relief Valves Several of the hydraulic control manifolds on your Groundsmaster include adjustable relief valves. The fol- lowing procedure can be used to adjust these relief valves. Refer to the Testing s...
Page 114 - Check Hydraulic Lines and Hoses; Priming Hydraulic Pumps
Groundsmaster 4500--D/4700--D Hydraulic System Page 4 -- 74 Check Hydraulic Lines and Hoses WARNING Keep body and hands away from pin hole leaks or nozzles that eject hydraulic fluid under high pressure. Use paper or cardboard, not hands, to search for leaks. Hydraulic fluid escaping under pressure ...
Page 115 - Flush Hydraulic System
Groundsmaster 4500--D/4700--D Hydraulic System Page 4 -- 75 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- In...
Page 117 - Charge Hydraulic System
Groundsmaster 4500--D/4700--D Hydraulic System Page 4 -- 77 Charge Hydraulic System NOTE: When initially starting the hydraulic system with new or rebuilt components such as pumps, motors or lift cylinders, it is important that the hydraulic system be charged properly. Air must be purged from the sy...
Page 118 - Gear Pump
Groundsmaster 4500--D/4700--D Hydraulic System Page 4 -- 78 Gear Pump 1. Piston pump assembly 2. Flat washer (4 used) 3. Gear pump assembly 4. 90 o hydraulic fitting (2 used) 5. 90 o hydraulic fitting (2 used) 6. 90 o hydraulic fitting 7. O--ring 8. Hydraulic tee fitting 9. 90 o hydraulic fitting 10...
Page 122 - Gear Pump Service; thrust plates for each pump section together do not
Groundsmaster 4500--D/4700--D Hydraulic System Page 4 -- 82 Gear Pump Service 1. Dust seal 2. Retaining ring 3. Flange washer 4. Shaft seal 5. Front cover 6. Dowel pin (16 used) 7. Pressure seal 8. Back--up gasket 9. Thrust plate (8 used) 10. Seal (8 used) 11. Idler gear 12. Drive shaft 13. Back--up...
Page 130 - Rear Traction Control Manifold
Groundsmaster 4500--D/4700--D Hydraulic System Page 4 -- 90 Rear Traction Control Manifold 1. Rear traction control manifold 2. Cap screw (2 used) 3. Flange nut (2 used) 4. HI/LOW range control manifold 5. Lift circuit junction manifold 6. Hydraulic tube 7. O--ring 8. Hydraulic straight fitting 9. O...
Page 132 - Rear Traction Control Manifold Service
Groundsmaster 4500--D/4700--D Hydraulic System Page 4 -- 92 Rear Traction Control Manifold Service 1. Rear traction manifold body 2. Relief valve (port RV) 3. Pressure reducing valve (port PR) 4. #4 zero leak plug with O --ring 5. #6 zero leak plug with O --ring 6. Check valve (port CV) 7. Orifice (...
Page 133 - Control Manifold Cartridge Valve Service
Groundsmaster 4500--D/4700--D Hydraulic System Page 4 -- 93 Control Manifold Cartridge Valve Service 1. Make sure the control manifold is clean before re- moving the cartridge valve from the control manifold. 2. If cartridge valve is solenoid operated, remove nut securing solenoid coil to the cartri...
Page 134 - HI/LOW Range Control Manifold
Groundsmaster 4500--D/4700--D Hydraulic System Page 4 -- 94 HI/LOW Range Control Manifold 1. HI/LOW range control manifold 2. Cap screw (2 used) 3. Flange nut (2 used) 4. Rear traction control manifold 5. Lift circuit junction manifold 6. Hydraulic tube 7. O--ring 8. Hydraulic tube 9. O--ring 10. Hy...
Page 135 - CHECK VALVE ADAPTER
Groundsmaster 4500--D/4700--D Hydraulic System Page 4 -- 95 Removal (Fig. 75) 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. To prevent contamination of hydraulic system during manifold...
Page 136 - Rear Axle Motor
Groundsmaster 4500--D/4700--D Hydraulic System Page 4 -- 96 Rear Axle Motor 1. Rear axle motor 2. O--ring 3. Pinion gear 4. External snap ring (2 used) 5. O--ring 6. Hydraulic fitting 7. O--ring 8. 90 o hydraulic fitting 9. Cap screw (2 used) 10. Flat washer (2 used) 11. O--ring 12. 90 o hydraulic f...
Page 138 - Front Wheel Motors
Groundsmaster 4500--D/4700--D Hydraulic System Page 4 -- 98 Front Wheel Motors 1. Flange head screw (6 per planetary) 2. Splined brake shaft 3. Planetary assembly 4. Wheel assembly 5. Lug nut (8 per wheel) 6. Retaining ring 7. Spring plate 8. Compression spring 9. Jam nut 10. Brake assembly (LH show...
Page 140 - Rear Axle and Front Wheel Motor Service
Groundsmaster 4500--D/4700--D Hydraulic System Page 4 -- 100 Rear Axle and Front Wheel Motor Service Figure 82 2 3 6 8 9 10 11 13 1 5 7 12 14 15 16 17 18 19 20 4 21 22 23 21 25 1. Plug with O --ring 2. Minimum angle stop 3. Bias spring 4. Servo piston 5. O--ring 6. O--ring 7. Socket head screw (5 us...
