caution

caution
PART NO. 02104SL (Rev. D)
Service Manual
GroundsmasterR 4500--D/4700--D
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 INSTRUCTIONS. 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 Serial Number to:
The Toro Company
Attn. Technical Publications
8111 Lyndale Avenue South
Bloomington, MN 55420--1196
This safety symbol means DANGER, WARNING,
or CAUTION, PERSONAL SAFETY INSTRUCTION. 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 repair of the machine.
IMPORTANT: The IMPORTANT notice will give important instructions which must be followed to prevent damage to systems or components on the
machine.
The Toro Company reserves the right to change product
specifications or this publication without notice.
E The Toro Company - 2002, 2003, 2005, 2007
This page is intentionally blank.
Groundsmaster 4500--D/4700--D
Product Records . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Equivalents and Conversions . . . . . . . . . . . . . . . .
Torque Specifications . . . . . . . . . . . . . . . . . . . . . . .
2 -2 -2 -2 --
1
1
2
3
Chapter 3 -- Kubota Diesel Engine
General Information . . . . . . . . . . . . . . . . . . . . . . . . 3 -- 2
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 -- 3
Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 -- 4
Service and Repairs . . . . . . . . . . . . . . . . . . . . . . . . 3 -- 5
KUBOTA WORKSHOP MANUAL, DIESEL ENGINE,
V2003--T SERIES
Chapter 4 -- Hydraulic System
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 -- 2
Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 -- 3
Service and Repairs . . . . . . . . . . . . . . . . . . . . . . . . 6 -- 4
Chapter 7 -- Chassis
General Information . . . . . . . . . . . . . . . . . . . . . . . . 7 -- 1
Service and Repairs . . . . . . . . . . . . . . . . . . . . . . . . 7 -- 2
Chapter 8 -- Cutting Units
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Service and Repairs . . . . . . . . . . . . . . . . . . . . . . . .
8 -8 -8 -8 -8 --
2
3
4
5
8
Chapter 9 -- Electrical Diagrams
Electrical Schematics . . . . . . . . . . . . . . . . . . . . . . . 9 -- 3
Circuit Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 -- 9
Wire Harness Drawings . . . . . . . . . . . . . . . . . . . . 9 -- 14
Groundsmaster 4500--D/4700--D
Rev. D
Electrical
Diagrams
Cutting Units
Chassis
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 -- 2
General Information . . . . . . . . . . . . . . . . . . . . . . . . 4 -- 3
Hydraulic Schematics . . . . . . . . . . . . . . . . . . . . . . . 4 -- 6
Hydraulic Flow Diagrams . . . . . . . . . . . . . . . . . . . . 4 -- 8
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 -- 20
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 -- 22
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 -- 25
Service and Repairs . . . . . . . . . . . . . . . . . . . . . . . 4 -- 52
Chapter 6 -- Axles, Planetaries, and Brakes
Product Records
and Maintenance
Chapter 2 -- Product Records and Maintenance
Kubota
Diesel Engine
Electrical Schematics and Electrical Harness and
Connectors Drawings . . . . . . . . . . . . . . . . . . . . . . 5 -- 2
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 -- 2
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 -- 3
Electrical System Quick Checks . . . . . . . . . . . . . . 5 -- 6
Component Testing . . . . . . . . . . . . . . . . . . . . . . . . . 5 -- 7
Service and Repairs . . . . . . . . . . . . . . . . . . . . . . . 5 -- 27
Hydraulic
System
General Safety Instructions . . . . . . . . . . . . . . . . . . 1 -- 2
Jacking Instructions . . . . . . . . . . . . . . . . . . . . . . . . . 1 -- 4
Safety and Instruction Decals . . . . . . . . . . . . . . . . 1 -- 5
Electrical
System
Chapter 5 -- Electrical System
Axles, Planetaries,
and Brakes
Chapter 1 -- Safety
Safety
Table Of Contents
This page is intentionally blank.
Groundsmaster 4500--D/4700--D
Safety
Table of Contents
GENERAL SAFETY INSTRUCTIONS . . . . . . . . . . . .
Before Operating . . . . . . . . . . . . . . . . . . . . . . . . . . . .
While Operating . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maintenance and Service . . . . . . . . . . . . . . . . . . . .
Groundsmaster 4500--D/4700--D
2
2
2
3
JACKING INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . 4
SAFETY AND INSTRUCTION DECALS . . . . . . . . . . 5
Page 1 -- 1
Safety
Safety
Chapter 1
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 accident prevention partially are dependent upon the design
and configuration of the machine, these factors are also
dependent upon the awareness, concern, and proper
training of the personnel involved in the operation, transport, maintenance, and storage of the machine. Improper use or maintenance of the machine can result in injury
or death. To reduce the potential for injury or death, comply with the following safety instructions.
WARNING
To reduce the potential for injury or death,
comply with the following safety instructions.
Before Operating
1. Read and understand the contents of the Operator’s
Manual before starting and operating the machine. Become 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:
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 carefully:
A. Use an approved fuel container.
The Toro Company
Attn. Technical Publications
8111 Lyndale Avenue South
Bloomington, Minnesota 55420--1196
B. Do not remove fuel tank cap while engine is hot or
running.
C. Do not smoke while handling fuel.
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.
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.
While Operating
1. Sit on the seat when starting and operating the machine.
5. Before getting off the seat:
2. Before starting the engine:
A. Ensure that traction pedal is in neutral.
B. Set parking brake.
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; 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 adequate ventilation. Exhaust fumes are hazardous and
could possibly be deadly.
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 ground. This relieves pressure
from the lift circuit and eliminates the risk of cutting
units accidentally lowering to the ground.
F. Do not park on slopes unless wheels are chocked
or blocked.
4. Do not touch engine, muffler or exhaust pipe while
engine is running or soon after it is stopped. These areas
could be hot enough to cause burns.
Safety
Page 1 -- 2
Groundsmaster 4500--D/4700--D
1. Before servicing or making adjustments, lower
decks, stop engine, set parking brake, and remove key
from the switch.
10.Do not overspeed the engine by changing governor
setting. To assure safety and accuracy, check maximum
engine speed.
2. Make sure machine is in safe operating condition by
keeping all nuts, bolts and screws tight.
11. Shut engine off before checking or adding oil to the
crankcase.
3. Never store the machine or fuel container inside
where there is an open flame, such as near a water heater or furnace.
12.Disconnect battery before servicing the machine.
Disconnect negative battery cable first and positive
cable last. If battery voltage is required for troubleshooting or test procedures, temporarily connect the battery.
Reconnect positive cable first and negative cable last.
4. Make sure all hydraulic line connectors are tight, and
all hydraulic hoses and lines are in good condition before applying pressure to the system.
5. Keep body and hands away from pin hole leaks in hydraulic 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 doctor familiar with this form of injury or gangrene may result.
6. Before disconnecting or performing any work on the
hydraulic system, all pressure in system must be relieved by stopping engine and lowering cutting units to
the ground.
7. If major repairs are ever needed or assistance is desired, contact an Authorized Toro Distributor.
8. To reduce potential fire hazard, keep engine area
free of excessive grease, grass, leaves and dirt. Clean
protective screen on machine frequently.
9. If engine 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 moving parts. Keep bystanders away.
Groundsmaster 4500--D/4700--D
13.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.
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 optimum performance and continued safety certification of
the machine, use genuine Toro replacement parts and
accessories. Replacement parts and accessories made
by other manufacturers may result in non-conformance
with the safety standards, and the warranty may be
voided.
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 supported by blocks or jack stands, the machine may move
or fall, which may result in personal injury (see Jacking
Instructions).
Page 1 -- 3
Safety
Safety
Maintenance and Service
Jacking Instructions
CAUTION
When changing attachments, tires, or performing 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 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 supported by blocks or jack
stands, the machine may move or fall, which
may result in personal injury.
1
2
Figure 1
1. Frame
2. Front tire (RH shown)
Jacking the Front End (Fig. 1)
1. Set parking brake and chock both rear tires to prevent 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 inside of the front tire.
2
1
2
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.
Figure 2
1. Rear axle
2. Rear tire
Jacking the Rear End (Fig. 2)
1. Set parking brake and chock both front tires to prevent the machine from moving.
2. Place jack securely under the center of rear axle.
3. Jack rear of machine off the ground.
4. Position jack stands or hardwood blocks under the
rear axle to support the machine.
Safety
Page 1 -- 4
Groundsmaster 4500--D/4700--D
Safety
Safety and Instruction Decals
Numerous safety and instruction decals are affixed to
the Groundsmaster 4500--D/4700--D. If any decal becomes illegible or damaged, install a new decal. Decal
part numbers are listed in your Parts Catalog.
Groundsmaster 4500--D/4700--D
Page 1 -- 5
Safety
This page is intentionally blank.
Safety
Page 1 -- 6
Groundsmaster 4500--D/4700--D
Product Records and Maintenance
Table of Contents
PRODUCT RECORDS . . . . . . . . . . . . . . . . . . . . . . . . .
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
EQUIVALENTS AND CONVERSIONS . . . . . . . . . . .
Decimal and Millimeter Equivalents . . . . . . . . . . . .
U.S. to Metric Conversions . . . . . . . . . . . . . . . . . . .
TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . .
Fastener Identification . . . . . . . . . . . . . . . . . . . . . . .
1
1
2
2
2
3
3
Standard Torque for Dry, Zinc Plated, and
Steel Fasteners (Inch Series) . . . . . . . . . . . . . . .
Standard Torque for Dry, Zinc Plated, and
Steel Fasteners (Metric Fasteners) . . . . . . . . . . .
Other Torque Specifications . . . . . . . . . . . . . . . . . .
Conversion Factors . . . . . . . . . . . . . . . . . . . . . . . . . .
4
5
6
6
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 accessories have been installed to your machine, insert
the Installation Instructions, Operator’s Manuals and
Parts Catalogs for those options at the end of this chapter.
Maintenance
Maintenance procedures and recommended service intervals for the Groundsmaster 4500--D/4700--D are covered in the Operator’s Manual. Refer to that publication
when performing regular equipment maintenance.
Groundsmaster 4500--D/4700--D
Page 2 -- 1
Rev. D
Product Records and Maintenance
Product Records
and Maintenance
Chapter 2
Equivalents and Conversions
0.09375
Product Records and Maintenance
Page 2 -- 2
Rev. D
Groundsmaster 4500--D/4700--D
Recommended fastener torque values are listed in the
following tables. For critical applications, as determined
by Toro, either the recommended torque or a torque that
is unique to the application is clearly identified and specified in this Service Manual.
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 Service Manual. The following factors shall be considered
when applying torque: cleanliness of the fastener, use
of a thread sealant (e.g. Loctite), degree of lubrication
on the fastener, presence of a prevailing torque feature,
hardness of the surface underneath the fastener’s head,
or similar condition which affects the installation.
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 engagement, etc.
The standard method of verifying torque shall be performed 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.
Fastener Identification
Grade 1
Grade 5
Grade 8
Class 8.8
Inch Series Bolts and Screws
Metric Bolts and Screws
Figure 1
Groundsmaster 4500--D/4700--D
Class 10.9
Figure 2
Page 2 -- 3
Product Records and Maintenance
Product Records
and Maintenance
Torque Specifications
Standard Torque for Dry, Zinc Plated, and Steel Fasteners (Inch Series)
Thread Size
# 6 -- 32 UNC
Grade 1, 5, &
8 with Thin
Height Nuts
SAE Grade 1 Bolts, Screws, Studs, &
Sems with Regular Height Nuts
(SAE J995 Grade 2 or Stronger Nuts)
in--lb
in--lb
N--cm
10 + 2
13 + 2
147 + 23
# 6 -- 40 UNF
# 8 -- 32 UNC
13 + 2
25 + 5
282 + 30
# 8 -- 36 UNF
# 10 -- 24 UNC
18 + 2
30 + 5
339 + 56
# 10 -- 32 UNF
SAE Grade 5 Bolts, Screws, Studs, &
Sems with Regular Height Nuts
(SAE J995 Grade 2 or Stronger Nuts)
SAE Grade 8 Bolts, Screws, Studs, &
Sems with Regular Height Nuts
(SAE J995 Grade 5 or Stronger Nuts)
in--lb
N--cm
in--lb
N--cm
15 + 2
170 + 20
23 + 2
260 + 20
17 + 2
190 + 20
25 + 2
280 + 20
29 + 3
330 + 30
41 + 4
460 + 45
31 + 3
350 + 30
43 + 4
485 + 45
42 + 4
475 + 45
60 + 6
675 + 70
48 + 4
540 + 45
68 + 6
765 + 70
1/4 -- 20 UNC
48 + 7
53 + 7
599 + 79
100 + 10
1125 + 100
140 + 15
1580 + 170
1/4 -- 28 UNF
53 + 7
65 + 10
734 + 113
115 + 10
1300 + 100
160 + 15
1800 + 170
5/16 -- 18 UNC
115 + 15
105 + 17
1186 + 169
200 + 25
2250 + 280
300 + 30
3390 + 340
5/16 -- 24 UNF
138 + 17
128 + 17
1446 + 192
225 + 25
2540 + 280
325 + 30
3670 + 340
ft--lb
ft--lb
N--m
ft--lb
N--m
ft--lb
N--m
3/8 -- 16 UNC
16 + 2
16 + 2
22 + 3
30 + 3
41 + 4
43 + 4
58 + 5
3/8 -- 24 UNF
17 + 2
18 + 2
24 + 3
35 + 3
47 + 4
50 + 4
68 + 5
7/16 -- 14 UNC
27 + 3
27 + 3
37 + 4
50 + 5
68 + 7
70 + 7
95 + 9
7/16 -- 20 UNF
29 + 3
29 + 3
39 + 4
55 + 5
75 + 7
77 + 7
104 + 9
1/2 -- 13 UNC
30 + 3
48 + 7
65 + 9
75 + 8
102 + 11
105 + 10
142 + 14
1/2 -- 20 UNF
32 + 3
53 + 7
72 + 9
85 + 8
115 + 11
120 + 10
163 + 14
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 UNC
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
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.
NOTE: Torque values may have to be reduced when
installing fasteners into threaded aluminum or brass.
The specific torque value should be determined based
Product Records and Maintenance
on the fastener size, the aluminum or base material
strength, length of thread engagement, etc.
NOTE: The nominal torque values listed above for
Grade 5 and 8 fasteners are based on 75% of the minimum proof load specified in SAE J429. The tolerance is
approximately + 10% of the nominal torque value. Thin
height nuts include jam nuts.
Page 2 -- 4
Groundsmaster 4500--D/4700--D
Thread Size
Class 8.8 Bolts, Screws, and Studs with
Regular Height Nuts
(Class 8 or Stronger Nuts)
Class 10.9 Bolts, Screws, and Studs with
Regular Height Nuts
(Class 10 or Stronger Nuts)
M5 X 0.8
57 + 5 in--lb
640 + 60 N--cm
78 + 7 in--lb
885 + 80 N--cm
M6 X 1.0
96 + 9 in--lb
1018 + 100 N--cm
133 + 13 in--lb
1500 + 150 N--cm
M8 X 1.25
19 + 2 ft--lb
26 + 3 N--m
27 + 2 ft--lb
36 + 3 N--m
M10 X 1.5
38 + 4 ft--lb
52 + 5 N--m
53 + 5 ft--lb
72 + 7 N--m
M12 X 1.75
66 + 7 ft--lb
90 + 10 N--m
92 + 9 ft--lb
125 + 12 N--m
M16 X 2.0
166 + 15 ft--lb
225 + 20 N--m
229 + 22 ft--lb
310 + 30 N--m
M20 X 2.5
325 + 33 ft--lb
440 + 45 N--m
450 + 37 ft--lb
610 + 50 N--m
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.
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
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% of the
nominal torque value.
Page 2 -- 5
Product Records and Maintenance
Product Records
and Maintenance
Standard Torque for Dry, Zinc Plated, and Steel Fasteners (Metric Fasteners)
Other Torque Specifications
SAE Grade 8 Steel Set Screws
Wheel Bolts and Lug Nuts
Thread Size
Recommended Torque
Thread Size
Square Head
Hex Socket
1/4 -- 20 UNC
140 + 20 in--lb
73 + 12 in--lb
5/16 -- 18 UNC
215 + 35 in--lb
145 + 20 in--lb
3/8 -- 16 UNC
35 + 10 ft--lb
18 + 3 ft--lb
1/2 -- 13 UNC
75 + 15 ft--lb
50 + 10 ft--lb
Recommended Torque**
7/16 -- 20 UNF
Grade 5
65 + 10 ft--lb
88 + 14 N--m
1/2 -- 20 UNF
Grade 5
80 + 10 ft--lb
108 + 14 N--m
M12 X 1.25
Class 8.8
80 + 10 ft--lb
108 + 14 N--m
M12 X 1.5
Class 8.8
80 + 10 ft--lb
108 + 14 N--m
** For steel wheels and non--lubricated fasteners.
Thread Cutting Screws
(Zinc Plated Steel)
Type 1, Type 23, or Type F
Thread Size
Baseline Torque*
No. 6 -- 32 UNC
20 + 5 in--lb
No. 8 -- 32 UNC
Thread Cutting Screws
(Zinc Plated Steel)
Thread
Size
Threads per Inch
Baseline Torque*
Type A
Type B
No. 6
18
20
20 + 5 in--lb
30 + 5 in--lb
No. 8
15
18
30 + 5 in--lb
No. 10 -- 24 UNC
38 + 7 in--lb
No. 10
12
16
38 + 7 in--lb
1/4 -- 20 UNC
85 + 15 in--lb
No. 12
11
14
85 + 15 in--lb
5/16 -- 18 UNC
110 + 20 in--lb
3/8 -- 16 UNC
200 + 100 in--lb
* Hole size, material strength, material thickness & finish
must be considered when determining specific torque
values. All torque values are based on non--lubricated
fasteners.
Conversion Factors
in--lb X 11.2985 = N--cm
ft--lb X 1.3558 = N--m
Product Records and Maintenance
N--cm X 0.08851 = in--lb
N--m X 0.7376 = ft--lb
Page 2 -- 6
Groundsmaster 4500--D/4700--D
Chapter 3
Kubota Diesel Engine
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . .
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Run Solenoid . . . . . . . . . . . . . . . . . . . . . . . .
SERVICE AND REPAIRS . . . . . . . . . . . . . . . . . . . . . .
Air Filter System . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Check Fuel Lines and Connections . . . . . . . . . . .
Drain and Clean Fuel Tank . . . . . . . . . . . . . . . . . .
Fuel Tank Removal . . . . . . . . . . . . . . . . . . . . . . . .
Fuel Tank Installation . . . . . . . . . . . . . . . . . . . . . . .
Groundsmaster 4500--D/4700--D
2
3
4
4
5
5
6
8
8
8
9
9
Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Engine Removal . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Engine Installation . . . . . . . . . . . . . . . . . . . . . . . . 14
Pump Adapter Plate . . . . . . . . . . . . . . . . . . . . . . . . 16
KUBOTA WORKSHOP MANUAL, DIESEL ENGINE,
V2003--T SERIES
Page 3 -- 1
Kubota Diesel Engine (Rev. A)
Kubota
Diesel Engine
Table of Contents
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 Manual. Information on engine
troubleshooting, testing, disassembly and reassembly
is identified in the Kubota Workshop Manual, Diesel Engine, 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)
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 repairs may dictate that the work be done at an engine repair facility.
Service and repair parts for Kubota engines are supplied through your Authorized Toro Distributor. If no
parts list is available, be prepared to provide your distributor with the Toro model and serial number.
Page 3 -- 2
Groundsmaster 4500--D/4700--D
Specifications
Item
Description
Make / Designation
Kubota, 4--Cycle, 4 Cylinder,
Water Cooled, Turbocharged, Diesel Engine
58 HP (43.3 kW) @ 2600 RPM
Bore mm (in.)
83.0 (3.27)
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 (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)
Groundsmaster 4500--D/4700--D
184 (406)
Page 3 -- 3
Kubota Diesel Engine (Rev. A)
Kubota
Diesel Engine
Horse Power
Adjustments
Engine Run Solenoid
1. When ignition switch is in the RUN position, the engine run solenoid should energize and position the fuel
stop lever to within 1/16” (1.6 mm) of stop on the injection pump.
4
2
3
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.
1
Figure 1
1. Run solenoid (ON)
2. Lever
3. Swivel
4. Lock nut
2
1
3
Figure 2
1. Run solenoid (OFF)
2. Solenoid lever
Kubota Diesel Engine (Rev. A)
Page 3 -- 4
3. Injection pump stop
Groundsmaster 4500--D/4700--D
Service and Repairs
Air Filter System
7
8
4
11
Kubota
Diesel Engine
10
1
RIGHT
2
9
FRONT
15
12
13
3
5
6 11
14
VACUATOR
DIRECTION
16
Figure 3
1.
2.
3.
4.
5.
6.
Air cleaner hose
Hose clamp
Air cleaner assembly
Service indicator
Air cleaner strap
Lock nut
7.
8.
9.
10.
11.
Hose clamp
Air cleaner hose
Hose clamp
Cap screw
Flat washer
12.
13.
14.
15.
16.
Removal
Air cleaner body
Filter element
Filter element
Air cleaner cover
Vacuator valve
4
1. Remove air cleaner components as needed using
Figure 3 as a guide.
1
Installation
3
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.
