Service Manual
Table Of Contents
- Title Page
- Revision History
- Reader Comments
- Preface
- Table Of Contents
- 1 - Safety
- 2 - Product Records and Maintenance
- 3 - Yanmar Diesel Engine
- 4 - Hydraulic System
- Table of Contents
- Specifications
- General Information
- Hydraulic Schematics
- Hydraulic Flow Diagrams
- Special Tools
- Troubleshooting
- Testing
- Traction Circuit Charge Pressure
- Traction Circuit Relief Pressure
- Reverse Traction Circuit Reducing Valve (PR) Pressure
- Rear Traction Circuit Relief (RV) Pressure
- Piston (Traction) Pump Flow
- Cutting Deck Circuit Pressure
- Cutting Deck Circuit Relief Pressure
- Deck Motor Case Drain Leakage
- Steering Circuit Relief Pressure
- Steering Cylinder Internal Leakage
- Lift/Lower Circuit Relief Pressure
- Engine Cooling Fan Circuit
- Gear Pump Flow
- Adjustments
- Service and Repairs
- General Precautions for Removing and Installing Hydraulic System Components
- Check Hydraulic Lines and Hoses
- Priming Hydraulic Pumps
- Flush Hydraulic System
- Filtering Closed-Loop Traction Circuit
- Charge Hydraulic System
- Gear Pump
- Gear Pump Service
- Piston (Traction) Pump
- Piston (Traction) Pump Service
- Rear Traction Control Manifold
- Rear Traction Control Manifold Service
- Control Manifold Cartridge Valve Service
- HI/LOW Range Control Manifold
- Rear Axle Motor
- Front Wheel Motors
- Rear Axle and Front Wheel Motor Service
- Cutting Deck Motor
- Cutting Deck Motor Service
- Deck Control Manifold
- Deck Control Manifold Service (GM 4500-D)
- Deck Control Manifold Service (GM 4700-D)
- Steering Control Valve
- Steering Control Valve Service
- Steering Cylinder
- Steering Cylinder Service
- Engine Cooling Fan Motor
- Engine Cooling Fan Motor Service
- Fan Control Manifold
- Fan Control Manifold Service
- Lift Control Manifold
- Lift Control Manifold Service (GM 4500-D)
- Lift Control Manifold Service (GM 4700-D)
- Lift Circuit Junction Manifold
- Lift Cylinders: Decks #1, #4 and #5
- Lift Cylinders: Decks #2 and #3
- Lift Cylinders: Decks #6 and #7 (GM 4700-D)
- Lift Cylinder Service
- Hydraulic Reservoir
- Radiator and Oil Cooler Assembly
- 5 - Electrical System
- Table of Contents
- General Information
- Special Tools
- InfoCenter Display
- Troubleshooting
- Electrical System Quick Checks
- Adjustments
- Component Testing
- Ignition Switch
- Fuses
- Fusible Link Harness
- PTO Switch
- Hi/Low Speed, Engine Speed Request and Cutting Deck Lift Switches
- Headlight Switch
- Seat Switch
- Parking Brake Switch
- Cutting Deck Position Switches
- Relays with Four (4) Terminals
- Relays with Five (5) Terminals
- Traction Pedal Position Sensor
- Toro Electronic Controllers (TEC)
- Hydraulic Solenoid Valve Coils
- Piston (Traction) Pump Control Solenoid Coils
- Hydraulic Oil Temperature Sender
- Fuel Pump (Models 30873 and 30874)
- Fuel Pump (Models 30881 and 30882)
- CAN-bus Termination Resistor
- Diode Assemblies
- Resistor Assemblies
- Fan Speed Switch (Machines with Two−Post ROPS Extension Operator Fan Kit)
- Resistor Module (Machines with Two−Post ROPS Extension Operator Fan Kit)
- Service and Repairs
- 6 - Axles, Planetaries and Brakes
- Table of Contents
- Specifications
- General Information
- Adjustments
- Service and Repairs
- Brake Assembly
- Brake Inspection and Repair
- Planetary Drive Assembly
- OPH-2 Series Planetary Drive Service
- VA02 Series Planetary Drive Service
- Rear Axle Assembly
- Rear Axle Service