Page 141 - REAR AXLE MOTOR FLUSHING VALVE
Groundsmaster 4500--D/4700--D Hydraulic System Page 4 -- 101 NOTE: The front wheel motors are identical (shown in Figure 82). The rear axle motor includes a flushing valve for cooling of the closed loop traction circuit and there- fore has some differences from the front motors (Fig. 83). Service of...
Page 142 - Cutting Deck Motor; Removal
Groundsmaster 4500--D/4700--D Hydraulic System Page 4 -- 102 Cutting Deck Motor The hydraulic motors used on all cutting decks are the same. Removal 1. Park machine on a level surface, lower cutting decks, stop engine, engage parking brake and remove key from the ignition switch. 2. Read the General...
Page 144 - Cutting Deck Motor Service
Groundsmaster 4500--D/4700--D Hydraulic System Page 4 -- 104 Cutting Deck Motor Service 1. Dust seal (2 used) 2. Retaining ring 3. Flange washer 4. Shaft seal 5. Front flange 6. Pressure seal 7. Backup gasket 8. Front wear plate 9. Drive gear 10. Dowel pin (4 used) 11. Idler gear 12. O--ring 13. Bod...
Page 148 - Deck Control Manifold
Groundsmaster 4500--D/4700--D Hydraulic System Page 4 -- 108 Deck Control Manifold 1. Deck control manifold 2. Filter mount bracket 3. Flange head screw (2 used) 4. Hydraulic oil filter assembly 5. Valve mount bracket 6. Flange head screw (2 used) 7. Lift control manifold 8. Flange head screw (2 use...
Page 154 - Steering Control Valve
Groundsmaster 4500--D/4700--D Hydraulic System Page 4 -- 114 Steering Control Valve 1. Steering wheel cover 2. Lock nut 3. Steering wheel 4. Flat washer 5. Socket head screw (4 used) 6. Flange head screw (4 used) 7. Steering column 8. Steering control valve 9. Socket head screw (4 used) 10. Flange n...
Page 156 - Steering Control Valve Service
Groundsmaster 4500--D/4700--D Hydraulic System Page 4 -- 116 Steering Control Valve Service 1. Relief valve assembly 2. Dust seal ring 3. Steering valve housing 4. Shaft seal 5. Thrust washer 6. Bearing race 7. Ring 8. Spring set 9. Cross pin 10. Sleeve 11. Spool 12. Cardan shaft 13. O--ring 14. Dis...
Page 158 - Steering Cylinder
Groundsmaster 4500--D/4700--D Hydraulic System Page 4 -- 118 Steering Cylinder 1. Steering cylinder 2. Ball joint 3. Ball joint 4. Retaining ring 5. Grease fitting 6. Grease fitting 7. 90 o hydraulic fitting 8. O--ring 9. O--ring 10. Drive axle assembly 11. Ball joint spacer 12. Axle washer 13. Slot...
Page 160 - Steering Cylinder Service
Groundsmaster 4500--D/4700--D Hydraulic System Page 4 -- 120 Steering Cylinder Service 1. Tube assembly 2. Lock nut 3. Seal 4. O--ring 5. O--ring 6. Piston 7. O--ring 8. Back--up seal 9. Seal 10. Head 11. Wiper 12. Retaining ring 13. Rod assembly Figure 102 7 10 4 11 8 5 1 6 3 9 2 12 13 7 10 4 11 8 ...
Page 162 - Engine Cooling Fan Motor
Groundsmaster 4500--D/4700--D Hydraulic System Page 4 -- 122 Engine Cooling Fan Motor 1. Cap screw (4 used) 2. Fan 3. Flange head screw (4 used) 4. Flange nut (4 used) 5. Fan motor and bracket assembly 6. Flange head screw (8 used) 7. Flat washer (8 used) 8. R--clamp (2 used) 9. Radiator/oil cooler ...
Page 166 - Engine Cooling Fan Motor Service
Groundsmaster 4500--D/4700--D Hydraulic System Page 4 -- 126 Engine Cooling Fan Motor Service 1. Flange washer 2. O--ring 3. Front flange 4. Dust seal 5. Retaining ring 6. Front wear plate 7. Shaft seal 8. Backup gasket 9. Pressure seal 10. Rear wear plate 11. Body 12. Idler gear 13. Cap screw (4 us...
Page 168 - Fan Control Manifold
Groundsmaster 4500--D/4700--D Hydraulic System Page 4 -- 128 Fan Control Manifold 1. Fan control manifold 2. Support bracket 3. Flange head screw (2 used) 4. Battery support 5. Air cleaner mount 6. Deck manifold (GM 4500--D shown) 7. Hydraulic hose 8. Hydraulic hose 9. Hydraulic tube 10. Hydraulic t...
Page 170 - Fan Control Manifold Service; UP
Groundsmaster 4500--D/4700--D Hydraulic System Page 4 -- 130 Fan Control Manifold Service 1. Manifold body 2. Zero leak plug (#6) (3 used) 3. Zero leak plug (#4) (2 used) 4. Check valve (port CV) 5. Flow divider cartridge (port FD) 6. Solenoid coil (2 used) 7. Nut 8. Solenoid valve (port S1) 9. Prop...