5
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):
A. Make sure that hose does not contact engine
valve cover. To modify clearance, move and/or rotate
air cleaner body in air cleaner strap. Verify that tabs
in strap mesh fully with slots in air cleaner body.
2
Figure 4
1. Air cleaner hose
2. Engine valve cover
3. Air cleaner strap
4. Air cleaner body
5. Muffler bracket
B. Position hose to allow 5/16” (7.9 mm) clearance
between air cleaner hose and muffler bracket.
Groundsmaster 4500--D/4700--D
Page 3 -- 5
Kubota Diesel Engine (Rev. A)
Exhaust System
1
14
3
11
2
4
5
16 to 22 ft--lb
(21 to 29 N--m)
7
9
7
16 to 22 ft--lb
(21 to 29 N--m)
12
11
8
8
RIGHT
10
6
6
FRONT
13
16 to 22 ft--lb
(21 to 29 N--m)
1.
2.
3.
4.
5.
Muffler
Muffler bracket/lift tab
Exhaust tailpipe
Flange head screw
Exhaust gasket
Kubota Diesel Engine (Rev. A)
6.
7.
8.
9.
10.
Figure 5
Lock nut
Cap screw
Flat washer
Spacer
Rubber hanger
Page 3 -- 6
11.
12.
13.
14.
Flange nut
Flange head screw
Engine mount
Muffler clamp
Groundsmaster 4500--D/4700--D
Removal
3
CAUTION
The muffler and exhaust pipe may be hot. To
avoid possible burns, allow the engine and exhaust system to cool before working on the muffler.
2
4
2. Remove muffler and/or muffler bracket from the engine as necessary using Figure 5 as a guide.
Installation
NOTE: Make sure muffler flange and exhaust manifold
sealing surfaces are free of debris or damage that may
prevent a tight seal.
1
Figure 6
1. Install new gasket if original gasket is damaged or
torn.
IMPORTANT: Failure to follow the suggested muffler fastener sequence may result in premature muffler 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 bracket.
C. Flange head screws that secure muffler flange to
engine.
D. Flange nuts that secure muffler bracket to engine.
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)
Kubota
Diesel Engine
1. Park machine on a level surface, lower cutting units,
stop engine, engage parking brake, and remove key
from the ignition switch.
Fuel System
1
16
6
3
7
4
RIGHT
2
8
5
FRONT
17
9
10
11
14
12
13
15
Figure 7
1.
2.
3.
4.
5.
6.
Suction fitting
Fuel line clamp
Fuel hose
Return fitting
Fuel hose
Fuel tank cap
7.
8.
9.
10.
11.
12.
Bushing
Fuel level gauge
Grommet
Fuel tank
Tank mount grommet (4 used)
Flat washer (4 used)
13.
14.
15.
16.
17.
Cap screw (4 used)
Hose clamp
Draincock
Hose clamp
Frame
Check Fuel Lines and Connections
DANGER
Because diesel fuel is highly flammable, use caution when storing or handling it. Do not smoke
while filling the fuel tank. Do not fill fuel tank
while engine is running, hot, or when machine is
in an enclosed area. Always fill fuel tank outside
and wipe up any spilled diesel fuel before starting the engine. Store fuel in a clean, safety--approved container and keep cap in place. Use diesel fuel for the engine only; not for any other
purpose.
Kubota Diesel Engine (Rev. A)
Check fuel lines and connections periodically as recommended in the Traction Unit Operator’s Manual. Check
lines for deterioration, damage, leaking, or loose connections. Replace hoses, clamps, and connections as
necessary.
Drain and Clean Fuel Tank
Drain and clean the fuel tank periodically as recommended in the Traction Unit Operator’s Manual. Also,
drain and clean the fuel tank if the fuel system becomes
contaminated or if the machine is to be stored for an extended period. To clean fuel tank, flush tank out with
clean diesel fuel. Make sure tank is free of contaminates
and debris.
Page 3 -- 8
Groundsmaster 4500--D/4700--D
Fuel Tank Removal
Fuel Tank Installation
1. Park machine on a level surface, lower cutting units,
stop engine, engage parking brake, and remove key
from the ignition switch.
1. Install fuel tank to frame using Figure 7 as a guide.
2. Disconnect fuel hoses from the suction and return fittings in top of tank.
3. Use draincock to empty fuel tank into a suitable container.
2. Connect fuel hoses to the suction and return fittings
in top of tank.
3. Make sure that draincock is closed.
4. Fill fuel tank (see Traction Unit Operator’s Manual).
Kubota
Diesel Engine
4. Remove fuel tank using Figure 7 as a guide.
Groundsmaster 4500--D/4700--D
Page 3 -- 9
Kubota Diesel Engine (Rev. A)
Radiator
4
RIGHT
FRONT
8
6
7
1
2
3
29
36
28
15
5
39
3
37
35
34
9
10
12
11
15
13
14
26 18
25
27
33
32
15
30
31
38
40
24
15
23 22
15
21
16
17
9
18
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
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. A)
10
19
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
18
Figure 8
Flange nut
Tank bracket
Flat washer
Flange 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
20
28.
29.
30.
31.
32.
33.
34.
35.
36.
37.
38.
39.
40.
O--ring
O--ring
Oil cooler mount plate
Oil cooler clamp
Flat washer
Cap screw
Wire form clamp
Cap screw
Washer
Oil cooler bracket (top)
Bulb seal
Foam seal
Foam seal
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 hood from the machine (see Traction Unit
Operator’s Manual).
4. Attach radiator fan shroud to the radiator with flange
screws and flat washers. Make sure that clearance between 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.
CAUTION
8. Make sure coolant drain is closed. Fill radiator with
coolant (see Traction Unit Operator’s Manual).
9. Install hood on the machine.
Kubota
Diesel Engine
Do not open radiator cap or drain coolant if the
radiator or engine is hot. Pressurized, hot coolant can escape and cause burns.
Ethylene--glycol antifreeze is poisonous. Dispose 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).
1
4. Disconnect hoses (upper and lower) from the radiator.
2
3
5. Remove air cleaner hose.
6. Disconnect reservoir hose from the vent tube.
7. Detach radiator fan shroud from the radiator by removing four flange head screws and flat washers. Position shroud away from radiator.
Figure 9
1. Oil filter housing
2. Coolant drain hose
3. Coolant draincock
8. Pivot rear screen and oil cooler away from radiator
(see Traction Unit Operator’s Manual).
1
9. Remove flange head screws and lock nuts securing
the radiator to the support frame. Pull radiator from the
machine.
2
10.Plug any radiator or hose openings to prevent contamination.
Installation
1. Remove any plugs used during the removal procedure.
2. Position radiator to the support frame. Secure radiator to the support frame with lock nuts and flange head
screws.
Figure 10
1. Coolant drain hose
2. Coolant draincock
3. Pivot and secure oil cooler and rear screen (see
Traction Unit Operator’s Manual).
Groundsmaster 4500--D/4700--D
Page 3 -- 11
Kubota Diesel Engine (Rev. A)
Engine
16 to 22 ft--lb
(21 to 29 N--m)
16
15 14
12
13
17
16 to 22 ft--lb
(21 to 29 N--m)
15
22
18
23
19
20
21
11
1
2
25
RIGHT
6
7
9
8
FRONT
24
10
3
4
5
4
1.
2.
3.
4.
5.
6.
7.
8.
9.
Engine
Flange head screw
Rubber engine support
Flange nut
Rebound washer
LH engine mount
Lock washer
Cap screw
Lock washer
Kubota Diesel Engine (Rev. A)
10.
11.
12.
13.
14.
15.
16.
17.
Figure 11
Bolt
LH engine mount
Muffler bracket/lift tab
Flange nut
Cap screw
Flat washer
Spacer
Rubber hanger (exhaust)
Page 3 -- 12
18.
19.
20.
21.
22.
23.
24.
25.
Lock nut
RH engine mount
Cap screw
RH engine mount
Fusible link
Engine wire harness
Cap screw
Lift tab
Groundsmaster 4500--D/4700--D
Engine Removal
1. Park machine on a level surface, lower cutting units,
stop engine, engage parking brake, and remove key
from the ignition switch. Raise hood.
2
3
2. Remove battery strap and cover. Disconnect negative battery cable first and then positive battery cable.
Remove battery from machine.
1
CAUTION
Do not open radiator cap or drain coolant if the
radiator or engine is hot. Pressurized, hot coolant can escape and cause burns.
Ethylene--glycol antifreeze is poisonous. Dispose of coolant properly, or store it in a properly
labeled container away from children and pets.
1. Alternator
2. Temperature sender
3. Drain coolant from radiator into a suitable container
(see Radiator Removal). Disconnect coolant hoses
from the radiator (Fig. 12).
Figure 12
3. Coolant hose
1
2
CAUTION
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).
Figure 13
1. Engine run solenoid
2. Solenoid harness
5. Remove air cleaner system from engine (see Air
Cleaner Removal).
1
6. Note location of cable ties used to secure wires. Disconnect the following electrical components:
3
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.
2
B. The engine run solenoid (Fig. 13).
C. The high temperature shutdown switch and glow
plug connection (Fig. 14).
Figure 14
1. Glow plug connection
2. High temp shutdown
3. Engine lift tab
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 pressure switch located on alternator side of engine (near
electric starter) (Fig. 16).
Groundsmaster 4500--D/4700--D
Page 3 -- 13
Kubota Diesel Engine (Rev. A)
Kubota
Diesel Engine
3
7. Disconnect fuel line from injection pump (Fig. 17).
Cap fuel line and injector pump fuel inlet to prevent contamination.
8. Disconnect throttle cable from the speed control lever by removing the washer and lock nut. Loosen jam
nut and take cable from mounting bracket (Fig. 17).
4
9. Remove coolant reservoir and bracket from fan
shroud.
5
10.Remove four flange head screws and flat washers
securing the fan shroud to the radiator.
1
2
11. Disconnect two wires from neutral switch on hydraulic traction 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).
3
Figure 15
1. Battery cable (+)
2. Battery cable (--)
3. Engine to frame ground
4. Engine wire harness
5. Fusible link harness
13.Make sure all cable ties securing the wiring harness,
fuel lines, or hydraulic hoses to the engine are removed.
3
14.Connect hoist or lift to the front (Fig. 11) and rear (Fig.
14) lift tabs on engine.
2
15.Remove flange head nuts, rebound washers, and
cap screws securing the engine mounts to the rubber
engine supports.
CAUTION
1
One person should operate lift or hoist while the
other person guides the engine out of the machine.
Figure 16
1. Electric starter
2. Fusible link connection
IMPORTANT: Make sure not to damage the engine,
fuel lines, hydraulic lines, electrical harness, or other parts while removing the engine.
3
3. Oil pressure switch
4
16.Slowly remove engine from the machine.
17.If necessary, remove engine mounts from the engine
using Figure 11 as a guide.
5
2
Engine Installation
1
1. If removed, install engine mounts to the engine using
Figure 11 as a guide.
2. Connect hoist or lift to the front (Fig. 11) and rear (Fig.
14) lift tabs on engine.
Figure 17
1. Engine run solenoid
2. Fuel line
3. Throttle cable
4. Cable jam nut
5. Cable washer/lock nut
3. Position fan shroud around the engine fan.
Kubota Diesel Engine (Rev. A)
Page 3 -- 14
Groundsmaster 4500--D/4700--D
13.Install air cleaner assembly to the engine (see Air
Cleaner Installation).
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 other 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. Connect throttle cable to the speed control lever with
washer and lock nut. Install cable to mounting bracket
(Fig. 17). Adjust throttle cable (see Traction Unit Operator’s Manual).
14.Install exhaust system to machine (see Muffler
Installation).
15.Connect coolant hoses to the radiator. Make sure radiator drain is shut. Fill radiator and reservoir with coolant.
16.Check position of wires, fuel lines, hydraulic hoses,
and cables for proper clearance with rotating, high temperature, and moving components.
17.Position battery to machine. Connect positive battery 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 Traction Unit Operator’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).
9. Connect fuel line to the injection pump (Fig. 17).
IMPORTANT: Support hydraulic pump assembly to
prevent it from 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 pressure switch located on alternator side of engine (near
electric starter) (Fig. 16).
Groundsmaster 4500--D/4700--D
Page 3 -- 15
Kubota Diesel Engine (Rev. A)
Kubota
Diesel Engine
CAUTION
Pump Adapter Plate
1
2
17 to 21 ft--lb
(23 to 28 N--m)
3
4
6
7
5
2
9
RIGHT
FRONT
10
11
8
17 to 21 ft--lb
(23 to 28 N--m)
10
35 to 43 ft--lb
(48 to 58 N--m)
12
Figure 18
1.
2.
3.
4.
Engine
Lock washer
Cap screw (4 used)
Pump adapter plate
Kubota Diesel Engine (Rev. A)
5.
6.
7.
8.
Plate pin (2 used)
Dowel (2 used)
Coupling spacer
Shoulder bolt (2 used)
Page 3 -- 16
9.
10.
11.
12.
Spring center coupling
Lock washer
Cap screw (6 used)
Cap screw (9 used)
Groundsmaster 4500--D/4700--D
Disassembly
1. Hydraulic pump assembly needs to be removed from
engine before coupling can be serviced (see Pump Assembly in Chapter 4 -- Hydraulic Systems).
4
3
2
2. Remove pump adapter plate, spring center coupling,
and coupling spacer from engine using Figure 18 as a
guide.
Assembly
2. Install four cap screws and lockwashers to coupling
spacer and flywheel. Torque cap screws from 17 to 21
ft--lb (23 to 28 N--m).
2
3
4
1
Figure 19
1. Coupling spacer
2. Shoulder bolt position
3. Cap screw position
4. Dowel position
3. Place 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 coupling spacer with cap screws and lockwashers. Torque
cap screws from 35 to 43 ft--lb (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.
Hydraulic
Pump Side
Engine Side
Spring Center
Coupling
Figure 20
Groundsmaster 4500--D/4700--D
Page 3 -- 17
Kubota Diesel Engine (Rev. A)
Kubota
Diesel Engine
1. Position coupling spacer to engine and align mounting holes. Use two 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).
This page is intentionally blank.
Kubota Diesel Engine (Rev. A)
Page 3 -- 18
Groundsmaster 4500--D/4700--D
Chapter 4
Hydraulic System
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 Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Lower Cutting Units . . . . . . . . . . . . . . . . . . . . . . . . . 10
Raise Cutting Units . . . . . . . . . . . . . . . . . . . . . . . . . 12
Mow Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 Kit . . . . . . . . . . . . . . . . . . . . . 21
Measuring Container . . . . . . . . . . . . . . . . . . . . . . . 21
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . 22
TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 for Removing and
Installing Hydraulic System Components . . . . 52
Check Hydraulic Lines and Hoses . . . . . . . . . . . . 52
Groundsmaster 4500--D/4700--D
Flush Hydraulic System . . . . . . . . . . . . . . . . . . . . . 53
Charge Hydraulic System . . . . . . . . . . . . . . . . . . . 54
Gear Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Gear Pump Service . . . . . . . . . . . . . . . . . . . . . . . . . 58
Piston (Traction) Pump . . . . . . . . . . . . . . . . . . . . . . 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 Control . . . . . . . . . . . . . . . 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--D) . . . . . . . . . . . . . . . . . . . . . . . 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/Front Wheel Motor Service . . . . . . . . . 86
Cutting Deck Motor . . . . . . . . . . . . . . . . . . . . . . . . . 89
Cutting Deck Motor Service . . . . . . . . . . . . . . . . . . 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--D) 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 #6 and #7 (GM 4700--D) . 110
Lift Cylinder Service . . . . . . . . . . . . . . . . . . . . . . . 112
Steering Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . 114
Steering Cylinder Service . . . . . . . . . . . . . . . . . . 116
Hydraulic Reservoir . . . . . . . . . . . . . . . . . . . . . . . 118
Hydraulic Oil Cooler . . . . . . . . . . . . . . . . . . . . . . . 119
Page 4 -- 1
Hydraulic System (Rev. A)
Hydraulic
System
Table of Contents
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 piston 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 l)
Hydraulic Oil
Hydraulic System (Rev. A)
See Traction Unit Operator’s Manual
Page 4 -- 2
Groundsmaster 4500--D/4700--D
General Information
Hydraulic Hoses
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.
WARNING
Before disconnecting or performing any work
on hydraulic system, relieve all pressure in
system. Stop engine; lower or support all attachment(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 surgically removed within a few hours by a doctor
familiar with this type of injury. Gangrene may
result from such an injury.
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.
Nut
Body
Sleeve
Seal
3. Lubricate the O--ring with a light 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.
Figure 1
5. Mark the nut and fitting body. Hold the body with a
wrench. Use another wrench to tighten the nut to the correct 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 or tubing)
6 (3/8 in.)
8 (1/2 in.)
10 (5/8 in.)
12 (3/4 in.)
16 (1 in.)
Final
Position
F.F.F.T.
Mark Nut
and Body
0.75 + 0.25
0.75 + 0.25
0.75 + 0.25
1.00 + 0.25
0.75 + 0.25
0.75 + 0.25
Extend Line
Finger Tight
Initial
Position
After Proper Tightening
Figure 2
Groundsmaster 4500--D/4700--D
Page 4 -- 3
Hydraulic System (Rev. A)
Hydraulic
System
Hydraulic hoses are subject to extreme conditions such
as pressure differentials during operation and exposure
to weather, sun, chemicals, very warm storage conditions, or mishandling during operation and maintenance. These conditions can cause damage or
premature deterioration. Some hoses are more susceptible to these conditions than others. Inspect the hoses
frequently for signs of deterioration or damage.
SAE Straight Thread O--Ring Port -- Non--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 fitting shows signs of leakage.
3. Lubricate the O--ring with a light coating of oil.
O--Ring
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
4 (1/4 in. nominal hose or tubing)
6 (3/8 in.)
8 (1/2 in.)
10 (5/8 in.)
12 (3/4 in.)
16 (1 in.)
F.F.F.T.
1.00 + 0.25
1.50 + 0.25
1.50 + 0.25
1.50 + 0.25
1.50 + 0.25
1.50 + 0.25
NOTE: Installation torque values for non--adjustable fittings 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.
Figure 3
Fitting Size
Installation Torque
4
9--10 ft--lb (12--13 N--m)
6
20--21 ft--lb (27--28 N--m)
8
35--37 ft--lb (47--50 N--m)
10
60--66 ft--lb (81--89 N--m)
12
81--87 ft--lb (110--117 N--m)
16
121--131 ft--lb (164--177 N--m)
Figure 4
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 fitting shows signs of leakage.
Lock Nut
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).
Back--up Washer
O--Ring
Figure 5
5. Install the fitting into the port and tighten finger tight
until the washer contacts the face of the port (Step 2).
6. To put the fitting 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).
Size
4 (1/4 in. nominal hose or tubing)
6 (3/8 in.)
8 (1/2 in.)
10 (5/8 in.)
12 (3/4 in.)
16 (1 in.)
Hydraulic System (Rev. A)
Step 1
Step 3
Step 2
Step 4
F.F.F.T.
1.00 + 0.25
1.50 + 0.25
1.50 + 0.25
1.50 + 0.25
1.50 + 0.25
1.50 + 0.25
Figure 6
Page 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 90o for towing.
1
See Traction Unit Operator’s Manual for additional towing procedures.
Figure 7
1. By--pass valve location
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 Unit Operator’s Manual for fluid level
checking procedure and oil recommendations.
1
Figure 8
1. Hydraulic reservoir cap
Groundsmaster 4500--D/4700--D
Page 4 -- 5
Hydraulic System (Rev. A)
Hydraulic
System
Check Hydraulic Fluid
Hydraulic System (Rev. A)
Page 4 -- 6
All solenoids are shown as
de--energized
Groundsmaster 4500--D
Hydraulic Schematic
2200
PSI
Hydraulic Schematics
Groundsmaster 4500--D/4700--D
Groundsmaster 4500--D/4700--D
Page 4 -- 7
Hydraulic System (Rev. A)
Hydraulic
System
All solenoids are shown as
de--energized
Groundsmaster 4700--D
Hydraulic Schematic
2200
PSI
Hydraulic System (Rev. A)
Page 4 -- 8
Working Pressure
Low Pressure (Charge)
Return or Suction
Flow
Groundsmaster 4500--D/4700--D
Traction Circuit (GM 4500--D Forward 4WD Shown)
2200
PSI
Hydraulic Flow Diagrams
Groundsmaster 4500--D/4700--D
Traction Circuit
Traction circuit pressure (forward and reverse) can be
measured at test ports located on the traction circuit hydraulic 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 replaced.
The gear pump section (P3) that supplies oil to the steering 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
Charge pressure is limited by a relief valve located in the
filtration and charge control manifold. Charge pressure
can be measured at the 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 (transport) operation is controlled by a solenoid valve (SV) located 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
and traction 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 transfer when traction circuit pressure increase is sensed by
directional valve (PD3) located in the power down and
traction assist control manifold.
Page 4 -- 9
Rev. D
Hydraulic System (Rev. A)
Hydraulic
System
The traction circuit piston pump is a variable displacement pump that is directly coupled to the engine flywheel. Pushing the top of the traction pedal engages a
hydraulic servo valve which controls the variable displacement 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 relief 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).