- Bevel Gear Case and Axle Case
- Differential Shafts
- Axle Shafts
- Input Shaft/Pinion Gear
- Differential Gear
- Pinion Gear to Ring Gear Engagement
- 7 - Chassis
- 8 - Cutting Decks
- 9 - Foldout Drawings
- Electrical Drawing Designations
- Groundsmaster 4500--D Hydraulic Schematic
- Groundsmaster 4500--D With Optional Flow Divider Kit Hydraulic Schematic
- Groundsmaster 4700--D Hydraulic Schematic
- Groundsmaster 4700--D With Optional Flow Divider Kit Hydraulic Schematic
- Electrical Schematic Groundsmaster 4500--D/4700--D Models 30881 and 30882 (Serial numbers below 315000300)
- Electrical Schematic Groundsmaster 4500--D/4700--DModels 30873 and 30874(Serial numbers below 315000300)
- Groundsmaster 4500--D/4700--D Electrical Schematic Models 30881 and 30882 (Serial Numbers 315000301 to 399999999)
- Groundsmaster 4500--D/4700--D Electrical Schematic Models 30873 and 30874 (Serial Numbers 315000301 to 399999999)
- Groundsmaster 4500--D/4700--D Electrical Schematic Models 30881 and 30882(Serial Numbers 400000000 to 403450000)
- Groundsmaster 4500--D/4700--D Electrical Schematic Models 30873 and 30874(Serial Numbers 400000000 to 403450000)
- Groundsmaster 4500--D/4700--D Electrical Schematic (Serial Numbers Serial Numbers 403450001 to 408000000)Models 30881 and 30882
- Groundsmaster 4500--D/4700--DElectrical Schematic(Serial Numbers Above 408000000)
- Groundsmaster 4500--D/4700--D Electrical Schematic (Serial Numbers Above 403450001) Models 30873 and 30874
- Electrical Schematic Groundsmaster 4500--D/4700--D Optional Operator Cab (Serial number below 399999999)
- Groundsmaster 4500--D/4700--D Electrical Schematic Optional Operator Cab (Serial Numbers Above 400000000)
- Groundsmaster 4500--D/4700--D Main Wire Harness (Serial number below 315000300)
- Groundsmaster 4500--D/4700--D Main Wire Harness (Serial Numbers 315000301 to 399999999)
- Groundsmaster 4500--D/4700--D Main Wire Harness (Serial Numbers 400000000 to 403450000)
- Groundsmaster 4500--D/4700--D Main Wire Harness (Serial Numbers Above 403450001)
- Groundsmaster 4500--D/4700--D Seat and Console Wire Harness (Serial number below 399999999)
- Groundsmaster 4500--D/4700--D Seat and Console Wire Harness (Serial Numbers 400000000 to 403450000)
- Groundsmaster 4500--D/4700--D Seat and Console Wire Harness (Serial Numbers Above 403450001)
- Groundsmaster 4500--D/4700--D Power Center Wire Harness(Serial number below 403450000)
- Groundsmaster 4500--D/4700--D Power Center Wire Harness(Serial Numbers Above 403450001)
- Deck 6 and 7 Wire Harness Groundsmaster 4700--D
- (Models 30881 and 30882) Engine Wire Harness Drawing Groundsmaster 4500--D/4700--D (Serial number below 315000000)
- Groundsmaster 4500--D/4700--D (Models 30881 and 30882) Engine Wire Harness Drawing(Serial Numbers 315000001 to 408000000)
- Groundsmaster 4500--D/4700--D(Models 30881 and 30882)Engine Wire Harness Drawing(Serial Numbers Above 408000000)
- Groundsmaster 4500--D/4700--D(Models 30881 and 30882)Engine DPF Sub--Wire Harness Drawing(Serial Numbers Above 408000000)
- (Models 30873 and 30874) Engine Wire Harness Drawing Groundsmaster 4500--D/4700--D
- Groundsmaster 4500--D/4700--D Wire Harness Diagram -- Two--Post ROPS Extension
- Groundsmaster 4500--D/4700--DPower Harness Kit -- Wiring Diagram
Groundsmaster 4500−D/4700−DPage 6 − 18Axles, Planetaries and Brakes
4. If previously removed, press bearing cups into hous-
ing. Cups should be pressed fully to shoulder of the
housing bore.