Page 172 - Lift Control Manifold
Groundsmaster 4500--D/4700--D Hydraulic System Page 4 -- 132 Lift Control Manifold 1. Deck control manifold 2. Filter mount bracket 3. Flange head screw (2 used) 4. Hydraulic oil filter assembly 5. Valve mount bracket 6. Flange head screw (2 used) 7. Lift control manifold 8. Flange head screw (2 use...
Page 178 - Lift Circuit Junction Manifold
Groundsmaster 4500--D/4700--D Hydraulic System Page 4 -- 138 Lift Circuit Junction Manifold 1. Lift circuit junction manifold 2. Flange head screw (2 used) 3. HI/LOW range control manifold 4. Rear traction control manifold Figure 116 FRONT RIGHT 2 3 1 4
Page 181 - Make sure that cutting decks are fully lowered; CUTTING DECK LOCATIONS
Groundsmaster 4500--D/4700--D Hydraulic System Page 4 -- 141 Removal (Fig. 119) 1. Park machine on a level surface, lower cutting decks, stop engine, engage parking brake and remove key from the ignition switch. 2. Read the General Precautions for Removing and Installing Hydraulic System Components ...
Page 186 - Lift Cylinder Service
Groundsmaster 4500--D/4700--D Hydraulic System Page 4 -- 146 Lift Cylinder Service 1. Tube assembly 2. Lock nut 3. Wear ring 4. Seal 5. Piston 6. O--ring 7. O--ring 8. Back--up ring 9. Seal 10. Retaining ring 11. Head 12. Wiper 13. Rod assembly 14. Grease fitting (2 used) Figure 125 12 10 9 5 7 4 2 ...
Page 188 - Hydraulic Reservoir
Groundsmaster 4500--D/4700--D Hydraulic System Page 4 -- 148 Hydraulic Reservoir 1. Plug 2. O--ring 3. Dipstick 4. Breather 5. Screen filter 6. Hydraulic reservoir 7. Reservoir strainer 8. O--ring 9. O--ring 10. Straight hydraulic fitting 11. O--ring 12. Cap screw (2 used) 13. Flat washer (2 used) 1...
Page 193 - Chapter 5; Electrical System; Elec
Groundsmaster 4500--D/4700--D Page 5 -- 1 Electrical System Chapter 5 Electrical System Table of Contents GENERAL INFORMATION 2 . . . . . . . . . . . . . . . . . . . . . Operator’s Manual 2 . . . . . . . . . . . . . . . . . . . . . . . . . . Electrical Drawings 2 . . . . . . . . . . . . . . . . . . ...
Page 195 - Yanmar Engine Electronic Control Unit (ECU); IMPORTANT: Do not plug or unplug the engine ECU
Groundsmaster 4500--D/4700--D Page 5 -- 3 Electrical System Yanmar Engine Electronic Control Unit (ECU) The Yanmar engine that powers the Groundsmaster 4500--D and 4700--D uses an electronic control unit (ECU) for engine management and also to communi- cate with the TEC controllers and the InfoCente...
Page 196 - Yanmar Engine Electrical Components
Groundsmaster 4500--D/4700--D Page 5 -- 4 Electrical System Yanmar Engine Electrical Components When servicing or troubleshooting the engine electrical components, use the correct engine service manual and troubleshooting manual. Also, the Yanmar SMART- ASSIST--Direct electronic control diagnostics ...
Page 198 - Multimeter
Groundsmaster 4500--D/4700--D Page 5 -- 6 Electrical System 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 (amps), resistance (ohms) or voltage. ...
Page 199 - Battery Hydrometer
Groundsmaster 4500--D/4700--D Page 5 -- 7 Electrical System Battery Hydrometer Use the battery hydrometer when measuring specific gravity of battery electrolyte. Obtain this tool locally. Figure 7 Elec tr ic al System
Page 200 - InfoCenter Display; Splash Screens; RPM
Groundsmaster 4500--D/4700--D Page 5 -- 8 Electrical System InfoCenter Display The InfoCenter Display used on your Groundsmaster is a LCD device that is located on the console. The Info- Center provides information for the machine operator during machine operation, provides electrical system diagnos...
Page 201 - Main Information Screens
Groundsmaster 4500--D/4700--D Page 5 -- 9 Electrical System Main Information Screens The two (2) InfoCenter main information screens (Figs. 10 and 11) are displayed after the initial splash screens have been displayed for several seconds. During nor- mal machine operation, the main information scree...
Page 202 - Main Menu Screen; Faults Screen
Groundsmaster 4500--D/4700--D Page 5 -- 10 Electrical System Main Menu Screen The main menu screen can be accessed from the Info- Center main information or splash screen by pressing and releasing the menu/back button (left button) on the display. Once to the main menu screen (Fig. 12), naviga- tion...
Page 203 - Service Screen
Groundsmaster 4500--D/4700--D Page 5 -- 11 Electrical System Service Screen The service screen (Fig. 14) contains machine opera- tional information including hours and counts. Values listed for these service menu items cannot be changed. If the machine PIN has been entered to allow access to protect...
Page 204 - Diagnostics Screen
Groundsmaster 4500--D/4700--D Page 5 -- 12 Electrical System Diagnostics Screen The diagnostics screen (Fig. 15) lists the various states of machine electrical components. The diagnostics screen should be used to check operation of machine controls and to verify that switches and circuit wiring are ...