Hydraulic System (Rev. A)
Page 4 -- 10
Groundsmaster 4500--D/4700--D
Working Pressure
Low Pressure (Charge)
Return or Suction
Flow
Groundsmaster 4500--D/GM--4700--D
Lower Cutting Units (GM 4500--D Shown)
2200
PSI
Lower Cutting Units
On the Groundsmaster 4500--D, a single lift lever is used
to lift and lower the five cutting decks. The Groundsmaster 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.
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 pushed to allow valve shift in the
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 of the lift cylinder. Oil flow to the piston
end of the lift cylinder causes the cylinder shaft to extend, 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 position.
An adjustable counterbalance valve (RV1) maintains
back pressure on the deck 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.
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 control valve is pushed to 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 circuit. 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.
#4 Deck
#1 Deck
#3
Deck
#2
Deck
#6 Deck
(GM4700)
#5 Deck
#7 Deck
(GM4700)
CUTTING DECK LOCATIONS
Figure 9
2200
PSI
GM 4700--D
CHARGE CIRCUIT
FROM TRACTION CIRCUIT
FROM GEAR PUMP (P3)
LOWER DECK #6 SHOWN
Figure 10
Groundsmaster 4500--D/4700--D
Page 4 -- 11
Hydraulic System (Rev. A)
Hydraulic
System
A three section gear pump is coupled to the piston (traction) 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. Hydraulic 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).
Hydraulic System (Rev. A)
Page 4 -- 12
Groundsmaster 4500--D/4700--D
Working Pressure
Low Pressure (Charge)
Return or Suction
Flow
Groundsmaster 4500--D/4700--D
Raise Cutting Units (GM 4500--D Shown)
2200
PSI
Raise Cutting Units
On the Groundsmaster 4500--D, a single lift lever is used
to lift and lower the five cutting decks. The Groundsmaster 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.
To raise a side cutting unit on the Groundsmaster
4700--D (deck #6 or #7), the appropriate outer lift lever
on the lift/lower control valve is pulled to allow valve shift
in the lift/lower control. This valve change allows hydraulic pressure to the rod end of the cylinder and
causes the lift cylinder shaft to retract, raising the cutting
unit. Oil from the piston end of the cylinder returns to the
traction charge circuit. When the 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.
Pressure to the lift/lower control valve can be monitored
at a port on the end of the gear pump.
#4 Deck
#1 Deck
Hydraulic
System
A three section gear pump is coupled to the piston (traction) 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 is delivered to the two circuits 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 manifold (RV7).
#5 Deck
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 hydraulic 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 cylinders are held in position.
#2
Deck
#6 Deck
(GM4700)
#3
Deck
#7 Deck
(GM4700)
CUTTING DECK LOCATIONS
Figure 11
2200
PSI
RAISE DECK #6 SHOWN
CHARGE CIRCUIT
FROM TRACTION CIRCUIT
FROM GEAR PUMP (P3)
GM 4700--D
Figure 12
Groundsmaster 4500--D/4700--D
Page 4 -- 13
Hydraulic System (Rev. A)
Hydraulic System (Rev. A)
Page 4 -- 14
Groundsmaster 4500--D/4700--D
Working Pressure
Low Pressure (Charge)
Return or Suction
Flow
Groundsmaster 4500--D/4700--D
Mow Circuit (GM 4500--D Shown)
2200
PSI
Mow Circuit
Return oil from the deck motors is directed to the oil cooler and oil filter. Deck motor case drain leakage returns
to the hydraulic reservoir.
Maximum mow circuit pressure is limited 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.
On the Groundsmaster 4700--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), a solenoid 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 lowered, the solenoid valves (SV2 and PRV1/PRV2) energize, 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)
#4 Deck
#6 Deck
(GM4700)
#5 Deck
#2
Deck
#3
Deck
#7 Deck
(GM4700)
CUTTING DECK LOCATIONS
Figure 13
FROM GEAR PUMP (P2)
TO HYDRAULIC RESERVOIR
#1 Deck
Hydraulic
System
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 solenoid 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 relief cartridges (RV8) control the stopping rate of the
blade when the solenoid valves are de--energized as the
PTO switch is turned OFF.
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 (RV9).
TO OIL COOLER
Hydraulic flow for the mow circuit is supplied by two sections 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).
GM 4700--D
ALL DECKS LOWERED
PTO SWITCH ON
Figure 14
Groundsmaster 4500--D/4700--D
Page 4 -- 15
Hydraulic System (Rev. A)
Cutting Deck Blade Braking
When the operator turns the cutting decks OFF, proportional 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 reduced 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 pressure 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 allows the blades to stop in a controlled manner (Fig. 17).
FROM
DECK
MOTORS
TO OIL
COOLER
ORIFICE
TO DECK
MOTORS
FROM
GEAR
PUMP
Figure 15
FROM
DECK
MOTORS
TO OIL
COOLER
ORIFICE
TO DECK
MOTORS
FROM
GEAR
PUMP
Figure 16
FROM
DECK
MOTORS
TO OIL
COOLER
ORIFICE
TO DECK
MOTORS
FROM
GEAR
PUMP
Figure 17
Hydraulic System (Rev. A)
Page 4 -- 16
Groundsmaster 4500--D/4700--D
Hydraulic
System
This page is intentionally blank.
Groundsmaster 4500--D/4700--D
Page 4 -- 17
Hydraulic System (Rev. A)
Hydraulic System (Rev. A)
Page 4 -- 18
Groundsmaster 4500--D/4700--D
Working Pressure
Low Pressure (Charge)
Return or Suction
Flow
Groundsmaster 4500--D/4700--D
Steering Circuit (GM 4500--D Right Turn Shown)
2200
PSI
Steering Circuit
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.
A three section gear pump is coupled to the piston (traction) pump. The gear pump section (P3) supplies hydraulic flow to the steering control valve and the lift/lower
control valve. Pump hydraulic flow is delivered to the two
circuits through a proportional flow divider. The gear
pump takes its suction from the hydraulic reservoir.
Steering circuit pressure is limited by a relief valve located in the steering control.
The steering wheel and steering control valve return to
the neutral position when turning is completed.
Pressure to the steering control valve can be monitored
at a port on the end of the gear pump.
When a right turn is made with the engine running, the
turning of the steering wheel positions the spool valve so
that flow goes through the bottom of the spool. Flow entering 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 circuit. 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 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.
With the steering wheel in the neutral position (rear
wheels positioned straight ahead) and the engine running, 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 remainder of the flow is drawn through the rotary meter
(V1) and out the L port. Pressure contracts the piston for
The steering wheel and steering control valve return to
the neutral position when turning is completed.
STEERING CYLINDER
STEERING CYLINDER
STEERING CYLINDER
NO PISTON MOVEMENT
PISTON MOVEMENT
PISTON MOVEMENT
L
R
L
R
1180
PSI
T
PB
P
L
R
1180
PSI
STEERING
CONTROL
NEUTRAL POSITION
T
PB
P
1180
PSI
STEERING
CONTROL
LEFT TURN
T
PB
P
STEERING
CONTROL
RIGHT TURN
Figure 18
Groundsmaster 4500--D/4700--D
Page 4 -- 19
Hydraulic System (Rev. A)
Hydraulic
System
Right Turn
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.
Figure 19
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 circuit 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 provide accurate reading at low pressure: 0 to 1000 PSI.
4. HIGH PRESSURE GAUGE: High range gauge
which accommodates pressures beyond the capacity 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
hydraulic tester connects to the hydraulic system circuit.
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
Rev. D
Groundsmaster 4500--D/4700--D
Hydraulic Test Fitting Kit -- TOR4079
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.
Figure 21
Measuring Container -- TOR4077
Hydraulic
System
Use this container for doing hydraulic motor efficiency
testing (motors with case drain lines only). Measure efficiency 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.
The table in Figure 23 provides gallons per minute
(GPM) conversion for measured milliliter or ounce motor
case drain leakage.
Figure 22
Figure 23
Groundsmaster 4500--D/4700--D
Page 4 -- 21
Hydraulic System (Rev. A)
Troubleshooting
The charts that follow contain information to assist in
troubleshooting. There may possibly be more than one
cause for a machine malfunction.
Refer to the Testing section of this Chapter for precautions and specific test procedures.
Problem
Possible Cause
Hydraulic system operates hot.
Engine RPM is too low.
Hydraulic reservoir oil level is low.
Hydraulic oil is contaminated or the wrong type.
Brakes are engaged or sticking.
Piston pump by--pass valve is open or damaged.
Cooling system is not operating properly.
Charge pressure is low.
Traction circuit pressure is incorrect.
Pump(s) or motor(s) are damaged.
Hydraulic oil in reservoir foams.
Hydraulic reservoir oil level is low.
Wrong type of oil is in the hydraulic system.
Air is leaking in suction line.
Machine operates in one direction
only.
Traction control linkage is faulty.
System charge check valve and/or system relief valve is defective.
Pilot direction valve in 4WD manifold is damaged or sticking.
Traction pedal is sluggish.
Traction control linkage is stuck or binding.
Piston pump servo control valve is damaged.
Charge pressure is low.
Traction power is lost or unit will not
operate in either direction.
Brakes are engaged or sticking.
Traction control linkage is damaged or disconnected.
Hydraulic reservoir oil level is low.
Piston pump by--pass valve is open or damaged.
Charge pressure is low.
System charge check valve and/or system relief valve is defective.
Traction circuit pressure is low.
Front wheel motor couplers are damaged.
Hydraulic System (Rev. A)
Page 4 -- 22
Rev. D
Groundsmaster 4500--D/4700--D
Problem
Possible Causes
Machine travels too far before stopping when the traction pedal is released.
Traction linkage is out of adjustment.
Piston pump servo control valve is damaged.
Traction pedal does not return to neutral.
Four wheel drive will not engage.
Electrical problem exists (see Chapter 5 -- Electrical System).
Solenoid valve in 4WD hydraulic manifold is faulty.
Cartridge valve in 4WD manifold is damaged or sticking.
Rear axle motor is damaged.
Four wheel drive will not disengage.
Electrical problem exists (see Chapter 5 -- Electrical System).
Solenoid valve in 4WD/2WD control manifold is faulty.
Cartridge valve in 4WD/2WD control manifold is damaged or sticking.
Electrical problem exists (see Chapter 5 -- Electrical System).
Gear pump sections P1 and P2 are damaged.
Gear pump coupler is damaged (steering and lift/lower also affected).
One cutting deck will not operate.
System pressure to the affected deck is low.
Spline on affected deck motor (or spindle) is damaged.
Deck motor relief valve is stuck or damaged.
Deck motor is damaged. Note: If appropriate, transfer a suspected
damaged motor to another cutting deck. If problem follows the motor,
motor needs repair or replacement.
Cartridge valve in deck manifold (SV2) is damaged or sticking (GM
4700--D decks #6 or #7).
Several cutting decks will not operate.
Electrical problem exists (see Chapter 5 -- Electrical System).
Control manifold solenoid for affected decks is faulty.
Proportional relief valve (PRV1 or PRV2) in deck control manifold is
stuck or damaged.
Gear pump section (P1 or P2) is damaged or inefficient.
All cutting decks operate slowly.
Engine RPM is low.
Deck motor is damaged.
Gear pump section (P1 or P2) is damaged or inefficient.
Cutting deck stops under load.
Relief valve in deck manifold is by--passing.
Deck motor relief valve is stuck or damaged.
Deck motor has internal leakage (by--passing oil).
Cutting deck gear pump section (P1 or P2) is inefficient.
Groundsmaster 4500--D/4700--D
Page 4 -- 23
Rev. D
Hydraulic System (Rev. A)
Hydraulic
System
No cutting decks will operate.
Problem
Possible Causes
Cutting units will not raise.
Engine RPM is too low.
Hydraulic oil level in reservoir is low.
Lift cylinder(s) is (are) damaged.
Lift arm pivots are binding.
Relief valve for lift/lower circuit is stuck.
Pilot valve in lift/lower manifold is damaged or sticking.
Proportional valve in gear pump is faulty.
Gear pump section for lift/lower circuit (P3) is inefficient.
Cutting units raise, but will not stay
up.
Lift circuit lines or fittings are leaking.
Detents in lift/lower control valve are worn.
Lift cylinder is damaged.
Cutting units will not lower.
Lift arm pivots are binding.
Lift cylinder is damaged.
Counterbalance pressure is excessive.
Lift/lower control valve is worn or damaged.
Pilot valve in lift/lower manifold is damaged or sticking.
Hydraulic System (Rev. A)
Page 4 -- 24
Groundsmaster 4500--D/4700--D
Testing
Before Performing Hydraulic Tests
IMPORTANT: All obvious areas such as oil supply,
filter, binding linkages, loose fasteners, or improper
adjustments must be checked before assuming that
a hydraulic component is the source of the problem.
Precautions for Hydraulic Testing
CAUTION
Failure to use gauges with recommended pressure (PSI) rating as listed in test procedures
could result in damage to the gauge and possible
personal injury from leaking hot oil.
CAUTION
All testing should be performed by two (2)
people. One person should be in the seat to operate the machine, and the other should read and
record test results.
CAUTION
Operate all hydraulic controls to relieve system
pressure and avoid injury from pressurized hydraulic oil. Controls must be operated with the
ignition switch in OFF. Remove key from the ignition switch.
WARNING
Before disconnecting or performing any work
on the hydraulic system, all pressure in the
system must be relieved and all rotating machine 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 hydraulic 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 components.
3. The engine must be in good operating condition. Use
a phototac to determine engine speed when performing
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 connected 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 connecting test equipment, make sure tank is full.
9. Check control linkages for improper adjustment,
binding, or broken parts.
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. Gangrene may result from such an injury.
Groundsmaster 4500--D/4700--D
WARNING
10.All hydraulic tests should be made with the hydraulic
oil at normal operating temperature.
11. Before returning machine to use, make sure that hydraulic reservoir has correct fluid level.
Page 4 -- 25
Hydraulic System (Rev. A)
Hydraulic
System
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).
TEST NO. 1: Traction Circuit Charge Pressure (Using Pressure Gauge)
FROM STEERING CONTROL
AND LIFT SYSTEM
CHARGE
CIRCUIT
TO TRACTION CONTROL
MANIFOLD
TO PTO (MOW) CIRCUIT
TO LIFT/LOWER CIRCUIT
TO STEERING CIRCUIT
FROM PTO (MOW) CIRCUIT
FROM STEERING CONTROL
Working Pressure
Low Pressure
FROM PTO (MOW) CIRCUIT
Return or Suction
Flow
Hydraulic System (Rev. A)
Page 4 -- 26
Groundsmaster 4500--D/4700--D
Procedure for Traction Circuit Charge Pressure Test
1. Make sure hydraulic oil is at normal operating temperature by operating the machine for approximately 10
minutes. Make sure the hydraulic tank is full.
1
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.
CAUTION
2
Figure 24
1. Right side frame rail
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).
2. Filter manifold
1
2
4. Start the engine and put throttle at full engine speed
(2800 + 50 RPM) with no load on the hydraulic system.
GAUGE READING TO BE 230 to 300 PSI.
5. If 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
/system relief valve in hydrostat. If necessary, check for
internal damage or worn parts in gear pump.
Figure 25
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 traction 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 (traction) 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 is not able to keep up with internal leakage
in traction circuit components.
Groundsmaster 4500--D/4700--D
Page 4 -- 27
Rev. D
Hydraulic System (Rev. A)
Hydraulic
System
Prevent personal injury and/or damage to equipment. Read all WARNINGS, CAUTIONS, and Precautions for Hydraulic Testing at the beginning
of this section.
TEST NO. 2: Traction Circuit Relief Pressure (Using Pressure Gauge)
CHARGE
CIRCUIT
NOTE: FORWARD DIRECTION TEST SHOWN
TO TRACTION CONTROL
MANIFOLD
TO LIFT/LOWER CIRCUIT
TO PTO (MOW) CIRCUIT
TO STEERING CIRCUIT
Working Pressure
FROM PTO (MOW) CIRCUIT
Low Pressure
FROM STEERING CONTROL
FROM PTO (MOW) CIRCUIT
Hydraulic System (Rev. A)
Page 4 -- 28
Return or Suction
Flow
Groundsmaster 4500--D/4700--D
Procedure for Traction Circuit Relief Pressure Test
1
1. Make sure hydraulic oil is at normal operating temperature by operating the machine for approximately 10
minutes. Make sure the hydraulic tank is full.
CAUTION
Move machine to an open area, away from people
and obstructions.
2
Figure 26
2. Drive machine to an open area, lower cutting units,
turn the engine off and engage the parking brake.
1. Forward traction port (faces forward)
2. Reverse traction port (faces rearward)
Prevent personal injury and/or damage to equipment. Read all WARNINGS, CAUTIONS, and Precautions for Hydraulic Testing at the beginning
of this section.
Hydraulic
System
CAUTION
2
3. Connect a 10,000 psi gauge to traction 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.
5. Sit on seat, apply brakes fully, and slowly depress the
traction pedal in the appropriate direction. While pushing traction pedal, look at pressure reading on gauge:
3
1
4. Start the engine and move throttle to full speed (2800
+ 50 RPM). Release parking brake.
Figure 27
1. Forward relief valve
2. Reverse relief valve
3. Traction pump
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 suspected 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.
Groundsmaster 4500--D/4700--D
Page 4 -- 29
Hydraulic System (Rev. A)
TO STEERING CIRCUIT
TO LIFT/LOWER CIRCUIT
FROM LIFT/LOWER CIRCUIT
TEST NO. 3: Cutting Deck Circuit Pressure (Using Pressure Gauge)
GM 4500--D
Working Pressure
Low Pressure
Return or Suction
Hydraulic System (Rev. A)
Page 4 -- 30
TO STEERING CIRCUIT
TO LIFT/LOWER CIRCUIT
FROM LIFT/LOWER CIRCUIT
Flow
GM 4700--D
Groundsmaster 4500--D/4700--D
Procedure for Cutting Deck Circuit Pressure Test
1
1. Make sure hydraulic oil is at normal operating temperature by operating the machine for approximately 10
minutes. Make sure the hydraulic tank is full.
2
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.
CAUTION
Prevent personal injury and/or damage to equipment. Read all WARNINGS, CAUTIONS, and Precautions for Hydraulic Testing at the beginning
of this section.
GM 4500--D DECK CONTROL MANIFOLDS
Figure 28
1. Test port (decks 2, 3, & 5)
2. Test port (decks 1 & 4)
Hydraulic
System
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).
CAUTION
1
2
Keep away from decks during test to prevent personal 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.
GM 4700--D DECK CONTROL MANIFOLDS
Figure 29
1. Test port (decks 2,3,5,7)
6. Cutting deck circuit pressure should be from 1000 to
3500 PSI and will vary depending on mowing conditions.
#4 Deck
2. Test port (decks 1,4,6)
#1 Deck
#5 Deck
7. Disengage cutting units. Shut off engine.
8. Disconnect test gauge with hose from manifold test
port.
#6 Deck
(GM4700)
#2
Deck
#3
Deck
#7 Deck
(GM4700)
CUTTING DECK LOCATIONS
Figure 30
Groundsmaster 4500--D/4700--D
Page 4 -- 31
Hydraulic System (Rev. A)
TO STEERING CIRCUIT
TO LIFT/LOWER CIRCUIT
TEST NO. 4: Cutting Deck Gear Pump Flow (Using Tester with Pressure Gauges and
Flow Meter)
NOTE: PUMP SECTION P1 TEST SHOWN
FROM DECK MOTORS
FROM DECK CONTROL
MANIFOLDS
FROM LIFT/LOWER CIRCUIT
Working Pressure
Low Pressure
Return or Suction
Flow
Hydraulic System (Rev. A)
Page 4 -- 32
Groundsmaster 4500--D/4700--D
Procedure for Cutting Deck Gear Pump Flow Test
8. Flow indication should be approximately 11.5 GPM.
NOTE: Over a period of time, the gears and wear plates
in the pump can wear. A worn pump will by pass oil and
make the pump less efficient. Eventually, enough oil loss
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.
9. Shut off engine.
1. Make sure hydraulic oil is at normal operating temperature by operating the machine for approximately 10
minutes. Make sure the hydraulic tank is full.
10.Disconnect flow tester from hydraulic hose and fitting. 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.
4
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.
3
2
Hydraulic
System
CAUTION
Prevent personal injury and/or damage to equipment. Read all WARNINGS, CAUTIONS, and Precautions 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 90o hydraulic fitting in gear pump (Fig. 31).
4. Install hydraulic flow meter in series with the disconnected hose and fitting in gear pump section.
1
Figure 31
1. Gear pump
2. 90o hydraulic fitting
3. Pump section P1 hose
4. Pump section P2 hose
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 before 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
Hydraulic System (Rev. A)
TO STEERING CIRCUIT
TO LIFT/LOWER CIRCUIT
TEST NO. 5: Cutting Deck Manifold Relief Pressure (Using Tester with Pressure Gauges
and Flow Meter)
GM 4500--D
FROM LIFT/LOWER CIRCUIT
TESTER
LOCATION FOR
PUMP SECTION P1
TESTER
LOCATION FOR
PUMP SECTION P2
Working Pressure
Low Pressure
Return or Suction
TO STEERING CIRCUIT
TO LIFT/LOWER CIRCUIT
Flow
GM 4700--D
FROM LIFT/LOWER CIRCUIT
TESTER
LOCATION FOR
PUMP SECTION P1
TESTER
LOCATION FOR
PUMP SECTION P2
Hydraulic System (Rev. A)
Page 4 -- 34
Groundsmaster 4500--D/4700--D
Procedure for Cutting Deck Manifold Relief
Pressure Test
Rotation Direction
1. Make sure hydraulic oil is at normal operating temperature 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.
1
2
CAUTION
3
Prevent personal injury and/or damage to equipment. Read all WARNINGS, CAUTIONS, and Precautions for Hydraulic Testing at the beginning
of this section.
