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 1 -- 4Safety
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 information when servicing the ma-
chine.
2. Before servicing or making adjustments, lower cut-
ting decks, stop engine, set parking brake and remove
key from the ignition switch.
3. Make sure machine is in safe operating condition by
keeping all nuts, bolts and screws tight.
4. Never store the machine or fuel container inside
where there is an open flame, such as near a water heat-
er or furnace.
5. Make sure all hydraulic line connectors are tight and
all hydraulic hoses and lines are in good condition be-
fore applying pressure to the hydraulic system.
6. 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.
7. Before disconnecting or performing any work on the
hydraulic system, all pressure in system must be re-
lieved by stopping engine and lowering cutting decks to
the ground.
8. If major repairs are ever needed or assistance is de-
sired, contact an Authorized Toro Distributor.
9. To reduce potential fire hazard, keep engine area
free of excessive grease, grass, leaves and dirt. Clean
protective screen on machine frequently.
10.If engine must be running to perform maintenance or
an adjustment, keep hands, feet, clothing and other
parts of t he body away from cutting decks and other
moving parts. Keep bystanders away.
11. To assure safety and accuracy, check that maximum
engine speed is correct.
12.Shut engine off before checking or adding oil to the
crankcase.
13.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 battery cable first and negative
cable last.
14.Battery acid is poisonous and can cause burns.
Avoid contact with skin, eyes and clothing. Protect your
face, eyes and clothing when working with a battery.
15.Battery gases can explode. Keep cigarettes, sparks
and flames away from the battery.
16.At the time of manufacture, the machine conformed
to the s afety standards for riding mowers. To assure op-
timum performance and continued safety certification of
the machine, use genuine Toro replacement parts and
accessories. Replacement partsandaccessoriesmade
by other manufacturers may result in non -conformance
with the safety standards and the warranty may be
voided.
17.When changing attachments, tires or performing
other service, use correct jacks, hoists and jack stands.
Make sure machine is parkedonasolidlevelsurface
such as a concrete floor. Prior to raising the machine, re-
move any attachments that may interfere with the safe
and proper raising of the machine. Always chock or
block wheels. Use appropriate jack stands to support
the raised machine. If the machine is not properly sup-
ported by jack stands, the machine may move or fall,
which may result in personal injury (see Jacking Instruc-
tions in this chapter).
18.When welding on machine, disconnect all battery
cables to prevent damage to machine electronic equip-
ment. Disconnect negative battery cable first and posi-
tive cable last. Also, disconnect wire harness connector
from the TEC controller(s), disconnect and remove the
engine ECU and disconnect the terminal connector from
the alternator. Attach welder ground cable no more than
two (2) feet (0.6 meters) from the welding location.
19.Make sure to dispose of potentially harmful waste
(e.g. fuel, oil, engine coolant, filters, battery) in an envir-
onmentally safe manner. Follow all local codes and reg-
ulations when recycling or disposing of waste.