Page 205 - Settings Screen
Groundsmaster 4500--D/4700--D Page 5 -- 13 Electrical System Settings Screen The settings screen identifies the InfoCenter language and decks (English or Metric). The settings screen also allows the operator to customize the backlight (bright- ness) and contrast settings for the InfoCenter display. ...
Page 206 - About Screen
Groundsmaster 4500--D/4700--D Page 5 -- 14 Electrical System About Screen The about screen (Fig. 18) identifies the machine model number, serial number and software revisions for the TEC controllers, InfoCenter and engine electronic con- trol unit (if available). The about screen also lists the CAN-...
Page 207 - Operator Advisories
Groundsmaster 4500--D/4700--D Page 5 -- 15 Electrical System Troubleshooting CAUTION Remove all jewelry, especially rings and watches, before doing any electrical trouble- shooting or testing. Disconnect the battery cables unless the test requires battery voltage. For effective troubleshooting and r...
Page 208 - Fault Codes; Fault Code
Groundsmaster 4500--D/4700--D Page 5 -- 16 Electrical System Fault Codes The list below identifies the fault codes that are gener- ated by the TEC controller to identify an electrical sys- tem malfunction (fault) that occurred during machine operation. Use the InfoCenter Display for fault retrieval....
Page 210 - Starting Problems
Groundsmaster 4500--D/4700--D Page 5 -- 18 Electrical System Starting Problems NOTE: Check InfoCenter Display for possible operator advisories or faults whenever diagnosing machine elec- trical problems. Problem Possible Causes No electrical power to machine (including gauges). Battery is discharged...
Page 211 - General Run and Transport Problems
Groundsmaster 4500--D/4700--D Page 5 -- 19 Electrical System Starting Problems (continued) Problem Possible Causes Engine cranks, but does not start. Fuel tank is empty. Engine is not cranking fast enough. Fuel pump or circuit wiring is faulty. Engine or fuel system is malfunctioning (see Yanmar Ser...
Page 212 - Cutting Deck Operating Problems
Groundsmaster 4500--D/4700--D Page 5 -- 20 Electrical System Cutting Deck Operating Problems NOTE: Check InfoCenter Display for possible operator advisories or faults whenever diagnosing machine elec- trical problems. Problem Possible Causes Cutting decks run, but should not, when raised. Decks shut...
Page 213 - Cutting Deck Lift/Lower Problems
Groundsmaster 4500--D/4700--D Page 5 -- 21 Electrical System Cutting Deck Lift/Lower Problems NOTE: Check InfoCenter Display for possible operator advisories or faults whenever diagnosing machine elec- trical problems. NOTE: To lower a cutting deck, the operator must be in the operator seat and the ...
Page 215 - Electrical System Quick Checks; Charging System Test
Groundsmaster 4500--D/4700--D Page 5 -- 23 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 o to 100 o F (16 o ...
Page 216 - Traction Pedal Adjustment
Groundsmaster 4500--D/4700--D Page 5 -- 24 Electrical System Adjustments Traction Pedal Adjustment The traction pedal includes a neutral assembly that is used to adjust the traction neutral position (Fig. 19). Traction pedal adjustment may be necessary to make sure that traction pedal movement provi...
Page 218 - Traction Pedal Position Sensor Calibration
Groundsmaster 4500--D/4700--D Page 5 -- 26 Electrical System Traction Pedal Position Sensor Calibration IMPORTANT: A properly installed and calibrated traction pedal position sensor is critical to accurate traction system response and for reliable sensor life. Use care when removing, installing and ...
Page 219 - Ignition Switch
Groundsmaster 4500--D/4700--D Page 5 -- 27 Electrical System 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 checking continuity of the switch terminals). NOTE:...
Page 220 - Fuses; Fuse Testing
Groundsmaster 4500--D/4700--D Page 5 -- 28 Electrical System Fuses Groundsmaster 4500--D and 4700--D use numerous fuses for circuit protection. The fuses reside in the power center behind the operator’s seat. Fuse Identification and Function (Fig. 27) Fuse A--1 (7.5 Amp) protects TEC--5002 output po...
Page 221 - Fusible Link Harness; Testing
Groundsmaster 4500--D/4700--D Page 5 -- 29 Electrical System Fusible Link Harness Your Groundsmaster uses two (2) fusible links for circuit protection. These fusible links are located in a harness that connects the starter B+ terminal to the wire harness (Fig. 28). If either of these links should fa...
Page 222 - PTO Switch
Groundsmaster 4500--D/4700--D Page 5 -- 30 Electrical System PTO Switch The two position PTO switch is located on the console arm (Fig. 30). The PTO switch is pulled up to engage the PTO and pushed in to disengage the PTO. NOTE: To engage the PTO, the seat has to be occu- pied, traction speed has to...
Page 223 - Hi/Low Speed, Engine Speed Request and Cutting Deck Lift Switches
Groundsmaster 4500--D/4700--D Page 5 -- 31 Electrical System Hi/Low Speed, Engine Speed Request and Cutting Deck Lift Switches The Hi/Low speed, engine speed request and cutting deck lift switches are all identical. These switches are located on the console arm (Fig. 32). The Hi/Low speed switch is ...
Page 224 - Headlight Switch
Groundsmaster 4500--D/4700--D Page 5 -- 32 Electrical System Headlight Switch The headlight switch is located on the operator side of the console arm (Fig. 34). This two (2) position rocker switch allows the headlights to be turned on and off. Testing 1. Park machine on a level surface, lower cuttin...