1. Pressure IN
2. Pressure OUT
Figure 32
3. Case drain
1
2
Hydraulic
System
3. Determine deck manifold relief to be tested. Disconnect the inlet hydraulic hose to the appropriate deck motor (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 disconnected hose and deck motor inlet.
GM 4500--D DECK CONTROL MANIFOLDS
5. Make sure the flow control valve on the tester is fully
open.
1. Deck 2, 3, & 5 relief valve (pump section P2)
2. Deck 1 & 4 relief valve (pump section P1)
Figure 33
1
CAUTION
2
Keep away from decks during test to prevent personal 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
3400 to 3750 PSI.
GM 4700--D DECK CONTROL MANIFOLDS
Figure 34
1. Deck 2, 3, 5, & 7 relief valve (pump section P2)
2. Deck 1, 4, & 6 relief valve (pump section P1)
9. Disengage cutting units. Shut off engine. If specification 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.
Groundsmaster 4500--D/4700--D
Page 4 -- 35
Hydraulic System (Rev. A)
TEST NO. 6: Cutting Deck Motor Case Drain Leakage (Using Tester with Pressure
Gauges and Flow Meter)
TO LIFT/LOWER CIRCUIT
FROM STEERING CONTROL VALVE
TO STEERING CIRCUIT
GM 4500--D DECK #2 TEST SHOWN
TESTER
LOCATION FOR
DECK 2
MEASURING
CONTAINER
Working Pressure
Low Pressure
Return or Suction
Flow
Hydraulic System (Rev. A)
Page 4 -- 36
Groundsmaster 4500--D/4700--D
Procedure for Cutting Deck Motor Case Drain
Leakage Test
5. Sit on seat and start the engine. Move throttle to full
speed (2800 + 50 RPM). Move PTO switch to ON.
NOTE: Over a period of time, a deck motor can wear internally. 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 hydraulic system, and affect quality of cut.
6. While watching pressure gauge, slowly close flow
control valve on tester until a pressure of 1200 PSI is obtained.
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 seconds).
1. Make sure hydraulic oil is at normal operating temperature by operating the machine for approximately 10
minutes. Make sure the hydraulic tank is full.
8. Disconnect tester from motor and hose. Reconnect
hose to the deck motor. Remove cap from bulkhead fitting and reconnect case drain hose.
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.
9. If flow is more than 0.7 GPM, the motor is worn or
damaged and should be repaired or replaced.
CAUTION
2
Prevent personal injury and/or damage to equipment. Read all WARNINGS, CAUTIONS, and Precautions 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).
1
Figure 35
1. Pressure return hose
2. Case drain hose
4. Disconnect the motor case drain hose (small diameter hose) where it connects to bulkhead fitting at the
frame rail (not at the motor). Put a steel cap on the bulkhead fitting; leave the case drain hose open (Fig. 36).
CAUTION
Cutting unit blades will rotate when lowered with
PTO switch in ON position. Keep away from cutting 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
Figure 36
Hydraulic System (Rev. A)
Hydraulic
System
NOTE: One method to find a failing or malfunctioning
deck motor is to have another person observe the machine while mowing in dense turf. A bad motor will run
slower, produce fewer clippings, and may cause a different appearance on the turf.
NOTE: Use a graduated container, special tool
TOR4077, to measure case drain leakage (Fig. 36).
TEST NO. 7: Steering Circuit Relief Pressure (Using Pressure Gauge)
STEERING CYLINDER
NOTE: LEFT TURN SHOWN
R
L
1180
PSI
STEERING CONTROL T
VALVE
PB
P
TO LIFT/LOWER CIRCUIT
CHARGE CIRCUIT
TO
RESERVOIR
TO PTO (MOW) CIRCUIT
G
50 / 50
PROPORTIONAL
FLOW DIVIDER
P3
P2
P1
P4
TRACTION
CIRCUIT
FROM
RESERVOIR
FROM OIL
FILTER
Working Pressure
Low Pressure
Return or Suction
Flow
Hydraulic System (Rev. A)
Page 4 -- 38
Groundsmaster 4500--D/4700--D
Procedure for Steering Circuit Relief Pressure Test
1. Make sure hydraulic oil is at normal operating temperature by operating the machine for approximately 10
minutes. Make sure the hydraulic tank is full.
2
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.
1
CAUTION
Prevent personal injury and/or damage to equipment. Read all WARNINGS, CAUTIONS, and Precautions for Hydraulic Testing at the beginning
of this section.
Figure 37
1. Steering circuit test port
2. Gear pump
Hydraulic
System
3. Raise seat to gain access to steering circuit test port
located on the front end of the gear pump (Fig. 37). Connect 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.
2
5. Turn steering all the way in one direction and momentarily hold the steering wheel against resistance.
3
1
GAUGE READING TO BE 1150 TO 1500 PSI.
Figure 38
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 if lift/lower problems also
exist, gear pump should be suspected of wear and inefficiency. If steering wheel continues to turn at end of cylinder travel (with lower than normal effort), steering
cylinder or steering control valve should be suspected
of wear or damage.
Groundsmaster 4500--D/4700--D
1. Steering control valve
2. Steering column
Page 4 -- 39
3. Steering relief valve
Hydraulic System (Rev. A)
TEST NO. 8: Lift/Lower Circuit Relief Pressure (Using Pressure Gauge)
FROM STEERING CIRCUIT
2200
PSI
GM 4500--D SHOWN
FROM STEERING CIRCUIT
TO PTO (MOW)
CIRCUIT
FROM PTO (MOW)
CIRCUIT
TO STEERING CIRCUIT
FROM PTO (MOW) CIRCUIT
Working Pressure
Low Pressure
Return or Suction
Flow
Hydraulic System (Rev. A)
Page 4 -- 40
Groundsmaster 4500--D/4700--D
Procedure for Lift/Lower Circuit Relief Pressure
Test
1. Make sure hydraulic oil is at normal operating temperature 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.
2
1
CAUTION
Prevent personal injury and/or damage to equipment. Read all WARNINGS, CAUTIONS, and Precautions for Hydraulic Testing at the beginning
of this section.
1. Lift circuit test port
Figure 39
2. Gear pump
2
1
Hydraulic
System
3. Raise seat to gain access to lift circuit test port located on the front end of the gear pump (Fig. 39). Connect a 5000 PSI gauge onto lift circuit test port. Route
gauge hose to allow seat to be safely lowered.
4. Sit on the 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.
3
3
Figure 40
1. GM 4500--D control manifold
2. GM 4700--D control manifold
3. Lift/lower relief valve
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 pressure).
1
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
(Fig. 41). Adjust the relief valve by rotating adjustment socket clockwise (increasing relief pressure).
2
C. If pressure is still too low after relief valve adjustment, pump or lift cylinder(s) should be suspected of
wear, damage or inefficiency.
Figure 41
1.
Groundsmaster 4500--D/4700--D
Page 4 -- 41
Relief valve cap
2.
Adjustment socket
Hydraulic System (Rev. A)
TEST NO. 9: Steering and 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 PTO (MOW) CIRCUIT
TO PTO (MOW) CIRCUIT
TO LIFT/LOWER CIRCUIT
FORWARD
50 / 50
PROPORTIONAL
FLOW DIVIDER
P3
P2
P1
TRACTION
CIRCUIT
P4
TOW
VALVE
FROM
RESERVOIR
FROM OIL
FILTER
CHARGE
CIRCUIT
Working Pressure
Low Pressure
Return or Suction
Flow
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 section is equally divided by 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 temperature by operating the machine for approximately 10
minutes. Make sure the hydraulic tank is full.
7. If the 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 restricted, remove gear pump and repair or replace as
necessary.
If the total of the two flows is 6.4 GPM but individual circuit 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.
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.
2
CAUTION
3
Figure 42
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.
1. Gear pump
2. Lift circuit 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.
1
2
3
IMPORTANT: The pump is a positive displacement
type. If pump flow is completely restricted or
stopped, damage to the pump, tester, or other components could occur.
4
4. Start the 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 RPM).
3. Steering circuit hose
Figure 43
1. Gear pump backplate
2. Lift circuit
3. Steering circuit
4. Proportional valve
FLOW GAUGE READING TO BE: Flow approximately 3.2 GPM at 1000 PSI.
6. Stop engine. Remove tester and reinstall hydraulic
hose to gear pump. Complete steps 3 through 6 for other
circuit hose.
Groundsmaster 4500--D/4700--D
Page 4 -- 43
Hydraulic System (Rev. A)
Hydraulic
System
1
Prevent personal injury and/or damage to equipment. Read all WARNINGS, CAUTIONS, and Precautions for Hydraulic Testing at the beginning
of this section.
TEST NO. 10: Counterbalance (RV1) Pressure (Using Pressure Gauge)
TO STEERING CIRCUIT
FROM PTO (MOW) CIRCUIT
FROM PTO (MOW) CIRCUIT
FROM STEERING CIRCUIT
FROM STEERING CIRCUIT
2200
PSI
GM 4500--D SHOWN
Working Pressure
Low Pressure
Return or Suction
Flow
Hydraulic System (Rev. A)
Page 4 -- 44
Groundsmaster 4500--D/4700--D
Procedure for Counterbalance (RV1) Pressure Test
1. Make sure hydraulic oil is at normal operating temperature by operating the machine for approximately 10
minutes. Make sure the hydraulic tank is full.
1
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.
2
CAUTION
Prevent personal injury and/or damage to equipment. Read all WARNINGS, CAUTIONS, and Precautions for Hydraulic Testing at the beginning
of this section.
Figure 44
3. Connect a 1000 PSI gauge to counterbalance test
port on power down and traction assist manifold under
operator’s seat (Fig. 44).
3
3
4. Start the engine and put throttle at full engine speed
(2800 + 50 RPM) with no load on the system. Do not engage the cutting units.
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 performed as follows:
NOTE: Do not remove the valve from the hydraulic
manifold for adjustment.
2
1
Figure 45
1. GM 4500--D traction assist manifold
2. GM 4700--D traction assist manifold
3. Counterbalance valve (RV1)
A. To increase pressure setting, turn the adjusting
dial on the counterbalance valve in a clockwise direction. 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 counterclockwise direction. A 1/8 turn on the dial will make a measurable 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)
Hydraulic
System
1. Traction assist manifold (GM 4500--D shown)
2. Counterbalance test port
TEST NO. 11: Rear Traction Circuit (RV5) Relief Pressure (Using Pressure Gauge)
CHARGE
CIRCUIT
TO TRACTION CONTROL
MANIFOLD
TO LIFT/LOWER CIRCUIT
TO PTO (MOW) CIRCUIT
TO STEERING CIRCUIT
Working Pressure
FROM PTO (MOW) CIRCUIT
Low Pressure
FROM STEERING CONTROL
FROM PTO (MOW) CIRCUIT
Hydraulic System (Rev. A)
Page 4 -- 46
Return or Suction
Flow
Groundsmaster 4500--D/4700--D
Procedure for Rear Traction Circuit (RV5) Relief
Pressure Test
1. Make sure hydraulic oil is at normal operating temperature by operating the machine for approximately 10
minutes. Make sure the hydraulic tank is full.
1
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.
2
CAUTION
Figure 46
Prevent personal injury and/or damage to equipment. Read all WARNINGS, CAUTIONS, and Precautions for Hydraulic Testing at the beginning
of this section.
1. 2WD/4WD control manifold (GM 4500--D shown)
2. Relief valve test port
2
Hydraulic
System
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, decrease pressure on the traction pedal, and monitor the
pressure gauge. Pressure should increase until the relief valve lifts.
1
Figure 47
1. Manifold: lower side
GAUGE READING TO BE 520 to 570 PSI.
2. Relief valve (RV5)
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 pressure (Fig. 48).
1
B. To decrease pressure setting, remove cap on relief 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).
2
C. Recheck relief pressure and readjust as needed.
Figure 48
1.
Groundsmaster 4500--D/4700--D
Page 4 -- 47
Relief valve cap
2.
Adjustment socket
Hydraulic System (Rev. A)
TEST NO. 12: Traction Circuit Reducing Valve (PR1) Pressure (Using Pressure Gauge)
CHARGE
CIRCUIT
TO TRACTION CONTROL
MANIFOLD
TO LIFT/LOWER CIRCUIT
TO PTO (MOW) CIRCUIT
TO STEERING CIRCUIT
Working Pressure
FROM PTO (MOW) CIRCUIT
Low Pressure
FROM STEERING CONTROL
FROM PTO (MOW) CIRCUIT
Hydraulic System (Rev. A)
Page 4 -- 48
Return or Suction
Flow
Groundsmaster 4500--D/4700--D
Procedure for Traction Circuit Reducing Valve (PR1)
Pressure Test
1. Make sure hydraulic oil is at normal operating temperature by operating the machine for approximately 10
minutes. Make sure the hydraulic tank is full.
1
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.
2
CAUTION
Figure 49
Prevent personal injury and/or damage to equipment. Read all WARNINGS, CAUTIONS, and Precautions for Hydraulic Testing at the beginning
of this section.
1. 2WD/4WD control manifold (GM 4500--D shown)
2. Relief valve test port
Hydraulic
System
3. Connect a 1000 PSI gauge to test port on 2WD/4WD
control manifold under operator’s seat (Fig. 49).
4. Start the engine and put throttle at full engine speed
(2800 + 50 RPM).
5. Sit on seat, apply brakes fully, and slowly depress the
traction pedal in the reverse direction. While pushing
traction pedal, look at pressure reading on gauge:
1
2
GAUGE READING TO BE 420 to 470 PSI.
Figure 50
6. Pressure reducing valve (PR1) is located on the lower, rear side of the 2WD/4WD control manifold (Fig. 50).
Adjustment of this valve can be performed as follows:
1. Manifold: lower side
2. Reducing valve (PR1)
NOTE: Do not remove the valve from the hydraulic
manifold for adjustment.
A. To increase pressure setting, remove cap on reducing valve and turn the adjustment socket on the
valve in a clockwise direction. A 1/8 turn on the socket will make a measurable change in pressure setting.
B. To decrease pressure setting, remove cap on reducing 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 pressure setting.
C. Recheck pressure setting and readjust as needed.
Groundsmaster 4500--D/4700--D
Page 4 -- 49
Hydraulic System (Rev. A)
TEST NO. 13: Traction Assist (RV2) Pressure (Using Pressure Gauges)
TO STEERING CIRCUIT
FROM PTO (MOW) CIRCUIT
FROM PTO (MOW) CIRCUIT
FROM STEERING CIRCUIT
FROM STEERING CIRCUIT
2200
PSI
GM 4500--D SHOWN
Working Pressure
Low Pressure
Return or Suction
Flow
Hydraulic System (Rev. A)
Page 4 -- 50
Groundsmaster 4500--D/4700--D
Procedure for Traction Assist (RV2) Pressure Test
1. Make sure hydraulic oil is at normal operating temperature by operating the machine for approximately 10
minutes. Make sure the hydraulic tank is full.
1
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.
2
CAUTION
Figure 51
Prevent personal injury and/or damage to equipment. Read all WARNINGS, CAUTIONS, and Precautions for Hydraulic Testing at the beginning
of this section.
1. Traction assist manifold (GM 4500--D shown)
2. Counterbalance test port
1
Hydraulic
System
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 hydraulic tube (Fig. 52).
4. Start the engine and put throttle at full engine speed
(2800 + 50 RPM) with no load on the system. Do not engage the cutting units.
Figure 52
1. Forward traction port (faces forward)
5. Sit on seat, apply brakes fully, and slowly depress the
traction pedal in the forward direction. While pushing
traction pedal monitor both pressure gauges.
3
3
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 traction 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.
A. To increase pressure setting, loosen the locknut
and turn the adjusting screw on the relief valve in a
clockwise direction. A 1/8 turn on the dial will make a
measurable change in pressure (Fig. 45).
2
1
Figure 53
1. GM 4500--D traction assist manifold
2. GM 4700--D traction assist manifold
3. Traction assist valve (RV2)
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
After Repair or Replacement of Components
1. Before removing any parts from the hydraulic system, park machine on a level surface, engage parking
brake, lower cutting units or attachments, and stop engine. Remove key from the ignition switch.
1. Check oil level in the hydraulic reservoir and add correct 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. 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.
CAUTION
Operate all hydraulic controls to relieve system
pressure and avoid injury from pressurized hydraulic 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. Put caps or plugs on any hydraulic lines, hydraulic fittings, and components left open or exposed to prevent
contamination.
2. Lubricate O--rings and seals with clean hydraulic oil
before installing hydraulic components.
3. Make sure caps or plugs are removed from the hydraulic tubes, hydraulic fittings, and components before
reconnecting.
4. Use proper tightening methods when installing hydraulic hoses and fittings (see Hydraulic Fitting Installation).
5. After repairs, check control linkages or cables for
proper adjustment, binding, or broken parts.
6. After disconnecting or replacing any hydraulic components, operate machine functions slowly until air is
out of system (see Charge Hydraulic System).
7. Check for hydraulic oil leaks. Shut off engine and correct leaks if necessary. Check oil level in hydraulic reservoir and add correct oil if necessary.
4. Put labels on disconnected hydraulic lines and
hoses for proper installation after repairs are completed.
5. Note the position of hydraulic fittings (especially elbow 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
WARNING
Keep body and hands away from pin hole leaks
or nozzles that eject hydraulic fluid under high
pressure. Use paper or cardboard, not hands, to
search for leaks. Hydraulic fluid escaping under
pressure can have sufficient force to penetrate
the skin and cause serious injury. 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. Gangrene may result from
such an injury.
Hydraulic System (Rev. A)
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.
Page 4 -- 52
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 changIng from petroleum base hydraulic fluid to a biodegradable fluid such as Mobil EAL 224H. Operate
machine under normal operating conditions for at
least four (4) hours before draining.
1. Park machine on a level surface. Lower cutting units,
stop engine, and engage parking brake. Remove key
from the ignition switch.
6. Reconnect all hydraulic hoses, lines, and components that were disconnected while draining system.
NOTE: Use only hydraulic fluids specified in the Traction 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 solenoid.
9. Turn ignition key switch; engage starter for 10 seconds to prime pump. Repeat this step again.
Operate all hydraulic controls to relieve system
pressure and avoid injury from pressurized hydraulic oil. Controls must be operated with the
ignition switch in OFF. Remove key from the ignition switch.
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 under no load.
12.Raise and lower cutting units several times. Turn
steering wheel fully left and right several times.
IMPORTANT: Make sure to clean around any hydraulic connections that will be disconnected for
draining.
13.Shut off engine and check for hydraulic oil leaks.
Check oil level in hydraulic reservoir and add correct
amount of oil if necessary.
2. Drain hydraulic reservoir (see Traction Unit Operator’s Manual).
14.Operate machine for 2 hours under normal operating
conditions.
3. Drain hydraulic system. Drain all hoses, tubes, and
components while the system is warm.
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 biodegradable fluid, repeat steps 1 through 14 again at least
once and until the oil is clean.
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
16.Assume normal operation and follow recommended
maintenance intervals.
Page 4 -- 53
Hydraulic System (Rev. A)
Hydraulic
System
10.Connect electrical connector to engine run solenoid.
CAUTION
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.
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 abnormal sounds, shut the engine off immediately and determine cause or problem. Inspect for the following:
A. Loose filter or suction lines.
1. Park machine on a level surface. Lower cutting units,
stop engine, and engage parking brake. Remove key
from the ignition switch.
B. Blocked suction line.
2. Make sure all hydraulic connections, lines, and components are secured tightly.
D. Faulty gear pump.
3. If component failure was severe or the system is contaminated, flush and refill hydraulic system and tank
(see Flush Hydraulic System).
4. Make sure hydraulic reservoir is full. Add correct hydraulic oil if necessary (see Traction Unit Operator’s
Manual).
5. Disconnect engine run solenoid lead to prevent the
engine from starting.
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.
C. Faulty charge relief valve.
12.If cylinder does move in 10 to 15 seconds, proceed
to step 13.
13.Operate the traction pedal in the 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 of the traction interlock switch (see
Traction Unit Operator’s Manual).
16.Remove blocks from frame and lower machine. Remove chocks from remaining wheels.
8. Reconnect engine run solenoid lead.
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.
WARNING
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 remaining wheels to prevent movement of the machine.
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.
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 of fill in 30 seconds, stop
the engine and determine the cause.