5. Fit inner bearing cone onto spindle. Make sure inner
bearing cone seats fully against spindle shoulder. If in-
ner bearing is not seated fully, lightly tap bearing cone
on inner hub until it seats properly.
6. Make sure that seal bore in housing is thoroughly
cleaned. If OD of seal is not rubber or does not have a
sealant coating, apply a light coating of silicone sealant
to seal bore in housing.
Install seal into housing so it is
flush with housing face.
7. Install boot seal. Cover surface of lip seal and boot
seal with grease.
8. Lightly oil bearing cups then place housing assembly
over spindle and inner bearing cone. Take care to not
damage seals or spindle during installation.
9. Fit outer bearing cone onto spindle.
10.Align key on spacer and install spacer onto spindle
shaft.
11. Align key on locking washer and install locking wash-
er onto spindle shaft.
IMPORTANT: .Perform the following steps without
interruption. Once the thread locking compound is
applied, you have only a few minutes before the cur-
ing process will influence the bearing lock nut
torque.
12.Install the bearing lock nut:
A. Apply high strength thread locking compound
(Loctite 263 or equivalent) and install the lock nut.
B. Tighten the lock nut to 110 ft−lb (150 N−m).
C. Rotate the housing on the spindle a few revolu-
tions to align the bearings.
D. Tighten the lock nut to 150 ft−lb (200 N−m).
E. Rotate the housing on the spindle a few revolu-
tions to seat the bearings.
IMPORTANT If installing the bearing nut with
the spindle installed on machine, have an assis-
tant hold the housing firmly in position during
the following step.
F. Loosen the lock nut completely, then tighten to 90
ft−lb (122 N−m).
IMPORTANT: Continue to tighten the lock nut
until it aligns with one of the locking washer tabs.
Do Not loosen the lock nut to align it with the
locking washer tabs.
G. Secure the lock nut by bending one of the locking
washer tabs into a slot in the lock nut.
13.Install secondary carrier and primary carrier making
sure that carrier gear teeth align with ring gear and
spline on spindle shaft.
14.If primary gear (item 25) was removed from drive
shaft, slide gear onto shaft and secure with retaining
rings.
15.Install drive shaft assembly (items 24−26) making
sure that drive shaft spline aligns with carrier gears.
16.Cover the outer face of the thrust plate with grease
and fit thrust plate onto end cap. Make sure that thrust
plate tabs are captive in end cap.
17.Apply a light coat of grease to a new O−ring and in-
stall it in the ring gear bore. Avoid pinching or cutting the
O−ring and install the end cap. Use a soft mallet to fully
seat the end cap.
18.Secure the end cap with the retaining ring. Make sure
the retaining ring is fully seated in the ring groove.
19.Check operation of planetary drive by hand. 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 examined for improper assembly or damaged
components.
20.Install front wheel assembly.
21.Fill planetary drive with gear lube; refer to traction
unit Operator’s Manual. A portion of the gear lube will
pass into the brake assembly automatically.
22.Test planetary drive operation.
Failure to maintain proper wheel lug nut torque
could result in failure or loss of wheel and may
result in personal injury.
WARNING
23.Remove jack stands and lower machine to ground.
Tighten wheel lug nuts in a crossing pattern from 85 to
100 ft−lb (116 to 135 N−m).