Page 225 - Seat Switch
Groundsmaster 4500--D/4700--D Page 5 -- 33 Electrical System Seat Switch The seat switch is normally open and closes when the operator is on the seat. The seat switch and its electrical connector are located in the seat assembly. If the trac- tion system or PTO switch is engaged when the operator ra...
Page 226 - Parking Brake Switch; Switch Testing
Groundsmaster 4500--D/4700--D Page 5 -- 34 Electrical System Parking Brake Switch The parking brake switch is a normally open proximity switch. The parking brake switch is attached to the bot- tom of the RH brake pedal (Fig. 37). When the parking brake is not applied, the parking brake detent is pos...
Page 227 - Cutting Deck Position Switches
Groundsmaster 4500--D/4700--D Page 5 -- 35 Electrical System Cutting Deck Position Switches The cutting deck position switches are normally open proximity switches that are located on the traction unit frame (Fig. 39). The sensing plate is located on the cut- ting deck lift arm. The Groundsmaster 45...
Page 231 - Traction Pedal Position Sensor
Groundsmaster 4500--D/4700--D Page 5 -- 39 Electrical System Traction Pedal Position Sensor The traction pedal position sensor is connected to the traction pedal assembly (Fig. 46). This position sensor determines the neutral band for the traction pedal, the direction of travel desired by the operat...
Page 234 - Hydraulic Solenoid Valve Coils
Groundsmaster 4500--D/4700--D Page 5 -- 42 Electrical System Hydraulic Solenoid Valve Coils Figure 51 1. Deck control manifold 2. Lift control manifold 3. Fan control manifold 4. HI/LOW range control manifold 1 4 3 2 FRONT RIGHT GROUNDSMASTER 4500--D SHOWN Numerous hydraulic solenoid valve coils are...
Page 236 - Piston (Traction) Pump Control Solenoid Coils; Solenoid Coil Testing
Groundsmaster 4500--D/4700--D Page 5 -- 44 Electrical System Piston (Traction) Pump Control Solenoid Coils The piston (traction) pump uses an electronic control as- sembly for swash plate rotation. Electrical outputs from the machine TEC controller are provided to two (2) solenoid coils for pump con...
Page 237 - Hydraulic Oil Temperature Sender
Groundsmaster 4500--D/4700--D Page 5 -- 45 Electrical System Hydraulic Oil Temperature Sender A temperature sender is used as an input for the TEC controller to identify if the hydraulic oil temperature has reached an excessive level. The hydraulic oil tempera- ture sender is attached to the rear ax...
Page 242 - Battery Care; Battery Storage
Groundsmaster 4500--D/4700--D Page 5 -- 50 Electrical System Service and Repairs NOTE: For engine component repair information (e.g. starter motor), refer to the Yanmar Service Manual that is correct for your Groundsmaster model. Battery Care 1. The top of the battery must be kept clean. lf the ma- ...
Page 243 - Battery Service
Groundsmaster 4500--D/4700--D Page 5 -- 51 Electrical System Battery Service The battery is the heart of the electrical system. With regular and proper service, battery life can be extended. Additionally, battery and electrical component failure can be prevented. CAUTION When working with batteries,...
Page 247 - Chapter 6; Axles, Planetaries and Brakes
Groundsmaster 4500--D/4700--D Page 6 -- 1 Axles, Planetaries and Brakes Chapter 6 Axles, Planetaries and Brakes Table of Contents SPECIFICATIONS 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . GENERAL INFORMATION 3 . . . . . . . . . . . . . . . . . . . . . Operator’s Manual 3 . . . . . . ....
Page 250 - Planetary Wheel Drive End Play; Endplay Checking Procedure
Groundsmaster 4500--D/4700--D Page 6 -- 4 Axles, Planetaries and Brakes Adjustments Planetary Wheel Drive End Play A front planetary wheel drive assembly that is properly operating should have no endplay. Any endplay in a planetary assembly indicates that there are potential problems with the planet...
Page 252 - Brake Assembly
Groundsmaster 4500--D/4700--D Page 6 -- 6 Axles, Planetaries and Brakes Service and Repairs Brake Assembly 1. Flange head screw (6 per planetary) 2. Splined brake shaft 3. Planetary assembly (2 used) 4. Front wheel assembly (2 used) 5. Lug nut (8 per wheel) 6. Retaining ring 7. Spring plate 8. Compr...
Page 253 - When changing attachments, tires or perform-
Groundsmaster 4500--D/4700--D Page 6 -- 7 Axles, Planetaries and Brakes Brake Assembly Removal (Fig. 1) 1. Park machine on a level surface and raise cutting decks to allow easier access to front brake assembly. Stop engine, engage parking brake and remove key from the ignition switch. 2. Drain oil f...
Page 256 - Brake Inspection and Repair
Groundsmaster 4500--D/4700--D Page 6 -- 10 Axles, Planetaries and Brakes Brake Inspection and Repair 1. Brake housing (LH shown) 2. Seal 3. Pull rod 4. Clevis pin (2 used) 5. Link (2 used) 6. Hitch pin (2 used) 7. Stationary disc (4 used) 8. Rotating disc (3 used) 9. Retaining ring 10. Gasket 11. Ro...
Page 258 - Planetary Wheel Drive Assembly; additional information and precautions.