Hydraulic System (Rev. A)
Page 4 -- 54
Groundsmaster 4500--D/4700--D
Hydraulic
System
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Groundsmaster 4500--D/4700--D
Page 4 -- 55
Hydraulic System (Rev. A)
Gear Pump
85 to 95 ft--lb
(115 to 128 N--m)
27
32
30
25
28
17
18
1
2
3
29
24
23 4
19
13
31
21
23
22
26
5
20
24
16
6
11
14
RIGHT
7
15
8
12
FRONT
9
10
Figure 54
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
Flat washer
Cap screw
90o hydraulic fitting
Hydraulic tee fitting
O--ring
Quick fitting
Dust cap
90o hydraulic fitting
Clamp
90o hydraulic fitting
O--ring
Hydraulic System (Rev. A)
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
O--ring
90o hydraulic fitting
Suction hose
Suction hose
O--ring
Hydraulic hose
Hydraulic hose
Hydraulic hose
Hydraulic hose
O--ring
Hydraulic fitting
Page 4 -- 56
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
O--ring
O--ring
O--ring
Gear pump assembly
Piston pump assembly
Coupler
Cap screw
Washer
O--ring
Spacer
Groundsmaster 4500--D/4700--D
Removal
Installation
1. Park machine on a level surface, lower cutting units,
stop engine, engage parking brake, and remove key
from the ignition switch.
1. Lubricate new o--rings with clean hydraulic oil and
position on gear pump.
2. Slide coupler onto the piston pump output shaft.
3. Drain the hydraulic reservoir (see Traction Unit Operator’s Manual).
3. Position 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. To prevent contamination of hydraulic system during
removal, thoroughly clean exterior of pump and fittings.
4. Remove caps and plugs from hydraulic lines and fittings. Install lines to gear pump.
5. Read the General Precautions for Removing and
Installing Hydraulic System Components at the beginning of the Service and Repairs section of this chapter.
5. Replace hydraulic filter and fill hydraulic reservoir
with new hydraulic oil.
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 falling.
8. Remove two (2) cap screws and washers securing
gear pump to piston pump. Remove gear pump, coupler, spacer, and o--rings from machine.
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.
Groundsmaster 4500--D/4700--D
Page 4 -- 57
Hydraulic System (Rev. A)
Hydraulic
System
2. Raise seat and secure it with prop rod to gain access
to gear pump.
Gear Pump Service
5
15
14
8
3
12
1
25 to 28 ft--lb
(34 to 38 N--m)
2
10
11
4
4
23
13
19
16
18 17
24
21 to 24 ft--lb
(29 to 33 N--m)
14
20
28
29
9
12
21
7
4
4
13
22
27
25
21 to 24 ft--lb
(29 to 33 N--m)
26
12
6
Figure 55
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
Shaft seal
Washer
Cap screw
O--ring
Washer
Proportional valve
Plug
Plug
O--ring
Front body
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
Drive gear assembly
Wear plate
Pressure seal
Backup gasket
Front plate assembly
Idler gear
Key
Gear
Middle body
Gear
Disassembly
Work in a clean area as cleanliness is extremely important 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), bodies (10, 19, 26), adapter plates (23, 24) and backplate
(27). This will assure proper reassembly.
Hydraulic System (Rev. A)
21.
22.
23.
24.
25.
26.
27.
28.
29.
Idler gear
Key
Front adapter plate
Rear adapter plate
Idler gear
Rear body
Backplate assembly
Plug
O--ring
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 on the pump housing to prevent distorting
the housing.
2. Clamp pump in vise, shaft end up and remove the
eight cap screws (3).
Page 4 -- 58
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).
Inspection
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.
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.
5. Remove plug (8) from front plate (15).
3. Inspect both the drive gear and idler gear shafts at
bushing points and seal area for rough surfaces and excessive wear.
7. Remove idler gear (21), slip fit gear (18), and key
(17).
8. Remove backplate (27) from rear body (26) by tapping on backplate with soft face hammer.
9. 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 adapter plate (24).
13.Remove backup gaskets (14) and pressure seals
(13) from wear plates (15) by carefully prying out with a
sharp tool.
4. Replace gear assembly if shaft measures less than
.873” (22.17mm) in bushing area. (One gear assembly
may be replaced separately; shafts and gears are available 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 l.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.
IMPORTANT: Do not damage the seal bore in the
front plate during seal removal.
12.Check for scoring on face of backplate and adapter
plates. Replace if wear exceeds .0015” (.038mm).
14.Remove shaft seal (1) and washer (2) from front
plate (15).
13.Check bodies inside gear pockets for excessive
scoring or wear.
15.Remove plug (7) and o--ring (9) from rear adapter
plate (24).
14.Replace bodies if l.D. of gear pockets exceeds
2.100” (53.34mm).
16.Remove proportional valve (6) from backplate assembly (27).
Groundsmaster 4500--D/4700--D
Page 4 -- 59
Hydraulic System (Rev. A)
Hydraulic
System
6. Remove front adapter plate (23) from front body (10)
by tapping on the adapter plate with a soft face hammer.
1. Clean and dry all pump components. Remove nicks
and burrs from all parts with emery cloth.
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 must 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 reassembly, 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), adapter 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 a thin coat of 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 against the front plate.
The side with the mid section cut away must be on suction side of pump.
7. Dip drive gear assembly (11) and idler gear assembly (16) into clean hydraulic oil. Slip both gear assemblies into gear pocket of front body (10) and into front
plate bushings.
10.Install key (17) in slot of drive gear shaft. Dip slip fit
gear (18) in clean 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 pressure 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.Secure pump components with cap screws (3).
Torque cap screws evenly in a crisscross pattern from
25 to 28 ft--Ib (34 to 38 N--m).
18.Place washer (2) over drive shaft into housing. Liberally oil 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.If removed, install plug (28) with o--ring into backplate and torque from 21 to 24 ft--lb (29 to 33 N--m).
22.Install proportional valve (6) into backplate. Torque
plug from 21 to 24 ft--lb (29 to 33 N--m).
8. Install 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 pressure seal and backup gasket against the front adapter
plate.
Hydraulic System (Rev. A)
Page 4 -- 60
Groundsmaster 4500--D/4700--D
Hydraulic
System
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)
27
32
30
25
28
17
18
1
2
3
29
24
23 4
19
13
31
21
23
22
26
5
20 16
24
33
35
6
36
5
14
RIGHT
7
15
8
12
34
21
FRONT
11
9
37
11
10
Figure 56
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
Flat washer
Cap screw
90o hydraulic fitting
Hydraulic tee fitting
O--ring
Quick fitting
Dust cap
90o hydraulic fitting
Clamp
90o hydraulic fitting
Hydraulic fitting
Hydraulic tee fitting
90o hydraulic fitting
Hydraulic System (Rev. A)
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
Suction hose
Suction hose
Wire harness
Hydraulic hose
Hydraulic hose
Hydraulic hose
Hydraulic hose
O--ring
Hydraulic fitting
O--ring
O--ring
O--ring
Page 4 -- 62
26.
27.
28.
29.
30.
31.
32.
33.
34.
35.
36.
37.
Gear pump assembly
Piston pump assembly
Coupler
Cap screw
Washer
O--ring
Spacer
O--ring
O--ring
O--ring
O--ring
O--ring
Groundsmaster 4500--D/4700--D
Removal
Installation
1. Park machine on a 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.
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
N--m).
3. Remove traction rod from control arm on piston
pump by removing lock nut, spacer and cap screw.
2. Install gear pump to piston pump (see Gear Pump
Installation).
4. Disconnect two wires from neutral switch on traction
pump.
3. Position traction rod to control arm on piston pump
by installing cap screw, spacer and lock nut.
5. Read the General Precautions for Removing and
Installing Hydraulic System Components at the beginning of the Service and Repairs section of this chapter.
4. Connect two wires to neutral switch on traction
pump.
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 retaining pump assembly to engine adapter plate. Carefully
pull pump assembly from adapter plate and raise it out
of the machine.
5. Remove plugs and caps from disconnected hydraulic 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 correct 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. Repeat 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.
Groundsmaster 4500--D/4700--D
Page 4 -- 63
Hydraulic System (Rev. A)
Hydraulic
System
6. Put a drain pan below the pump assembly. Remove
hydraulic hoses and fittings connected to piston and
gear pumps. Put plugs or caps on disconnected hydraulic hoses to prevent contamination of the system. Put
plugs in open ports of pumps.
Piston (Traction) Pump Service
100 to 110 ft--lb
(136 to 149 N--m)
27 to 31 ft--lb
(37 to 42 N--m)
16
20
150 to 160 in--lb
(17 to 18 N--m)
38
18
100 to 110 ft--lb
(136 to 149 N--m)
15
4 to 6 ft--lb
(5 to 8 N--m)
14
1
29
26
4
22
45
10
33
28
23
17
8
30
7
5
27
40 to 48 in--lb
(4.5 to 5.4 N--m)
34
43
35
31
32
44
36
11
40 to 48 in--lb
(4.5 to 5.4 N--m)
37
19
25 to 28 ft--lb
(34 to 38 N--m)
42
41
40
6
31
5
39
37
21
12
40 to 48 in--lb
(4.5 to 5.4 N--m)
33
3
3
9
13
24
2
25
Figure 57
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
Jam nut
Retaining ring
Retaining ring
Seal washer
Socket head screw
Rotating kit assembly
Servo piston assembly
Piston follower
Cover plate
Cover plate
Camplate assembly
Thrust race
Thrust bearing
Bypass valve
Cap screw
Hydraulic System (Rev. A)
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
Relief valve (Reverse)
Socket head screw
Valve plate
Pump housing
Backplate assembly
Drive shaft
Nut
Lock washer
Washer
Shaft seal
Relief valve (Forward)
Control arm
Servo control assembly
Washer
Orifice plate (3 used)
Page 4 -- 64
31.
32.
33.
34.
35.
36.
37.
38.
39.
40.
41.
42.
43.
44.
45.
Flat washer
Housing gasket
Cover plate gasket
Control assembly gasket
Plug
O--ring
Seal sub--assembly
Roll pin
Bearing
Dowel bushing
Cradle sub--assembly
Cap screw
Button head cap screw
Bushing
Bearing
Groundsmaster 4500--D/4700--D
Work in a clean area as cleanliness is extremely important 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, clamping 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 assembly 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 rotating kit assembly (6), still in housing
(19).
3. From backplate (20), remove bypass valve (14), forward relief valve (26) and reverse relief valve (16). Note:
Mark the valves in relationship to the cavity it was removed, 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 gasket (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 input 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 assembly in position. Lower pump so that the shaft end
(flange end) is up. Set the 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 rotating kit assembly (6) and camplate assembly(11).
7. Remove camplate (11) from rotating kit assembly (6)
and servo piston follower (8) from camplate (11).
(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. Move the cradle sub--assembly 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 setting is at the dimension shown in Figure 58, bearing
removal is not required.
B. Check roll pin (38) in backplate (20). If tight and
set to the dimension shown in Figure 58, removal not
required.
Numbered end
.173 inch
(4.39 mm)
.090 inch
(2.29 mm)
Figure 58
2. Check the bearing (39) (press fit) in pump housing
(19). If needles remain in cage, move freely, and setting
at the dimension shown in Figure 59, bearing removal
is not required.
8. Remove the four socket head screws (5) and washers (31) retaining each cover plate (9 & 10).
9. Remove jam nut (1), washer (29), and seal washer
(4). Hold the servo piston bolt with hex key and unscrew
cover plate (10) from bolt.
Numbered end
Flange end of housing
.070 inch
(1.78 mm)
10.Remove servo piston assembly (7) and seal sub--assemblies (two sets) (37) from housing. Note: Disassembly 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
Figure 59
Hydraulic System (Rev. A)
Hydraulic
System
Disassembly
3. Inspect camplate assembly:
A. The finish on the piston shoe surfaces of the camplate (11) should show no signs of scoring.
3
2
1
B. Inspect camplate (11) bushing surface for wear.
Also inspect surface for coating transfer from bushing.
5
4. Inspect bushing (44) for contamination embedment
within coating of bushing surface coming in contact with
camplate (11).
4
Figure 60
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, examine the bore for scoring or contamination.
B. 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 a flat smooth surface that comes in contact with the camplate. Do not lap piston shoes.
1. Piston assemblies
2. Spider
3. Spider pivot
4. Piston block
5. Retainer
.500 inch
(12.7 mm)
Left Side
Right Side
C. Examine the spider for wear in the pivot area.
D. Examine the spider pivot to insure smoothness
and no signs of wear.
Front flange -- Drive shaft end of pump
Adjust to center piston
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. Install 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 assembly (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--lb (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)
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 nut from 150 to 160 in--lb (17
to 18 N--m). Check the centering of servo piston assembly (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--lb (4.5 to 5.4 N--m).
6. Press dowel 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--lb
(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--assembly 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).
Page 4 -- 66
Groundsmaster 4500--D/4700--D
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 controller 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 open end of housing up,
clamping housing on the outer portion of the flange.
12.Install gasket (32) onto housing.
13.If 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 outward. 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 & 26). Install
relief valve in the cavity in backplate and torque from 100
to 110 ft--lb (136 to 149 N--m).
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 position onto the backplate (20), with steel side against
backplate.
17.Install backplate assembly (20) onto housing assembly (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 in position with petroleum jelly. Position the feedback link at 90 degrees from control housing. Install
manual servo control assembly (28) onto housing making sure feedback link entered small groove in servo piston assembly (7).
20.Secure control assembly with six socket head
screws (17). Torque screws from 40 to 48 in--lb (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--lb (28 to 32
N--m). Torque 1--1/4 in. plug from 40 to 45 ft--lb (54 to 61
N--m).
15.Install new o--ring on bypass valve (14). Install bypass 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
Hydraulic System (Rev. A)
Hydraulic
System
8. Place exterior retaining ring (3), thrust race (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.
Piston Pump Manual Servo Control Assembly
44 to 52 ft--lb
(60 to 70 N--m)
15
10
1
2
14
3
4
5
7
4
9
13
12
8
6
16
24
17 to 26 in--lb
(2 to 3 N--m)
17
23
11
22
28 to 34 in--lb
(3.2 to 3.8 N--m)
21
18
20
19
Figure 62
1.
2.
3.
4.
5.
6.
7.
8.
Plug
O--ring
Retaining ring
Spring retainer
Spring
Spool valve
Control housing
Input shaft
9.
10.
11.
12.
13.
14.
15.
16.
O--ring
Wiper seal
O--ring
Adaptor
Ball
Pin
Neutral switch
O--ring
17.
18.
19.
20.
21.
22.
23.
24.
Set screw
Set screw
Pin
Retaining ring
Feedback link
Dowel pin
Bell crank
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.
1. Install spring retainer, spring, and second spring retainer onto spool valve. Compress spring to allow retaining ring (3) to be installed onto spool valve.
2. Remove set screw (24) from plug that retains valve
spool. Remove plug from control housing and o--ring
from plug.
2. Install spool valve into control housing making sure
that metering notches on spool valve can be seen in the
metering ports.
3. Remove retaining ring (20) from pin that retains feedback link and spool valve. Remove pin, feedback link,
spool valve, and bell crank from control housing.
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. Compress spring and remove retaining ring (3). Remove spring retainer, spring, and second spring retainer
from spool valve.
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.
5. Clean all parts and lubricate in clean hydraulic oil for
reassembly.
Hydraulic System (Rev. A)
Page 4 -- 68
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. Adjust plug 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--lb (2 to 3
N--m).
5. Test the switch by moving the control arm to the detent 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
“A”
Reassembly
Step 4--D
“B”
Reassembly
Step 4--E
“B”
Disassembly -- Neutral Switch
2. Remove adapter from control housing.
3. Remove pin, ball, and o--rings (11 & 16) from adapter.
Hydraulic
System
1. Loosen set screw (17) in adapter and remove neutral
switch from adapter.
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 petroleum jelly to hold in place during installation.
3. Install adapter into control housing. Torque from 44
to 52 ft--lb (60 to 70 N--m).
4. Apply Loctite #222 or equivalent to 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 the leads from a test light to the switch terminals. Note: A multimeter could be used instead of
a test light.
“A”
Figure 63
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 until the light goes off.
Mark this position “B”.
E. Unscrew the switch one third of the distance between “B” and “A”. 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 in--lb (3.2 to 3.8 N--m).
Groundsmaster 4500--D/4700--D
Page 4 -- 69
Hydraulic System (Rev. A)
Hydraulic Control Manifolds: 2 Wheel/4 Wheel Drive, Filtration and Charge, Power Down
and Traction Assist
1
4
2
RIGHT
3
6
FRONT
5
7
Figure 64
1. Power down/traction assist manifold
2. Flange head screw (3 used)
3. Filtration/charge manifold
Hydraulic System (Rev. A)
4. Flange head screw (4 used)
5. 2WD/4WD manifold
Page 4 -- 70
6. Cap screw (2 used)
7. Flange nut (2 used)
Groundsmaster 4500--D/4700--D
Removal
Installation
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. Install hydraulic manifold to the frame using Figure
64 as guide.
1. Read the General Precautions for Removing and
Installing Hydraulic System Components at the beginning of the Service and Repairs section of this chapter.
2. If 2WD/4WD control manifold is being removed, disconnect electrical connector from the solenoid valve.
2. Remove caps and plugs from fittings and hoses.
Properly connect hydraulic lines to manifold.
3. If 2WD/4WD control manifold was removed, connect
electrical connector to the solenoid valve.
4. Fill hydraulic reservoir with hydraulic fluid as required (see Traction Unit Operator’s Manual).
3. Disconnect hydraulic lines from manifold being removed and put caps or plugs on open hydraulic lines
and fittings. Label disconnected hydraulic lines for proper reassembly.
Hydraulic
System
4. Remove hydraulic manifold from the frame using
Figure 64 as guide.
Groundsmaster 4500--D/4700--D
Page 4 -- 71
Hydraulic System (Rev. A)
Hydraulic Control Manifold Service: 2 Wheel/4 Wheel Drive Control
80 to 90 ft--lb
(108 to 122 N--m)
18
19 12
13
18
7
16 17
19
18
1
80 to 90 ft--lb
(108 to 122 N--m)
19
17
21
18
17
19
16
16
16 17
5
17
16
25
20
7
4
12
24
11
60 to 70 ft--lb
(81 to 95 N--m)
9
10
8
20
2
25 to 30 ft--lb
(34 to 41 N--m)
23
13
17
15
16
14
13
12
21
3
35 to 40 ft--lb
(47 to 54 N--m)
4 to 6 ft--lb
(5 to 8 N--m)
6
22
PLUG TORQUE
SAE #2: 41 TO 49 in--lb (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--lb (13 to 20 N--m)
SAE #6: 15 to 20 ft--lb (20 to 27 N--m)
SAE #10: 35 to 40 ft--lb (48 to 54 N--m)
Figure 65
1.
2.
3.
4.
5.
6.
7.
8.
9.
Manifold body
Solenoid valve (SV: port 2)
Seal kit
Check valve (CV: port 3)
Seal kit
Expander plug (not serviced)
Seal kit
Relief valve (RV5: port 7)
Seal kit
10.
11.
12.
13.
14.
15.
16.
17.
18.
Reducing valve (PR1: port 8)
Seal kit
Plug (SAE #2)
O--ring
Plug (SAE #4)
O--ring
Plug (SAE #5)
O--ring
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 solenoid 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.
19. O--ring
20. Plug (SAE #10)
21. O--ring
22. Solenoid coil
23. Nut
24. Expander plug (not serviced)
25. Control valve (PD1 & PD2: ports 5A &
5B)
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 surfaces, damaged threads, and contamination.
2. If cartridge is solenoid operated, remove nut securing solenoid to the cartridge valve. Carefully slide solenoid off the valve.
Hydraulic System (Rev. A)
Page 4 -- 72
Groundsmaster 4500--D/4700--D
5. Visually inspect cartridge valve 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.
B. If valve sealing surfaces appear pitted or damaged, the hydraulic system may be overheating or
there may be water in the system.
CAUTION
A. Lubricate new seal kit components with clean hydraulic 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 sealing.
IMPORTANT: Use care when handling the valve cartridge. Slight bending or distortion of the stem tube
can cause binding and malfunction.
B. Thread cartridge valve carefully into manifold
port. The valve should go in easily without binding.
6. Clean cartridge valve using clean mineral spirits.
Submerge valve in clean mineral spirits to flush out contamination. Particles as fine as talcum powder can affect
the operation of high pressure hydraulic valves. If cartridge 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 cartridge. Use compressed air for cleaning.
C. Torque cartridge valve using a deep socket to value identified in manifold illustration.
D. If cartridge is solenoid operated, carefully install
solenoid coil to the cartridge valve. Apply Loctite
#242 or equivalent to the threads of the valve. Torque
nut to value identified in manifold illustration.
8. If problems still exist, remove valve and clean again
or replace valve.
Page 4 -- 73
Hydraulic System (Rev. A)
Hydraulic
System
Use eye protection such as goggles when using
compressed air.
Groundsmaster 4500--D/4700--D
7. Reinstall the cartridge valve:
Hydraulic Control Manifold Service: Filtration and Charge Control
35 to 40 ft--lb
(47 to 54 N--m)
4
60 to 70 ft--lb
(81 to 95 N--m)
7
6
2
10
5
11
12
10
13
9
8
3
11
12
1
15
8
14
16
PLUG TORQUE
SAE #4: 6 to 10 ft--lb (8 to 13 N--m)
SAE #5: 10 to 15 ft--lb (13 to 20 N--m)
SAE #6: 15 to 20 ft--lb (20 to 27 N--m)
SAE #10: 35 to 40 ft--lb (48 to 54 N--m)
Figure 66
1.
2.
3.
4.
5.
6.
Filter manifold assembly
Check valve (Reservoir return)
Seal kit
Check valve (Filter bypass)
Seal kit
Check valve (Charge pressure)
7.
8.
9.
10.
11.
Seal kit
Plug (SAE #4)
O--ring
Plug (SAE #6)
O--ring
12.
13.
14.
15.
16.
Plug (SAE #5)
O--ring
Plug (SAE #10)
O--ring
Oil filter element
NOTE: The ports on the manifold are marked for easy
identification of components. Example: P2 is the gear
pump connection port and P1 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
Control Manifold Service: 2 Wheel/4 Wheel Drive Control 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)
3
25 ft--lb
(33.9 N--m)
20 ft--lb
(27.1 N--m)
25 ft--lb
(33.9 N--m)
2
6
20 ft--lb
(27.1 N--m)
5
Hydraulic
System
4
1
6
Figure 67
1. Manifold body
2. Traction assist valve (RV2: port 2)
3. Counterbalance valve (RV1: port 4)
4. Expanding plug (not serviced)
5. Lift relief valve (RV7: port 7)
6. Traction pressure sensing valve
(PD3: port 5)
NOTE: The ports on the manifold are marked for easy
identification of components. Example: CB is the connection port from the lift/lower control valve 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 Control 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--lb
(33.9 N--m)
3
2
20 ft--lb
(27.1 N--m)
25 ft--lb
(33.9 N--m)
3
4
20 ft--lb
(27.1 N--m)
20 ft--lb
(27.1 N--m)
6
7
5
20 ft--lb
(27.1 N--m)
7
1
7
Figure 68
1. Manifold body
2. Traction assist valve (RV2: port 2)
3. Power down valve (deck 6)
4. Counterbalance valve (RV1: port 4)
5. Traction pressure sensing valve
(PD3: port 5)
6. Lift relief valve (RV7: port 7)
7. Expanding plug (not serviced)
8. Power down valve (deck 7)
NOTE: The ports on the manifold are marked for easy
identification of components. Example: C1 is the connection 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 Control in this section. Refer to Figure 68 for cartridge valve
installation torque.
Hydraulic System (Rev. A)
Page 4 -- 76
Groundsmaster 4500--D/4700--D
Hydraulic
System
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)
9
8
16
15
1
2
17
10
11
11
3
2
13
18
11
4
RIGHT
FRONT
2
5
11
12
4
10
6
12
13
14
7
Figure 69
1.
2.
3.
4.
5.
6.
Hydraulic manifold: decks 2, 3, & 5
Hydraulic adapter
90o hydraulic fitting
90o hydraulic fitting
Hydraulic manifold: decks 1 & 4
Straight hydraulic fitting
7.
8.
9.
10.
11.
12.
90o hydraulic fitting
Quick fitting
Dust cap
O--ring
O--ring
O--ring
Removal
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).
1. Read the General Precautions for Removing and
Installing Hydraulic System Components at the beginning of the Service and Repairs section of this chapter.
2. Disconnect electrical connector from the solenoid
valve.
13.
14.
15.
16.
17.
18.
O--ring
O--ring
O--ring
Flange nut
Cap screw
Plug
3. Disconnect hydraulic lines from manifold and put
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.
Hydraulic System (Rev. A)
Page 4 -- 78
Groundsmaster 4500--D/4700--D
Hydraulic Control Manifold Service: Deck Drive (GM 4500--D)
7
4 to 5 ft--lb
(5.4 to 6.8 N--m)
3
165 in--lb
(18.6 N--m)
20 ft--lb
(27.1 N--m)
5
9
25 ft--lb
(33.9 N--m)
25 ft--lb
(33.9 N--m)
4
6
8
198 in--lb
(22.4 N--m)
1
120 in--lb
(13.6 N--m)
10
11
11
Figure 70
1.
2.
3.
4.
Manifold body
Solenoid valve (PRV2)
Solenoid coil
Logic cartridge (LC1)
5.
6.
7.
8.
Relief valve (RV8)
Pilot piston
Nut
Zero leak plug (#6)
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 70 for cartridge valve installation torque.
Groundsmaster 4500--D/4700--D
9. Plug (SAE #4)
10. Zero leak plug (#4)
11. Expanding plug (not serviced)
NOTE: The Groundsmaster 4500--D deck drive manifold uses several zero leak plugs. These plugs have a
tapered sealing surface on the plug head that is designed to resist vibration induced plug loosening. 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.
Page 4 -- 79
Hydraulic System (Rev. A)
Hydraulic
System
2
Hydraulic Control Manifold: Deck Drive (GM 4700--D)
9
8
15
17
1
11
2
10
2
16
2
11
3
13
4
11
12
4
2
18
RIGHT
10
5
13
FRONT
11
12
14
6
7
Figure 71
1.
2.
3.
4.
5.
6.
Hydraulic manifold: decks 2, 3, 5, & 7
Hydraulic adapter
90o hydraulic fitting
90o hydraulic fitting
Hydraulic manifold: decks 1, 4, & 6
Straight hydraulic fitting
7.
8.
9.
10.
11.
12.
90o hydraulic fitting
Quick fitting
Dust cap
O--ring
O--ring
O--ring
Removal
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).
1. Read the General Precautions for Removing and
Installing Hydraulic System Components at the beginning of the Service and Repairs section of this chapter.
2. Disconnect electrical connector from the solenoid
valve.
13.
14.
15.
16.
17.
18.
O--ring
O--ring
O--ring
Cap screw
Flange nut
Plug
3. Disconnect hydraulic lines from manifold and put
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.
Hydraulic System (Rev. A)
Page 4 -- 80
Groundsmaster 4500--D/4700--D
Hydraulic Control Manifold Service: Deck Drive (GM 4700--D)
8
4 to 5 ft--lb
(5.4 to 6.8 N--m)
20 ft--lb
(27.1 N--m)
8
20 ft--lb
(27.1 N--m)
7
5
5
25 ft--lb
(33.9 N--m)
3
7
25 ft--lb
(33.9 N--m)
4
198 in--lb
(22.4 N--m)
9
2
198 in--lb
(22.4 N--m)
9
6
1
120 in--lb
(13.6 N--m)
10
75 ft--lb
(101.7 N--m)
9
198 in--lb
(22.4 N--m)
12
11
165 in--lb
(18.6 N--m)
Figure 72
1.
2.
3.
4.
Manifold body
Proportional relief solenoid (PRV2)
Solenoid valve (SV2)
Logic valve (LC1 and LC2)
5.
6.
7.
8.
Relief valve (RV8 and RV9)
Pilot piston
Solenoid coil
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 cartridge valve installation torque.
Groundsmaster 4500--D/4700--D
9.
10.
11.
12.
Zero leak plug (#6)
Zero leak plug (#12)
Plug (SAE #4)
Zero leak plug (#4)
NOTE: The Groundsmaster 4700--D deck drive manifold uses several zero leak plugs. These plugs have a
tapered sealing surface on the plug head that is designed to resist vibration induced plug loosening. 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.
Page 4 -- 81
Hydraulic System (Rev. A)
Hydraulic
System
25 ft--lb
(33.9 N--m)
9
Rear Axle Motor
Arrows on side of
motor case point up
5
6
7
7
8
4
5
3
2
1 10
9
59 to 73 ft--lb
(80 to 99 N--m)
RIGHT
FRONT
Figure 73
1.
2.
3.
4.
Axle motor
O--ring
Pinion gear
External snap ring
Hydraulic System (Rev. A)
5. O--ring
6. Hydraulic fitting
7. O--ring
Page 4 -- 82
8. 90o hydraulic fitting
9. Cap screw
10. Flat washer
Groundsmaster 4500--D/4700--D
Removal
Installation
1. Park machine on a level surface, lower cutting units,
stop engine, engage parking brake, and remove key
from the ignition switch.
1. If removed, install pinion gear to axle motor.
2. Read the General Precautions for Removing and
Installing Hydraulic System Components at the beginning 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 hydraulic lines.
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 washers. Torque screws from 59 to 73 ft--lb (80 to 99 N--m).
4. Remove plugs from ports. Attach hydraulic hoses to
axle motor.
3. Disconnect hydraulic hoses from motor. Put caps or
plugs on ports to prevent contamination.
5. Fill hydraulic reservoir with hydraulic fluid as required (see Traction Unit Operator’s Manual).
IMPORTANT: Support axle motor to prevent motor
from falling during removal.
6. After assembly is completed, verify that hydraulic
hoses and fittings do not contact anything.
Hydraulic
System
4. Remove motor using Figure 73 as a guide.
Groundsmaster 4500--D/4700--D
Page 4 -- 83
Hydraulic System (Rev. A)
Front Wheel Motors
1
2
20
3
21
10
14
18
22
16
14
15
23 24
25
19 18
6
10
19
17
16
10
15
14
75 to 85 ft--lb
(101 to 115 N--m)
RIGHT
13
12
10
11
9
8
5
7
4
Arrows on side of
motor case point up
FRONT
Figure 74
1.
2.
3.
4.
5.
6.
7.
8.
9.
Flange head screw
Splined brake shaft
Planetary assembly
Wheel assembly
Lug nut
Retaining ring
LH brake assembly
Flange head screw
Plug
Hydraulic System (Rev. A)
10.
11.
12.
13.
14.
15.
16.
17.
O--ring
Piston wheel motor
Flat washer
Cap screw
O--ring
90o hydraulic fitting
O--ring
90o hydraulic elbow
Page 4 -- 84
18.
19.
20.
21.
22.
23.
24.
25.
O--ring
O--ring
RH brake assembly
Hydraulic tee fitting
45o hydraulic fitting
O--ring
Hydraulic fitting
O--ring
Groundsmaster 4500--D/4700--D
Removal
Installation
1. Park machine on a level surface, lower cutting units,
stop engine, engage parking brake, and remove key
from the ignition switch.
1. Position wheel motor to brake assembly making sure
that arrows on the side of motor case point upward.
2. Read the General Precautions for Removing and
Installing Hydraulic System Components at the beginning 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 contamination.
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--lb
(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).
IMPORTANT: Support wheel motor to prevent motor from falling during removal.
Groundsmaster 4500--D/4700--D
Page 4 -- 85
Hydraulic
System
4. Remove wheel motor using Figure 74 as a guide.
Hydraulic System (Rev. A)
Rear Axle/Front Wheel Motor Service
15 to 18 ft--lb
(20 to 24 N--m)
FRONT WHEEL MOTOR SHOWN
1
7
9
10
13
10
2
9
11
18
8
6
19
20
14
15
16
12
4
5
3
17
Figure 75
1.
2.
3.
4.
5.
6.
7.
Drive shaft
Backplate
Housing assembly
Rotating assembly
Cam plate insert
Retaining ring
Cap screw
8.
9.
10.
11.
12.
13.
14.
Shaft seal (front motor only)
Retaining ring
Thrust race
O--ring
Valve plate
Thrust bearing
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 of the front and rear motors requires the
same procedure.
NOTE: The rear axle motor does not have a shaft seal.
The case drain from the rear axle motor provides lubrication for the input gear case of the rear axle.
Cleanliness is extremely important when repairing hydraulic motors. Work in a clean area. Before disconnecting 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)
15.
16.
17.
18.
19.
20.
Roll pin
Bearing
Bearing
Washer
Plug
O--ring
Disassembly
1. Clamp the drive shaft end of the piston motor in a protected 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 backplate. It is not necessary to remove roll pins (14 and 15)
in backplate.
Page 4 -- 86
Groundsmaster 4500--D/4700--D
2. If necessary, install new needle bearing (17) in housing (3) with numbered end of the bearing outward.
5. Remove the camplate insert (5) from housing. Use
caution not to mar the finish that makes contact with pistons.
3. Install retaining ring (9) on shaft. Install thrust race
(10), thrust bearing (13), and second thrust race (10).
Secure with second retaining ring (9).
6. Remove retaining ring (6) from housing. Press shaft
from housing and remove shaft seal (8) and washer
(18).
4. Install shaft in housing. Install washer (18), new shaft
seal (8), and retaining ring (6).
7. Remove retaining rings (9) from shaft and remove
thrust races (10) and thrust bearing (13).
5. Install camplate insert (5) with the lettering side of insert to the front of the housing. Use petroleum jelly to
hold in place during assembly.
8. Discard the shaft seal and o--ring, and replace with
new items upon reassembly.
6. Install rotating assembly (4) into housing. Make sure
that piston shoes make contact with the camplate insert.
Inspection
7. Clamp motor assembly in a protected jaw vise with
the open end of the housing up.
1. Check the condition of the needle bearing (16) in
backplate (2) and replace if necessary.
2. Inspect valve plate (12) on the bronze side next to the
piston block for wear. A smooth surface is required. Do
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.
8. If roll pins were removed, install to dimension shown
in Figure 76 and with opening of roll pin oriented away
from bearing within 5o of bearing center line.
9. To replace bearing (16) in backplate (2). Press bearing 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)
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.
.090 in (2.3 mm)
Bearing
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
a flat smooth surface that comes in contact with the camplate. 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 camplate 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.
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 backplate assembly (2) onto housing assembly. Make sure
valve plate stays in position.
Reassembly
12.Insert cap screws and torque from 15 to 18 ft--Ib (20
to 24 N--m) in a criss--cross pattern.
1. Clean all parts in suitable solvent and lubricate all internal parts with clean hydraulic oil before reassembly.
13.Fill case half full of new hydraulic oil.
Groundsmaster 4500--D/4700--D
Page 4 -- 87
Hydraulic System (Rev. A)
Hydraulic
System
4. Remove motor from vise and remove rotating assembly (4) from motor housing.
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.
2
Removal
1. Park machine on a level surface, lower cutting units,
stop engine, engage parking brake, and remove key
from the ignition switch.
1
2. Read the General Precautions for Removing and
Installing Hydraulic System Components at the beginning of the Service and Repairs section of this chapter.
NOTE: Before disconnecting the hydraulic lines, clean
the port area of the deck motor.
1
Figure 77
1. Socket head screw
2. Hydraulic motor
Hydraulic
System
3. Disconnect hydraulic lines from deck motor. Put
caps or plugs on fittings and hoses to prevent contamination. Tag hydraulic lines for proper reassembly.
4. Remove two socket head screws that secure hydraulic motor to cutting deck (Fig. 77).
5. Lift hydraulic motor from cutting deck.
Installation
1. Align splines on motor shaft and spindle shaft. Position 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 components.
Groundsmaster 4500--D/4700--D
Page 4 -- 89
Hydraulic System (Rev. A)
Cutting Deck Motor Service
1
2
3
8
4
5
6
7
7
8
12
9
5
10
38 to 43 ft--lb
(51 to 58 N--m)
11
30 to 35 ft--lb
(41 to 47 N--m)
13
15
14
Figure 78
1.
2.
3.
4.
5.
Outer shaft seal
Inner shaft seal
Retaining ring
Front flange
Pressure seal
6.
7.
8.
9.
10.
Front bearing block
O--ring
Dowel pin
Housing
Drive gear
Disassembly (Fig. 78)
1. Plug motor ports and clean the outside of the motor
thoroughly. After cleaning, remove plugs and drain any
oil out of the motor.
11.
12.
13.
14.
15.
Idler gear
Rear bearing block
Rear cover
Cap screw
Relief valve assembly
SCRIBE MARK
2. Use a marker or scribe to make a diagonal mark
across the front flange, housing, and rear cover for reassembly 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
end down.
Figure 79
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
8. Carefully remove rear bearing block, idler gear, drive
gear, and front bearing block from the front flange.
5. Inspect front flange and rear cover for damage or
wear.
C. Thickness of bearing blocks should be equal.
3
10.Turn front flange over, with seal side up.
2
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.
1
Inspection
4
1. Remove any nicks and burrs from all parts with
emery cloth.
1.
2.
Gear shaft spline
Gear shaft
Figure 80
3.
4.
Gear teeth
Gear face edge
Reassembly (Fig. 78)
CAUTION
Use eye protection such as goggles when using
compressed air.
NOTE: When reassembling the motor, check the marker or scribe marks on each part to make sure the parts
are properly aligned during reassembly.
2. Clean all parts with solvent. Dry all parts with compressed air.
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.
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 indicates 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
2. Install inner shaft seal into front flange with seal lip
facing in (Fig. 81). Seal should be pressed into place until 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 facing 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, on a flat surface.
6. Install the pressure seals into the grooves in the
bearing blocks.
7. Apply a light coating of petroleum jelly to the exposed
side of the front flange.
Page 4 -- 91
Hydraulic System (Rev. A)
Electrical
System
9. Remove and discard pressure seals from bearing
blocks.
Product Records
and Manuals
B. Face of bearing blocks that are in contact with
gears should be free of wear, roughness or scoring.
Kubota
Diesel Engine
IMPORTANT: Note position of the open and closed
side of the bearing blocks before removing. Also,
identify bearing blocks (front and rear) for proper reassembly.
Hydraulic
System
A. Bearing areas should not have excessive wear or
scoring.
Safety
4. Inspect bearing blocks for the following:
Wheels, Brakes,
and Chassis
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.
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 the
bearing block with the pressure seal side down. Carefully install shaft into front flange.
2
9. Lubricate the idler gear shaft with clean hydraulic oil.
Install idler gear shaft into the remaining position in the
bearing block. Apply a 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.
1
3
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 assembly.
13.Gently slide the housing onto the assembly. Firm
hand pressure should be sufficient to engage the dowel
pins.
Figure 81
1. Inner shaft seal
2. Retaining ring
3. Outer shaft seal
Rotation Direction
14.Check to make sure that the surface of the rear bearing 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. Correct before proceeding.
1
2
15.Apply a light 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.
3
17.Install the four cap screws and hand tighten.
Figure 82
IMPORTANT: Avoid using excessive clamping
pressure on the motor housing to prevent distorting
the housing.
1. Pressure IN
2. Pressure OUT
3. Case drain
18.Place front flange of the motor into a vise and alternately torque the cap screws from 38 to 43 ft--lb (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
Groundsmaster 4500--D/4700--D
Relief Valve Service
IMPORTANT: Do not remove the relief valve assembly unless testing shows it to be faulty.
1. When removing or installing the relief valve, motor
should be removed from deck and positioned horizontally with the relief valve pointed down (Fig. 83). This
process will prevent the relief valve from falling into motor passages.
5
4
NOTE: The relief valve seat is difficult to remove because 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.
3
RELIEF VALVE KIT
2
2. Remove plug with o--ring, spring, and relief valve
from the rear cover.
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 6 ft--lb
(5.4 to 8.1 N--m).
Figure 83
1. Plug
2. O--ring
3. Spring
4. Relief valve
5. Relief valve seat
Hydraulic
System
3. Clean and inspect removed parts. Visually inspect
relief valve seat and plug threads in the rear cover.
1
5. Apply hydraulic oil to relief valve components. Replace the relief valve assembly: install relief valve,
spring, and plug with o--ring into the rear cover. Torque
plug from 30 to 35 ft--lb (41 to 47 N--m).
6. Install motor on cutting deck.
Groundsmaster 4500--D/4700--D
Page 4 -- 93
Hydraulic System (Rev. A)
Lift/Lower Control Valve (GM 4500--D)
10
11
9
25
9
12
5
6
13
8
7
4
3
24
14
2
15
1
16
17
23
22
21
18
20
RIGHT
19
FRONT
Figure 84
1.
2.
3.
4.
5.
6.
7.
8.
9.
Control valve assembly (1 spool)
O--ring
Hydraulic adapter
O--ring
Hydraulic fitting
Orifice (port B)
Cap screw
Spacer
Spacer tube
Hydraulic System (Rev. A)
10.
11.
12.
13.
14.
15.
16.
17.
Lift lever
Control knob
Curved washer
Cotter pin
Thread forming screw
Proximity switch
Flange head screw
Switch plate
Page 4 -- 94
18.
19.
20.
21.
22.
23.
24.
25.
Insert nut
Flange nut
Extension spring
Cap screw
Valve support
Link
Lock nut
O--ring
Groundsmaster 4500--D/4700--D
Removal
Installation
1. Park machine on a level surface, lower cutting units,
stop engine, engage parking brake, and remove key
from the ignition switch.
1. Install control valve using Figure 86 as a guide.
2. Read the General Precautions for Removing and
Installing Hydraulic System Components at the beginning of the Service and Repairs section of this chapter.
2. Make sure hydraulic tank is full. Add correct oil if necessary before returning machine to service.
NOTE: Before disconnecting the hydraulic lines, clean
the port area of the lift/lower control valve assembly.
3. Tag hydraulic lines for proper reassembly.
Hydraulic
System
4. Remove lift/lower control valve using Figure 86 as a
guide.
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)
19
13
24
25
30 to 35 ft--lb
(41 to 48 N--m)
10 to 12 ft--lb
(13 to 16 N--m)
23
18
9
17
26
22
11
27
6
7
15
30 to 35 ft--lb
(41 to 48 N--m)
12
4
28
1
2
5
21
20 to 25 ft--lb
(27 to 33 N--m)
15
8
10
16
3
14
20
Figure 85
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
Poppet
Plunger
Spacer
Spool
Seat
Plug
Seat retaining plug
Bushing
Lockout spring
Spool cap
Hydraulic System (Rev. A)
11.
12.
13.
14.
15.
16.
17.
18.
19.
Detent plunger
Control valve body
Detent plug
Spool spring
O--ring
Retaining ring
Detent spring
Disc
Plug
Page 4 -- 96
20.
21.
22.
23.
24.
25.
26.