Groundsmaster 4500--D/4700--D Page 6 -- 12 Axles, Planetaries and Brakes Planetary Wheel Drive Assembly Figure 7 FRONT RIGHT 1. Flange head screw (6 per planetary) 2. Splined brake shaft 3. Planetary assembly (2 used) 4. Front wheel assembly (2 used) 5. Lug nut (8 per wheel) 6. Retaining ring 7. Spr...
Page 260 - Planetary Wheel Drive Service
Groundsmaster 4500--D/4700--D Page 6 -- 14 Axles, Planetaries and Brakes Planetary Wheel Drive Service 1. Spindle 2. Boot seal 3. Oil seal 4. Inner bearing cone 5. Inner bearing cup 6. Wheel stud (8 used) 7. Socket head screw (16 used) 8. Lock washer (16 used) 9. Housing 10. Dowel pin (2 used) 11. O...
Page 264 - Rear Axle Assembly
Groundsmaster 4500--D/4700--D Page 6 -- 18 Axles, Planetaries and Brakes Rear Axle Assembly Figure 13 70 ft--lb (94 N--m) maximum FRONT RIGHT 85 to 100 ft--lb (116 to 135 N--m) 1. Rear axle motor 2. O--ring 3. Pinion gear 4. External snap ring (2 used) 5. O--ring 6. Hydraulic fitting 7. O--ring 8. 9...
Page 268 - Rear Axle Service
Groundsmaster 4500--D/4700--D Page 6 -- 22 Axles, Planetaries and Brakes Rear Axle Service Figure 19 3 2 4 5 6 7 8 9 10 14 13 12 11 15 1 10 11 8 9 8 13 16 17 18 19 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 20 41 42 43 50 44 45 46 47 48 49 51 54 55 56 57 58 59 52 53 60 61 62 63 64 2...
Page 270 - Bevel Gear Case and Axle Case
Groundsmaster 4500--D/4700--D Page 6 -- 24 Axles, Planetaries and Brakes Bevel Gear Case and Axle Case 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 asse...
Page 271 - Inspection
Groundsmaster 4500--D/4700--D Page 6 -- 25 Axles, Planetaries and Brakes 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. 23). 6. While holding the bevel gear case, tap the upper end of the bevel gea...
Page 274 - Differential Shafts
Groundsmaster 4500--D/4700--D Page 6 -- 28 Axles, Planetaries and Brakes 9. Remove the bevel gear case/axle case assembly from the axle support. Coat a new O-ring with grease and temporarily install the axle cover assembly. Position a dial indicator at the tooths center. Prevent the axle from turnin...
Page 275 - Axle Shafts
Groundsmaster 4500--D/4700--D Page 6 -- 29 Axles, Planetaries and Brakes 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 as an assembly (Fig. 32). 2. Use...
Page 276 - Input Shaft/Pinion Gear
Groundsmaster 4500--D/4700--D Page 6 -- 30 Axles, Planetaries and Brakes Input Shaft/Pinion Gear Figure 35 1 1. Nut (2 used) 2. Lock washer (2 used) 3. Stud (2 used) 4. Lock nut 5. Stake washer 6. Oil seal 7. O-ring 8. Seal collar 9. Bearing 10. O-ring 11. Input shaft/pinion gear 12. Bearing case 13...
Page 278 - Differential Gear
Groundsmaster 4500--D/4700--D Page 6 -- 32 Axles, Planetaries and Brakes 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 assemblies (see Bevel Gear Case/Axle Case Assembly in this section of thi...
Page 281 - Pinion Gear to Ring Gear Engagement; Toe
Groundsmaster 4500--D/4700--D Page 6 -- 35 Axles, Planetaries and Brakes 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- lowing procedure. GEAR TOOTH DEFINITIONS (Fig. 46): Toe -- the portion of t...
Page 283 - Chapter 7; Chassis; Cha
Groundsmaster 4500--D/4700--D Page 7 -- 1 Chassis Chapter 7 Chassis Table of Contents GENERAL INFORMATION 2 . . . . . . . . . . . . . . . . . . . . . Operator’s Manual 2 . . . . . . . . . . . . . . . . . . . . . . . . . . Cutting Deck Identification 2 . . . . . . . . . . . . . . . . . . . . SERVICE ...
Page 286 - Steering Column
Groundsmaster 4500--D/4700--D Page 7 -- 4 Chassis Service and Repairs Steering Column 1. Steering wheel cover 2. Lock nut 3. Steering wheel 4. Flat washer 5. Socket head screw (4 used) 6. Flange head screw (4 used) 7. Steering column 8. Steering control valve 9. Socket head screw (4 used) 10. Flange...
Page 290 - Console Arm
Groundsmaster 4500--D/4700--D Page 7 -- 8 Chassis Console Arm 1. Console arm frame 2. LH cover 3. RH cover 4. Washer head screw (10 used) 5. Phillips head screw 6. Lock nut 7. Cover plate 8. Flange head screw (2 used) 9. Mount 10. U--nut (5 used) 11. Flange head screw (5 used) 12. Switch panel 13. R...
Page 298 - Operator Seat
Groundsmaster 4500--D/4700--D Page 7 -- 16 Chassis Operator Seat 1. Seat frame 2. Seat plate 3. Torsion spring 4. Seat plate latch 5. Clevis pin 6. Flat washer 7. Cotter pin 8. Hair pin (4 used) 9. Seat frame rod (2 used) 10. R--clamp (2 used) 11. Flat washer (3 used) 12. Hair pin 13. Seat pivot sha...