27.
28.
Washer
Wiper seal
Backup washer
O--ring
O--ring
O--ring
O--ring
Backup washer
O--ring
Groundsmaster 4500--D/4700--D
Disassembly
1. Plug all ports and clean outside of valve thoroughly.
2. Remove spool cap (10). Do not remove 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.
Assembly
1. Thoroughly clean and dry all parts. Apply a light coating 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.
3. Install plug (6) with new back--up washer (22) and O-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.
5. Remove plug (6).
IMPORTANT: Check location and positioning of
plunger during installation.
IMPORTANT: Check location and positioning of
plunger when removing from body to assure proper
assembly.
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. Remove seat retaining plug (7), lockout spring (9),
poppet (1), seat (5) and plunger (2).
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--lb (41 to 48 N--m).
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.
3. Inspect spool spring (14), lockout spring (9), and detent spring (17) for breakage.
4. If spool (4) has excessive wear, the control valve becomes non--serviceable as the spool and spool bore are
matched. Damaged spools cannot be replaced.
Groundsmaster 4500--D/4700--D
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--lb
(27 to 33 N--m).
12.Install new wiper seal (21).
Page 4 -- 97
Hydraulic System (Rev. A)
Hydraulic
System
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.
Lift/Lower Control Valve (GM 4700--D)
14
13
12
16
8
4
11
10
15
7
6 5
4
9
17
6
4
18
20
3
19
2
1
27
21
26
25
22
RIGHT
24
23
FRONT
Figure 86
1.
2.
3.
4.
5.
6.
7.
8.
9.
Control valve assembly (3 spool)
O--ring
Hydraulic adapter
O--ring
Hydraulic fitting
O--ring
Orifice (port D)
Cap screw
90o hydraulic fitting
Hydraulic System (Rev. A)
10.
11.
12.
13.
14.
15.
16.
17.
18.
Spacer
Left lift lever
Control knob (3 used)
Center lift lever
Right lift lever
Curved washer (if equipped)
Cotter pin
Thread forming screw
Proximity switch (3 used)
Page 4 -- 98
19.
20.
21.
22.
23.
24.
25.
26.
27.
Lock nut
Flange head screw
Switch plate
Nut insert
Flange nut
Extension spring (3 used)
Cap screw
Valve support
Link (3 used)
Groundsmaster 4500--D/4700--D
Removal
Installation
1. Park machine on a level surface, lower cutting units,
stop engine, engage parking brake, and remove key
from the ignition switch.
1. Install control valve using Figure 86 as a guide.
2. Read the General Precautions for Removing and
Installing Hydraulic System Components at the beginning of the Service and Repairs section of this chapter.
2. Make sure hydraulic tank is full. Add correct oil if necessary before returning machine to service.
NOTE: Before disconnecting the hydraulic lines, clean
the port area of the lift/lower control valve assembly.
3. Tag hydraulic lines for proper reassembly.
Hydraulic
System
4. Remove lift/lower control valve using Figure 86 as a
guide.
Groundsmaster 4500--D/4700--D
Page 4 -- 99
Hydraulic System (Rev. A)
Lift/Lower Control Valve Service (G 4700--D)
6
30 to 35 ft--lb
(41 to 48 N--m)
4
29
28
10 to 12 ft--lb
(13 to 16 N--m)
4 to 5 ft--lb
(5 to 7 N--m)
18
19
20
17
26
22
12
21
27
11
2
16
25
5
24
1
13
23
20 to 25 ft--lb
(27 to 33 N--m)
10
9
30 to 35 ft--lb
(41 to 48 N--m)
12
8
14
15
3
7
Figure 87
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
Poppet
Plunger
Spacer
Spool
Seat
Plug
Seat retaining plug
Bushing
Lockout spring
Spool cap
Hydraulic System (Rev. A)
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
Control valve body
O--ring
Retaining ring
Washer
Spool spring
Plunger
Detent plunger
Detent plug
Disc
Detent spring
Page 4 -- 100
21.
22.
23.
24.
25.
26.
27.
28.
29.
Plug
Wiper seals
Backup washer
O--ring
O--ring
O--ring
O--ring
O--ring
Backup washer
Groundsmaster 4500--D/4700--D
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 broken.
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 proper assembly.
6. Remove seat retaining plugs (7), lockout springs (9),
poppets (1), seats (5) and plungers (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
Assembly
1. Thoroughly clean and dry all parts. Apply a light coating 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--lb (41 to 48
N--m).
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 seat 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).
1. Remove all nicks and burns from parts and inspect
for excessive wear.
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.
2. Inspect all plungers and poppet seats for burrs or
roughness.
11. Install spool caps (10) and tighten from 20 to 25 ft--lb
(27 to 33 N--m).
3. Inspect spool springs (15), lockout springs (9), and
detent springs (20) for breakage.
12.Install new wiper seals (22).
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 replaced.
Groundsmaster 4500--D/4700--D
Page 4 -- 101
Hydraulic System (Rev. A)
Hydraulic
System
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.
Steering Valve
7
20 to 26 ft--lb
(28 to 35 N--m)
6
5
8
4
9
10
3
11
12
21
13
20
9
19
RIGHT
2
17
18
FRONT
14
15
1
16
Figure 88
1.
2.
3.
4.
5.
6.
7.
Steering valve
Steering column
Flange head screw (3 used)
Dust cover
Steering wheel
Hex nut
Steering wheel cover
Hydraulic System (Rev. A)
8.
9.
10.
11.
12.
13.
14.
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
15.
16.
17.
18.
19.
20.
21.
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--D
Removal
Installation
1. Park machine on a level surface, lower cutting units,
stop engine, engage parking brake, and remove key
from the ignition switch.
1. Install steering valve using Figure 88 as a guide.
2. Read the General Precautions for Removing and
Installing Hydraulic System Components at the beginning of the Service and Repairs section of this chapter.
2. Make sure hydraulic tank is full. Add correct oil if necessary before returning machine to service.
NOTE: Before disconnecting the hydraulic lines, clean
the port area of the steering valve assembly.
3. Tag hydraulic lines for proper reassembly.
Hydraulic
System
4. Remove steering valve from machine using Figure
88 as a guide.
Groundsmaster 4500--D/4700--D
Page 4 -- 103
Hydraulic System (Rev. A)
Steering Valve Service
8
1
3
24
2
4
5
20
19
23
6
7
19
22
21
150 in--lb
(17 N--m)
9
10
13
11
12
14
18
17
16
140 to 160 in--lb
(16 to 18 N--m)
15
Figure 89
1.
2.
3.
4.
5.
6.
7.
8.
Steering valve housing
Dust seal
O--ring
Spool
Spring retaining ring
Pin
Sleeve
Centering springs/spacers
9.
10.
11.
12.
13.
14.
15.
16.
Cap screw
End cap
O--ring
Seal ring
O--ring
Geroter
O--ring
Spacer
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 machined surfaces.
17.
18.
19.
20.
21.
22.
23.
24.
Geroter drive
Wear plate
Bearing race
Thrust bearing
Plug
O--ring
Relief valve
Quad seal
4. Slide the spool and sleeve assembly from the housing.
5. Remove the thrust bearing and bearing races (2).
6. Remove the quad seal.
1. Remove the seven cap screws from the steering
valve assembly.
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.
2. Remove end cap, geroter, spacer, geroter drive,
wear plate, seal ring, and o--rings from housing (Fig. 89).
8. Remove the pin that holds the spool and sleeve together.
3. Remove the plug and relief valve.
9. Carefully slide the spool out of the sleeve. The centering springs and spring retaining ring will stay with the
spool as it is removed.
Hydraulic System (Rev. A)
Page 4 -- 104
Groundsmaster 4500--D/4700--D
8. Put the thrust bearing and races into the housing.
The thrust bearing goes between the two races
(Fig. 90).
The centering springs are under tension. Remove the retaining ring carefully.
IMPORTANT: Do not damage the dust or quad seals
when installing the spool and sleeve assembly.
10.Remove the spring retaining ring and centering
springs from the spool.
9. Apply a light coating of clean hydraulic fluid to the
spool and sleeve assembly and slide carefully the assembly into the housing.
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 pressurized 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 hydraulic fluid.
10.Clamp the housing in a vise. Use only enough clamping force to hold the 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.
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.
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 gerotor star groove.
18.Install the spacer.
D. Fit the quad seal into its seat through the input end
of the housing. Be sure the seal is not twisted.
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).
E. Remove the sleeve and bearing race.
20.Remove the steering control unit from the vise.
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.
21.Install the relief valve and plug. Tighten the plug to
150 in-lb (17 N--m).
Thrust Bearing
and Race (2)
Dust Seal
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.
Quad Seal
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
Figure 90
Hydraulic System (Rev. A)
Hydraulic
System
CAUTION
Lift Cylinders: Decks #1, #4, and #5
9
8
7
6
5
3
4
2
10
11
12
2
13
4
13
1
5
RIGHT
FRONT
Figure 91
1.
2.
3.
4.
5.
Lift arm (deck #4)
Flange nut
Lift arm (deck #1)
Cylinder pin (3 used)
Flange head screw
Hydraulic System (Rev. A)
6.
7.
8.
9.
O--ring
90o hydraulic fitting
O--ring
Lift arm (deck #5)
Page 4 -- 106
10.
11.
12.
13.
Lift cylinder (deck #4)
Lift cylinder (deck #1)
Lift cylinder (deck #5)
Cylinder pin (3 used)
Groundsmaster 4500--D/4700--D
Removal (Fig. 91)
1. Park machine on a level surface, lower cutting units,
stop engine, engage parking brake, and remove key
from the ignition switch.
#4 Deck
#1 Deck
#5 Deck
2. Read the General Precautions for Removing and
Installing Hydraulic System Components at the beginning 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.
#6 Deck
(GM4700)
#2
Deck
#3
Deck
#7 Deck
(GM4700)
3. Disconnect hydraulic hoses from lift cylinder.
4. Remove flange nut and flange head screw that secure the cylinder pin (4) to the lift arm. Remove pin from
lift arm and cylinder shaft clevis which will free lift cylinder from lift arm.
CUTTING DECK LOCATIONS
Figure 92
Hydraulic
System
5. Remove flange nut and flange head screw that secure 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 cylinder 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 are not contacted
by anything.
Groundsmaster 4500--D/4700--D
Page 4 -- 107
Hydraulic System (Rev. A)
Lift Cylinders: Decks #2 and #3
8
9
4
7
11
10
7
6
12
6
5
4
2
3
14
RIGHT
13
1
FRONT
Figure 93
1.
2.
3.
4.
5.
Lift arm (deck #2 shown)
Cylinder pin
Flange head screw
O--ring
90o hydraulic fitting
Hydraulic System (Rev. A)
6.
7.
8.
9.
10.
O--ring
Retaining ring
Cylinder pin
Hydraulic fitting
Grease fitting
Page 4 -- 108
11.
12.
13.
14.
Lift cylinder
Flange nut
Rotation stop
Set screw
Groundsmaster 4500--D/4700--D
Removal (Fig. 93)
1. Park machine on a level surface, lower cutting units,
stop engine, engage parking brake, and remove key
from the ignition switch.
#4 Deck
#1 Deck
#5 Deck
2. Read the General Precautions for Removing and
Installing Hydraulic System Components at the beginning of the Service and Repairs section of this chapter.
NOTE: Before disconnecting the hydraulic lines, clean
the port area of the steering valve assembly.
#6 Deck
(GM4700)
#2
Deck
#3
Deck
#7 Deck
(GM4700)
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.
CUTTING DECK LOCATIONS
Figure 94
Hydraulic
System
4. Remove flange head screw and flange nut that secure 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 frame and cylinder barrel
clevis.
6. Remove lift cylinder from machine.
Installation (Fig. 93)
1. Position cylinder barrel clevis to frame and insert cylinder pin (8) with one retaining ring installed through the
frame and cylinder clevis. Secure pin with second retaining ring.
2. Insert cylinder 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
Hydraulic System (Rev. A)
Lift Cylinders: Decks #6 and #7 (GM 4700--D)
1
14 10
13
12
11
10
7
9
8
4
2
1
15
7
6
1
3
5
16
RIGHT
2
FRONT
4
1
3
Figure 95
1.
2.
3.
4.
5.
6.
Retaining ring
Cylinder pin
Thrust washer
Lift link
Link assembly
Bushing
Hydraulic System (Rev. A)
7.
8.
9.
10.
11.
Plastic roller
Rear link
Lock nut
90o hydraulic fitting
Lift cylinder
Page 4 -- 110
12.
13.
14.
15.
16.
O--ring
Grease fitting
O--ring
Support frame
Lift arm (deck #6 shown)
Groundsmaster 4500--D/4700--D
Removal (Fig. 95)
1. Park machine on a level surface, lower cutting units,
stop engine, engage parking brake, and remove key
from the ignition switch.
#4 Deck
#1 Deck
#5 Deck
2. Read the General Precautions for Removing and
Installing Hydraulic System Components at the beginning 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.
#6 Deck
(GM4700)
#2
Deck
#3
Deck
#7 Deck
(GM4700)
3. Disconnect hydraulic hoses from lift cylinder.
CUTTING DECK LOCATIONS
Figure 96
Hydraulic
System
4. Remove lock nuts (9) that secure link assembly (5).
Remove rear link (8) from link assembly. Pull link assembly 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 cylinder clevis.
5. Remove one retaining ring that secures the cylinder
pin (2) to the support frame. Pull pin from frame and cylinder 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. Insert 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 not contacted
by anything.
Groundsmaster 4500--D/4700--D
Page 4 -- 111
Hydraulic System (Rev. A)
Lift Cylinder Service
12
10
9
5
7
4
1
2
3
11
6
8
Figure 97
1.
2.
3.
4.
Barrel with clevis
Collar
Shaft with clevis
Dust seal
Hydraulic System (Rev. A)
5.
6.
7.
8.
Rod seal
O--ring
Back--up ring
Head
Page 4 -- 112
9.
10.
11.
12.
O--ring
Uni--ring
Piston
Locking nut
Groundsmaster 4500--D/4700--D
Disassembly
Assembly
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.
1. Make sure all parts are clean before reassembly.
2. Mount lift cylinder into a vice. Remove collar with a
spanner wrench.
3. Extract shaft with head and piston by carefully twisting and pulling on the shaft.
IMPORTANT: Do not clamp vise jaws against the
shaft surface. Protect shaft surface before mounting in a vice.
4. Mount shaft securely in a vise by clamping on the clevis 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. Remove O--ring, back--up ring, rod seal, and dust seal from
the head.
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 mounting in a vice.
3. Mount shaft securely in a vise by clamping on the clevis 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 piston 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.
Groundsmaster 4500--D/4700--D
Page 4 -- 113
Hydraulic System (Rev. A)
Hydraulic
System
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. Coat new O--rings, Uni--ring, rod seal, back--up ring,
and dust seal with clean hydraulic oil.
Steering Cylinder
9
6
7
4
9
1
8
5
2
4
10
3
15
12
100 to 125 ft--lb
(135 to 169 N--m)
13
14
11
RIGHT
100 to 125 ft--lb
(135 to 169 N--m)
FRONT
Figure 98
1.
2.
3.
4.
5.
Steering cylinder
Ball joint
Ball joint
Retaining ring
Grease fitting
Hydraulic System (Rev. A)
6.
7.
8.
9.
10.
Grease fitting
90o hydraulic fitting
O--ring
O--ring
Ball joint spacer
Page 4 -- 114
11.
12.
13.
14.
15.
Ball joint spacer
Axle washer
Hex slotted nut
Cotter pin
Drive axle assembly
Groundsmaster 4500--D/4700--D
Removal
Installation
1. Park machine on a level surface, lower cutting units,
stop engine, engage parking brake, and remove key
from the ignition switch.
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. Read the General Precautions for Removing and
Installing Hydraulic System Components at the beginning of the Service and Repairs section of this chapter.
NOTE: To ease reassembly, tag the hydraulic hoses to
show their correct position on the steering cylinder. Also,
clean hydraulic fittings and hose ends prior to disconnecting the hoses.
2. Install hydraulic hoses to steering cylinder.
3. Remove hydraulic hoses from steering cylinder.
4. After assembly is completed, operate steering cylinder to verify that hydraulic hoses and fittings are not contacted by anything.
Hydraulic
System
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.
3. Fill reservoir with hydraulic fluid as required (see
Traction Unit Operator’s Manual).
Groundsmaster 4500--D/4700--D
Page 4 -- 115
Hydraulic System (Rev. A)
Steering Cylinder Service
11
4
10
8
7
2
5
9
3
6
1
Figure 99
1.
2.
3.
4.
Butt and tube assembly
Shaft
Piston rod assembly
Gland
Hydraulic System (Rev. A)
5.
6.
7.
8.
Lock nut
O--ring
PTFE seal
O--ring
Page 4 -- 116 Rev. C
9. O--ring
10. U--cup
11. Wiper
Groundsmaster 4500--D/4700--D
Disassembly
Assembly
IMPORTANT: To prevent damage when clamping
cylinder barrel or rod in a vise, clamp only on pivotal
ends.
1. Use a complete repair kit when rebuilding the cylinder. Put a coating of clean hydraulic oil on all new seals,
and O--rings.
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. Install new O--rings and PTFE seal to the piston rod
and new O--ring, U--cup, and wiper to gland.
2. Mount cylinder in a vise so piston rod end of cylinder
is tilted up slightly. Do not close vise so firmly that cylinder tube could become distorted. Loosen gland with
spanner wrench.
3. Grasp end of piston rod and use a twisting and pulling motion to carefully extract piston, piston rod, and
gland from cylinder tube.
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
IMPORTANT: Do not clamp vise jaws against
smooth piston rod surface; the piston rod will become 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 compressed 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 damage (deep scratches, out--of--round, etc.). Replace entire 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. C
Hydraulic System (Rev. A)
Hydraulic Reservoir
5
6
4
3
2
1
19
80 to 87 ft--lb
(108 to 118 N--m)
9
16
8
12
7
RIGHT
18
10
11
FRONT
11
13
17
14
15
30 to 60 in--lb
(3.4 to 6.8 N--m)
1.
2.
3.
4.
5.
6.
7.
Hydraulic reservoir cap
O--ring
Dipstick
Air breather
Breather adapter
Hydraulic tank
Hydraulic fitting
8.
9.
10.
11.
12.
13.
Figure 100
O--ring
O--ring
Hydraulic tee fitting
O--ring
O--ring
Tank mount grommet (3 used)
14.
15.
16.
17.
18.
19.
Flat washer (3 used)
Flange head screw (3 used)
Tank strainer
Clamp
O--ring
Filter screen
Removal
Inspection
1. Park machine on a level surface, lower cutting units,
stop engine, engage parking brake, and remove key
from the ignition switch.
1. Clean hydraulic reservoir and suction strainer with
solvent.
2. Read the General Precautions for Removing and
Installing Hydraulic System Components at the beginning of the Service and Repairs section of this chapter.
3. Drain reservoir into a suitable container (see Traction Unit Operator’s Manual).
4. Disconnect hydraulic hoses from reservoir.
5. Remove hydraulic reservoir using Figure 100 as a
guide.
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--lb (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).
Hydraulic System (Rev. A)
Page 4 -- 118
Groundsmaster 4500--D/4700--D
Hydraulic Oil Cooler
Removal
1
CAUTION
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.
3
2
1. Park machine on a level surface, lower cutting units,
stop engine, engage parking brake, and remove key
from the ignition switch.
1. Oil cooler latch
2. Hose to oil cooler
2. Read the General Precautions for Removing and
Installing Hydraulic System Components at the beginning of the Service and Repairs section of this chapter.
Figure 101
3. Hose from oil cooler
1
Hydraulic
System
3. Remove oil cooler using Figures 101, 102, and 103
as guides.
Inspection
1. Back flush oil cooler with cleaning solvent. After cooler is clean, make sure all solvent is drained from the
cooler.
CAUTION
2
Figure 102
1. Oil cooler latch
2. Oil cooler
Use eye protection such as goggles when using
compressed air.
3
2. Dry inside of oil cooler using compressed air in the
opposite direction of the oil flow.
2
3
1
10
3. Plug both ends of oil cooler. Clean exterior of cooler.
Make sure fins are clear of dirt and debris.
9
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.
8
2. Fill reservoir with hydraulic fluid as required (see
Traction Unit Operator’s Manual).
RIGHT
4
FRONT
5
6
7
Figure 103
1.
2.
3.
4.
5.
Groundsmaster 4500--D/4700--D
Page 4 -- 119
Oil cooler
Washer
Flange head screw
Flange nut
Mount plate
6.
7.
8.
9.
10.
Clamp
Flat washer
Cap screw
Wire form latch
Cap screw
Hydraulic System (Rev. A)
This page is intentionally blank.