Page 300 - Operator Seat Service
Groundsmaster 4500--D/4700--D Page 7 -- 18 Chassis Operator Seat Service 1. Backrest cushion 2. Seat cushion 3. LH armrest cover 4. LH armrest 5. Bushing (2 used) 6. Backrest 7. Plug (2 used) 8. Cable tie (3 used) 9. LH adjustment rail 10. Bumper (2 used) 11. Washer 12. Cap screw (2 used) 13. Seat 1...
Page 302 - Operator Seat Suspension
Groundsmaster 4500--D/4700--D Page 7 -- 20 Chassis Operator Seat Suspension 1. Cover 2. Cover 3. Level control 4. Air control valve 5. Shock absorber 6. Air spring 7. Air tube assembly 8. Wire harness 9. Compressor 10. Bellows 11. Stop 12. Bumper set (2 used) 13. Roller (4 used) 14. Washer (2 used) ...
Page 304 - Hood
Groundsmaster 4500--D/4700--D Page 7 -- 22 Chassis Hood 1. Screen 2. Latch keeper 3. Pop rivet (2 used) 4. Hood 5. Plastic plug (20 used) 6. Hood screen 7. Radiator mount 8. Flange head screw 9. Hair pin (2 used) 10. Rear bumper 11. Washer (2 used) 12. Rubber bumper (2 used) 13. Flange nut (2 used) ...
Page 307 - Chapter 8; Cutting Decks; Cutting
Groundsmaster 4500--D/4700--D Cutting Decks Page 8 -- 1 Chapter 8 Cutting Decks Table of Contents SPECIFICATIONS 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . GENERAL INFORMATION 3 . . . . . . . . . . . . . . . . . . . . . Operator’s Manual 3 . . . . . . . . . . . . . . . . . . . . . . ....
Page 309 - Never install or work on the cutting decks or lift
Groundsmaster 4500--D/4700--D Cutting Decks Page 8 -- 3 General Information CAUTION Never install or work on the cutting decks or lift arms with the engine running. Always stop en- gine and remove key from ignition switch first. Operator’s Manual The Cutting Deck Operator’s Manual provides informa- ...
Page 310 - Factors That Can Affect Quality of Cut; Factor
Groundsmaster 4500--D/4700--D Cutting Decks Page 8 -- 4 Troubleshooting There are a number of factors that can contribute to un- satisfactory quality of cut, some of which may be turf conditions. Turf conditions such as excessive thatch, “sponginess”, uneven ground conditions or attempting to cut of...
Page 311 - Rear Roller Bearing and Seal Installation Tools; Front Roller Bearing Installation Tool
Groundsmaster 4500--D/4700--D Cutting Decks Page 8 -- 5 Special Tools Order special tools from your Toro Distributor. Rear Roller Bearing and Seal Installation Tools These tools are used to assemble the cutting deck rear roller. Toro Part Numbers: Inner Seal Tool 115--0852 Bearing/Outer Seal Tool 11...
Page 312 - Blade Stopping Time
Groundsmaster 4500--D/4700--D Cutting Decks Page 8 -- 6 Adjustments CAUTION Never install or work on the cutting decks or lift arms with the engine running. Always stop en- gine and remove key from ignition switch first. See the Cutting Deck Operator’s Manual for adjustment procedures for cutting de...
Page 314 - Blade Spindle Assembly
Groundsmaster 4500--D/4700--D Cutting Decks Page 8 -- 8 Service and Repairs CAUTION Never install or work on the cutting decks or lift arms with the engine running. Always stop en- gine and remove key from ignition switch first. Blade Spindle Assembly 1. Flange nut (6 used) 2. Hydraulic deck motor 3...
Page 316 - Blade Spindle Service
Groundsmaster 4500--D/4700--D Cutting Decks Page 8 -- 10 Blade Spindle Service Disassembly (Fig. 6) 1. Remove blade spindle from cutting deck (see Blade Spindle Removal in this section). 2. Loosen and remove spindle nut from top of spindle shaft. 3. Remove the spindle shaft from the spindle housing ...
Page 318 - Rear Roller
Groundsmaster 4500--D/4700--D Cutting Decks Page 8 -- 12 Rear Roller 1. Deck frame 2. Rear roller assembly 3. Grease fitting 4. Roller shaft screw 5. Roller mount 6. Flange head screw 7. Skid bracket 8. Cap screw Figure 10 8 5 4 1 7 6 3 2 FRONT RIGHT 29 to 35 ft--lb (40 to 47 N--m) 29 to 35 ft--lb (...
Page 320 - Rear Roller Service; IMPORTANT: During assembly process, frequently
Groundsmaster 4500--D/4700--D Cutting Decks Page 8 -- 14 Rear Roller Service 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...
Page 322 - Front Roller Service; IMPORTANT: Use Front Roller Bearing Installation
Groundsmaster 4500--D/4700--D Cutting Decks Page 8 -- 16 Front Roller Service Disassembly (Fig. 18) 1. Remove roller mounting bolt. 2. Remove roller assembly from carrier frame. 3. To remove bearings and bearing spacer: A. Insert punch through end of roller and drive oppo- site bearing out by altern...
Page 324 - Cutting Deck Carrier Frame
Groundsmaster 4500--D/4700--D Cutting Decks Page 8 -- 18 Cutting Deck Carrier Frame 1. Carrier frame 2. Lynch pin 3. Thrust washer 4. Pivot shaft 5. Lift arm (#4 shown) 6. Flange nut (2 used per deck) 7. Hardened washer (2 used per deck) 8. Cap screw (2 used per deck) 9. Cap screw 10. Rebound washer...
Page 327 - Chapter 9; Foldout Drawings; Foldo
Groundsmaster 4500--D/4700--D Foldout Drawings Page 9 - 1 Chapter 9 Foldout Drawings Table of Contents ELECTRICAL DRAWING DESIGNATIONS 2 . . . . . . . HYDRAULIC SCHEMATICS Groundsmaster 4500--D 3 . . . . . . . . . . . . . . . . . . . . . Groundsmaster 4500--D with Optional Flow Divider Kit 4 . . . ....
Page 328 - Electrical Drawing Designations; ABBREVIATION
Groundsmaster 4500--D/4700--D Foldout Drawings Page 9 - 2 Electrical Drawing Designations The following abbreviations are used for wire harness colors on the electrical schematics and wire harness drawings in this chapter. ABBREVIATION COLOR BK BLACK BR or BN BROWN BU BLUE GN GREEN GY GRAY OR ORANGE...
Page 329 - Hydraulic Schematic
Page 9 - 3 Hydraulic Schematic Groundsmaster 4500--D 1. FLOWS SHOWN ARE CALCULATED AT HIGH IDLE AND 95% PUMP EFFICIENCY UNLESS OTHERWISE NOTED 0.630” ROD 0.630” ROD 1050 PSI 1600 PSI 6.2 GPM 11.4 GPM 3500 PSI 3500 PSI 1500 PSI 1500 PSI P1 P2 T1 G1 PRV1 PRV2 LC1 LC2 M1 M2 M3 M4 T RV09 PRV S1 CV FD P2...
Page 330 - With Optional Flow Divider Kit
Page 9 - 4 Hydraulic Schematic With Optional Flow Divider Kit 1. FLOWS SHOWN ARE CALCULATED AT HIGH IDLE AND 95% PUMP EFFICIENCY UNLESS OTHERWISE NOTED 0.630” ROD 0.630” ROD 1050 PSI 1600 PSI 6.2 GPM 11.4 GPM 3500 PSI 3500 PSI 1500 PSI 1500 PSI P1 P2 T1 G1 PRV1 PRV2 LC1 LC2 M1 M2 M3 M4 T RV09 PRV S1...
Page 333 - Electrical Schematic
Page 9 - 7 Electrical Schematic Groundsmaster 4500--D/4700--D Models 30881 and 30882 GM4700- D TRACTION PEDAL POSITION SENSOR TRACTION PEDAL POSITION SENSOR LH (#4) DECK RH (#5) DECK All relays and solenoids are shown as de-- energized.All ground wires are black. WIRE COLOR ABBREVIATIONS. NOTE: REFE...
Page 335 - Optional Operator Cab
Page 9 - 9 Electrical Schematic Groundsmaster 4500--D/4700--D Optional Operator Cab All relays and solenoids are shown as de-- energized.All ground wires are black. WIRE COLOR ABBREVIATIONS. NOTE: REFER TO ELECTRICAL DRAWING DESIGNATIONS IN THIS CHAPTER FOR
Page 336 - Main Wire Harness
Page 9 - 10 Groundsmaster 4500--D/4700--D Main Wire Harness P26 DECK PTO 1 P24 DECK PTO 2 P19 S5 P20 S6 P89 INTERCONNECT TO SEAT/CONSOLE P04 HEADLIGHT RH P79HEADLIGHT LH P07 RH (#5) DECKPOSITION SWITCH P13 P87 GM4700 INTERCONNECT GROUND P88 GM4700 INTERCONNECT P93ENGINE GROUND P21 FAN DIRECTION P22F...
Page 338 - Seat and Console Wire Harness
Page 9 - 12 Groundsmaster 4500--D/4700--D Seat and Console Wire Harness
Page 340 - Power Center Wire Harness
Page 9 - 14 Groundsmaster 4500--D/4700--D Power Center Wire Harness
Page 342 - Deck 6 and 7 Wire Harness
Page 9 - 16 Deck 6 and 7 Wire Harness Groundsmaster 4700--D LH (#7) DECK RH (#6) DECK POSITION SWITCH POSITION SWITCH 1 11 21 31 41 30 20 10 40 50 NOTE TAB POSITION PIN AND BACKSHELL ORIENTATION (TEC--5001)
Page 344 - Engine Wire Harness Drawing
Page 9 - 18 (Models 30881 and 30882) Engine Wire Harness Drawing Groundsmaster 4500--D/4700--D PIN AND BACKSHELL ORIENTATION FOR P01 & P02
Page 345 - Engine Wire Harness Diagram
Page 9 - 19 (Models 30881 and 30882) Engine Wire Harness Diagram DRAWING DESIGNATIONS IN THIS CHAPTER NOTE: THIS DRAWING IDENTIFIES WIRE GAUGE SIZE AND WIRE COLOR. REFER TO ELECTRICAL FOR ADDITIONAL INFORMATION. Groundsmaster 4500--D/4700--D