Hydraulic System (Rev. A)
Page 4 -- 120
Groundsmaster 4500--D/4700--D
Chapter 5
Electrical System
ELECTRICAL SCHEMATICS AND ELECTRICAL
HARNESS AND CONNECTORS DRAWINGS . . . 2
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . 3
Starting Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
General Run & Transport Problems . . . . . . . . . . . . 4
Cutting Unit Operating Problems . . . . . . . . . . . . . . 5
ELECTRICAL SYSTEM QUICK CHECKS . . . . . . . . 6
Battery Test (Open Circuit) . . . . . . . . . . . . . . . . . . . 6
Check Operation of Interlock Switches . . . . . . . . . 6
COMPONENT TESTING . . . . . . . . . . . . . . . . . . . . . . . 7
Ignition Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Indicator Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
PTO and Hi--Lo Speed Control Switches . . . . . . 10
Seat Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Parking Brake Switch . . . . . . . . . . . . . . . . . . . . . . . 11
Cutting Deck Position Switch . . . . . . . . . . . . . . . . 12
Cutting Deck Lift/Lower Switch . . . . . . . . . . . . . . . 13
Ramp--up Module . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Groundsmaster 4500--D/4700--D
Hour Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Glow Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Start, Neutral, Seat, Cutting Deck, Parking Brake,
and High Temperature Relays . . . . . . . . . . . . . . 16
Hydraulic Valve Solenoids . . . . . . . . . . . . . . . . . . . 17
Engine Run Solenoid . . . . . . . . . . . . . . . . . . . . . . . 18
Fuel Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Glow Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Temperature Sender . . . . . . . . . . . . . . . . . . . . . . . . 21
Temperature Gauge . . . . . . . . . . . . . . . . . . . . . . . . 22
High Temperature Shutdown Switch . . . . . . . . . . 23
Traction Neutral Switch . . . . . . . . . . . . . . . . . . . . . 24
Diode Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Diode Circuit Board . . . . . . . . . . . . . . . . . . . . . . . . . 25
Standard Control Module . . . . . . . . . . . . . . . . . . . . 26
SERVICE AND REPAIRS . . . . . . . . . . . . . . . . . . . . . 27
Battery Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Battery Care . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Battery Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Page 5 -- 1
Electrical System (Rev. A)
Electrical
System
Table of Contents
Electrical Schematics and Electrical Harness and
Connectors 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 circuits 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 meter in the voltage mode will make sure that excess current is not allowed through the meter. This excess
current can cause damage to circuits not designed to
carry it.
Figure 1
Skin--Over Grease
Special non--conductive grease (Toro Part No.
505--165) which forms a light protective skin to help waterproof electrical switches and contacts.
Figure 2
Electrical System (Rev. A)
Page 5 -- 2 Rev. D
Groundsmaster 4500--D/4700--D
Troubleshooting
For effective troubleshooting and repairs, you must
have a good understanding of the electrical circuits and
components used on this machine (see Chapter 9 -Electrical Diagrams).
CAUTION
Remove all jewelry, especially rings and
watches, before doing any electrical troubleshooting or testing. Disconnect the battery
cables unless the test requires battery voltage.
If the machine has any interlock switches by--passed,
reconnect the switches for proper troubleshooting and
safety.
Starting Problems
Problem
Possible Causes
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.
Low battery charge.
NOTE: If the solenoid clicks, the problem is not in the in- Loose or corroded battery cables.
terlock circuit.
Loose or corroded ground.
Faulty wiring at the starter.
Faulty starter solenoid.
Faulty starter.
Nothing happens when start attempt is made. Control
panel lights and gauges operate with the ignition
switch in ON.
The traction pedal is not in neutral position or the
neutral switch or circuit wiring is faulty.
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
released from the START position.
The engine run solenoid is out of adjustment or circuit
wiring is faulty.
High temperature shutdown switch or circuit wiring is
faulty.
Groundsmaster 4500--D/4700--D
Page 5 -- 3
Electrical System (Rev. A)
Electrical
System
Starter solenoid clicks, but starter will not crank.
Starting Problems (continued)
Problem
Possible Causes
Engine cranks, but does not start.
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).
Starter cranks, but should not when the traction pedal
is depressed.
The traction neutral switch is out of adjustment.
The traction neutral switch or circuit wiring is faulty.
General Run and Transport Problems
Engine continues to run, but should not, when the
ignition switch is turned off.
The engine fuel stop solenoid is stuck open.
Engine continues to run, but should not, when the
traction pedal is engaged with no operator in the seat.
The seat switch or circuit wiring is faulty.
The engine stops during operation, but is able to
restart.
The operator is lifting off the seat.
Ignition switch or circuit wiring is faulty.
Traction neutral switch or circuit wiring is faulty.
The seat switch or circuit wiring is faulty.
The engine shutdown delay is faulty.
The ignition switch or circuit wiring is faulty.
The engine kills when the traction pedal is depressed.
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.
Battery does not charge.
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, corroded, or
damaged.
Electrical System (Rev. A)
Page 5 -- 4
Groundsmaster 4500--D/4700--D
Cutting Unit Operating Problems
Cutting units run, but should not, when raised. Units
shut off with PTO switch.
The cutting deck position switch or circuit wiring is
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
PTO switch in the OFF (disengage) position.
The PTO switch or circuit wiring is faulty.
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.
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 faulty.
A hydraulic problem exists (see Troubleshooting
section of Chapter 4 -- Hydraulic System).
Cutting deck(s) operation is intermittent over rough
terrain.
The cutting deck lift/lower switch or circuit wiring for the
affected decks is faulty.
Diode D1--C on Diode Circuit Board is faulty.
Groundsmaster 4500--D/4700--D
Page 5 -- 5
Electrical System (Rev. A)
Electrical
System
The Ramp--up module or circuit wiring is faulty.
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 100oF (16 to 38oC).
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 negative battery post.
Voltage Measured
Battery Charge Level
12.68 V (or higher)
Fully charged (100%)
12.45 V
75% charged
12.24 V
50% charged
12.06 V
25% charged
11.89 V
0% charged
NOTE: This test provides a relative condition of the battery. Load testing of the battery will provide additional
and more accurate information.
Check Operation of Interlock Switches
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 operating the machine.
Electrical System (Rev. A)
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.
Page 5 -- 6
Rev. D
Groundsmaster 4500--D/4700--D
Component Testing
For accurate resistance and/or continuity checks, electrically disconnect the component being tested from the
circuit (e.g. unplug the ignition switch connector before
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.
CAUTION
When testing electrical components for continuity with a multimeter (ohms setting), make sure
that power to the circuit has been disconnected.
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.
CIRCUIT
OFF
NONE
ON / PREHEAT
B + I + A, X + Y
START
B+I+S
B
S
Y
X
I
2
4
1
3
Figure 3
1. Key
2. Hex nut
3. Lock washer
4. Ignition switch
OFF
45 °
ON / PREHEAT
45 °
START
Figure 4
Groundsmaster 4500--D/4700--D
Page 5 -- 7
Electrical System (Rev. A)
Electrical
System
POSITION
A
Fuses
The fuse block is located under the operator’s control
panel. Machines with serial numbers below 220999999
have four (4) fuses (Fig. 5). Machines with serial numbers above 230000000 have six (6) fuses (Fig. 6).
1
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.
2
Fuse 1 (15 Amp)
A. Supplies power to ignition switch terminal B.
Fuse 2 (10 Amp)
Figure 5
1. Control panel
A. Supplies power to the PTO circuit.
Fuse 3 (10 Amp)
2. Fuse block
1
A. Supplies power to the power point outlet.
Fuse 4 (10 Amp)
A. Supplies power from ignition switch terminal I.
Fuse 5 (2 Amp) (Only on machines with Serial Number
above 230000000)
2
A. Supplies power from ignition switch terminal I to
Standard Control Module.
Fuse 6 (10 Amp) (Only on machines with Serial Number
above 230000000)
Figure 6
1. Control panel
2. Fuse block
A. Supplies power from ignition switch terminal S.
Testing
2A
10A
10A
10A
10A
Remove fuses from the fuse block for testing. Fuse
should have continuity between fuse terminals.
6
15A
5
1
2
3
4
Figure 7
Electrical System (Rev. A)
Page 5 -- 8
Groundsmaster 4500--D/4700--D
Indicator Lights
Testing Indicator Lights
2
3
1. Apply 12 VDC to terminals 1A and 2A.
2. Ground terminals 1B and 2B.
1
4
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 test the 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 indicating correct operation of the electrical wiring to the oil
pressure switch.
High Temperature Shutdown Light
Figure 8
1. Charge indicator
2. Engine oil pressure
5
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 flywheel end of engine (see High Temperature Shutdown
Switch in this Chapter). Warning light should illuminate
and engine should stop running.
Glow Plug Indicator Light
3
2
4
1
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 seconds
while the ignition switch is left in ON.
6
Charge Indicator Light
The charge indicator light should come on when the ignition switch is in ON with the engine not running, or with
an improperly operating charging circuit while the engine is running.
1B
1A (+)
2B
2A (+)
Figure 9
1. Charge indicator
2. Engine oil pressure
3. High temp shutdown
Groundsmaster 4500--D/4700--D
3. High temp shutdown
4. Glow plug indicator
Page 5 -- 9
4. Glow plug indicator
5. Warning light front
6. Warning light back
Electrical System (Rev. A)
Electrical
System
If the engine coolant temperature rises to 230oF
(110oC), the high temperature light should come on as
the high temperature shutdown switch stops the engine.
PTO and Hi--Lo Speed Control Switches
The PTO and Hi--Lo Speed Control Switches are located 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 below. With the use of a multimeter (ohms setting), the
switch functions may be tested to determine whether
continuity exists between the various terminals for each
switch position. Verify continuity between switch terminals.
SWITCH
POSITION
NORMAL
CIRCUITS
OTHER
CIRCUITS
ON
2+3
5+6
OFF
1+2
4+5
1
2
Figure 10
1. PTO switch
2. Hi--Lo speed switch
4
5
6
1
2
3
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 electrical connector are located directly under the seat. Testing of the switch can be done without seat removal by
disconnecting the seat wire from the machine wiring
harness.
1
2
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 terminals.
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.
Electrical
System
6. Replace switch as needed. Reconnect switch connector.
Parking Brake Switch
The switch used for the parking brake is a normally open
proximity switch. The parking brake switch is located under 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.
3
2
Switch Testing
1
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 terminals.
4. With the parking brake released, there should be
continuity across the switch terminals.
Figure 13
1. Parking brake switch
2. Sensing plate
3. Brake rod (brake ON)
5. Apply the parking brake. 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 between 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 Position Switch
The cutting deck position switch is a normally open proximity 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.
3
1
2
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
PTO relay and the 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.
Figure 14
1. Position switch
2. Switch connector
2. Disconnect deck position switch that requires testing
from machine wiring harness.
3. Lift arm (#5 shown)
#4 Deck
#1 Deck
#5 Deck
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
should be continuity across the switch terminals.
5. Raise the cutting unit. There should be no continuity
across the switch terminals.
#6 Deck
(GM4700)
#2
Deck
#3
Deck
#7 Deck
(GM4700)
6. Replace switch as needed. Reconnect switch.
Switch Adjustment
1. Adjust switch to have 1/16 in (1.6 mm) clearance between switch and sensing plate on the lift arm.
Electrical System (Rev. A)
Page 5 -- 12
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.
2
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 designed to keep the PTO relay energized in this situation
to maintain cutting deck operation.
1
3
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, engage parking brake, and remove key
from the ignition switch.
GM 4700--D SHOWN
2. Remove console cover from machine.
3. Locate cutting deck lift/lower switch that requires
testing. Disconnect switch connector from machine wiring harness.
4
4. Check the continuity of the switch by connecting a
multimeter (ohms setting) across the switch connector
terminals.
3
2
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 in the lever. The switch should open before the lever
applies any pressure to the spool in the lift/lower control
valve.
Electrical
System
5
1
Figure 17
1. Lever support
2. Switch plate
3. Switch plate screw
4. Lift/lower switch
5. Thread forming 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
SWITCH
FROM PTO SWITCH
(PTO SWITCH ON)
(IN CENTER POSITION)
FRONT PTO
(DECKS 2, 3, 5)
FRONT DECK
POSITION
(DECK LOWERED)
FRONT DECK
POSITION
(DECK LOWERED)
FRONT PTO
(DECKS 1,4)
TO GROUND
Figure 18
Groundsmaster 4500--D/4700--D
Page 5 -- 13
Electrical System (Rev. A)
Ramp--up Module
The ramp--up module is located under the console cover
(Fig. 19).
1
The ramp--up module is used to prevent hydraulic
spikes that could affect cutting system hydraulic components. As the PTO relay for decks #1 to #5 is energized,
the ramp--up module provides a gradual, increasing current 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.
2
The ramp--up module can be monitored by the three
LED’s located on the module below the harness connection.
1. All module LED’s will be off when the PTO switch is
OFF.
Figure 19
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 immediately. The “S1” and “S2” LED’s will gradually illuminate 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 go 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
Hour Meter
The meter is located on the control console next to the
operator seat.
Hobbs
1. Connect the positive (+) terminal of a 12 VDC source
to the positive (+) terminal of the hour meter.
QUARTZ
00001
HOURS
2. Connect the negative (--) terminal of the voltage
source to the other terminal of the hour meter.
1
10
+
3. The hour meter should move a 1/10 of an hour in six
minutes.
4. Disconnect voltage source from the hour meter.
BACK
Figure 20
Glow Relay
Two styles of glow relays have been used on the
Groundsmaster 4500--D/4700--D. On machines with serial numbers below 260000600, two of the four relay
connections are secured with screws (Fig. 21). On machines 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 of the meter and test leads. Subtract this value 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).
86
87
85
30
87
85
30
86
Figure 21
86
87
30
85
85
A. On machines with serial numbers below
260000600, resistance should be from 41 to 51
ohms.
30
86
87
Figure 22
B. On machines with serial numbers above
260000600, resistance should be approximately 72
ohms.
2. Connect multimeter (ohms setting) leads to relay terminals 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.
Groundsmaster 4500--D/4700--D
Page 5 -- 15 Rev. D
Electrical System (Rev. A)
Electrical
System
The glow relay is attached to the battery support bracket. When energized, the glow relay allows electrical current to the engine glow plugs.
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.
1
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.
3
4
2
5
6
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 of the meter and test leads. Subtract this value from from the measured value of the component you
are testing.
7
8
9
Figure 23
1.
2.
3.
4.
5.
Control panel
K8 relay: seat
K9 relay: neutral (behind)
K7 relay: parking brake
K3 relay: GM4700 deck 7
6.
7.
8.
9.
K2 relay: decks 1 -- 5
K6 relay: high temp
K5 relay: start
K1 relay: GM4700 deck 6
1. Verify coil resistance between terminals 85 and 86
with a multimeter (ohms setting):
86
A. For the Tyco Electronics relay (#VF4--65F11), resistance should be from 71 to 88 ohms.
87A
87
86
B. For the Hella Electronics relay (#66211), resistance should be from 70 to 80 ohms.
2. Connect multimeter (ohms setting) leads to relay terminals 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.
87
87A
85
30
85
30
3. Disconnect voltage from terminal 85 and multimeter
lead from terminal 87.
4. Connect multimeter (ohms setting) leads to relay terminals 30 and 87A. Apply +12 VDC to terminal 85. The
relay should make and break continuity between terminals 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 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 solenoids can be done with the solenoid on the hydraulic
valve.
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 value from from the measured value of the component you
are testing.
2
2
1
3
1
Figure 25
1. Deck manifold (4500--D)
2. Valve solenoid
3. Solenoid connector
2
1. Make sure engine is off. Disconnect hydraulic valve
solenoid electrical connector (Fig. 25).
2
2. Apply 12VDC source directly to the solenoid. Listen
for solenoid to switch on.
3
3. Remove 12VDC source from the solenoid. Listen for
solenoid to switch off.
1
5. Install new solenoid if necessary.
Figure 26
A. Apply “Loctite 242” or equivalent to threads on
end of valve stem before installing nut.
1. Deck manifold (4700--D)
2. Valve solenoid
3. Solenoid connector
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 malfunction.
6. Reconnect electrical connector to the solenoid.
Groundsmaster 4500--D/4700--D
Page 5 -- 17
Electrical System (Rev. A)
Electrical
System
3
4. Measure resistance between the two connector terminals. The resistance for the solenoid coil should be
about 7.2 ohms.
Engine Run Solenoid
The engine run solenoid must be energized for the engine to run. The solenoid is mounted on the engine block
near the injection pump.
2
1
In Place Testing
3
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 value from from the measured value of the component you
are testing.
1. Disconnect the connector from the engine run solenoid.
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.
Figure 27
1. Engine run solenoid
2. Solenoid connector
3. Injection pump
2
3
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
4. Connect solenoid to the wiring harness.
1
Live Testing
1. Disconnect connector from the engine run solenoid.
NOTE: The solenoid may be removed from the engine
or tested in place.
Figure 28
1. Engine run solenoid
2. Red wire (hold coil)
3. White wire (pull coil)
4. Black wire (common)
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.
3. Connect a positive (+) test lead from 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 of 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 solenoid.
Electrical System (Rev. A)
Page 5 -- 18
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.
1
2
3
Fuel Pump Capacity Test
1. Park machine on a 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.
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 ignition switch ON. Allow pump to run for 30 seconds, then
release ignition switch to OFF.
Figure 29
1. Fuel pump
2. Fuel pre--filter
3. Pump discharge hose
Fuel Pump Specifications
Pump Capacity
Pressure
Max. Current
Draw
23.5 fl oz/min (695 ml/min)
3.3 psi (22.8 kPa)
0.9 amp
Electrical
System
3. Disconnect fuel pump discharge hose from the water
separator.
7. The amount of fuel collected in the graduated cylinder should be approximately 11.75 fl oz (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 solenoid.
10.Bleed the fuel system (see Traction Unit Operator’s
Manual).
Groundsmaster 4500--D/4700--D
Page 5 -- 19 Rev. D
Electrical System (Rev. A)
Glow Controller
The glow controller is located under the console cover.
2
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 position, the glow plugs will energize and the glow lamp will
not light.
2. Disconnect electrical connector to the run solenoid
to prevent the engine from starting.
2
5
1
4
3
Figure 30
1. Glow controller end view
2. Controller top view
1. Make sure there is power from the battery.
6
1
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
3
3. Controller side view
5. If any of the conditions in step 3 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 -- Electrical Schematics and Diagrams).
3. Place ignition switch in the ON position. Verify the following while in the ON position:
A. Glow indicator lamp is on.
B. Verify continuity of the circuitry from the battery to
ignition switch, glow controller, glow lamp, glow
relay, and ground (see Chapter 9 -- Electrical Schematics and Diagrams).
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:
C. Replace parts as necessary.
6. Connect electrical connector to the run solenoid.
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: If there is no power to terminal 1 of the glow controller, 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
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.
1
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).
2
CAUTION
Figure 31
1. Temperature sender
2. Alternator
NOTE: Prior to taking 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 of the meter and test leads. Subtract this value
from from the measured value of the component you are
testing.
3. Check resistance of the sender with a multimeter
(ohms setting) as the temperature increases.
VOA
Figure 32
A. The meter should indicate more than 600 ohms at
70oF (21oC).
B. The meter should indicate approximately 460
ohms at 100oF (38oC).
C. The meter should indicate from 54 to 78 ohms at
200oF (93oC).
D. Replace sender if specifications are not met.
4. Install sender to the water flange.
A. Clean threads of water flange and sender thoroughly. Apply thread sealant to the threads of the
sender.
B. Screw sender into the water flange. Torque sender from 16 to 20 ft--lb (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 Operator’s Manual).
Groundsmaster 4500--D/4700--D
Page 5 -- 21
Electrical System (Rev. A)
Electrical
System
Handle the hot oil with extreme care to prevent
personal injury or fire.
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
CAUTION
VARIABLE
RESISTANCE
Make sure the voltage source is turned OFF before connecting it to the electrical circuit to avoid
electrical shock and prevent damaging the
gauge.
14 VDC + 0.01 VDC
+
--
1. Connect temperature gauge to the variable resistance and DC voltage source (Fig. 33).
Figure 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 resistance setting, the needle must be pointed between
the two white dots.
1
2
4
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 (80oC).
3
B. Set variable resistance to 38 ohms. The needle
should point between the green and red area
(105oC).
3. Turn off the voltage source. Disconnect voltage
source, gauge, and variable resistance.
Figure 34
1. Middle position
2. High temp position
3. Edge of glass cover
4. Cold temp position
Temperature Gauge Check
The following procedure can be used to check the temperature gauge and the gauge circuit:
1
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 temperature sender. The gauge needle should move toward
the high temp position.
4. Reconnect wire to temperature sender.
Electrical System (Rev. A)
2
Figure 35
1. Temperature sender
Page 5 -- 22
2. Alternator
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 system are encountered, the following procedure can be
used to determine if the problem is related to the switch
or the switch circuit:
2
1. Start engine.
1
2. Use a jumper wire to ground the high temperature
shutdown switch terminal.
Figure 36
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.
1. High temperature shutdown switch
2. Glow plug connection
VOA
Shutdown Switch Test
Make sure engine is cool before removing the
temperature switch.
1. Lower coolant level in the engine and remove the
temperature shutdown switch.
Figure 37
6. Install switch to the water flange.
A. Clean threads of cylinder head and switch thoroughly. Apply thread sealant to the threads of the
switch.
2. Put switch in a container of oil with a thermometer
and slowly heat the oil (Fig. 37).
B. Screw switch into the cylinder head and tighten.
CAUTION
C. Connect blue/white wire to switch.
Handle the hot oil with extreme care to prevent
personal injury or fire.
7. Fill engine cooling system (see Traction Unit Operator’s Manual).
3. Check continuity of the switch with a multimeter
(ohms setting). The temperature switch is normally
open and should close between 225o to 235oF (107o to
113oC).
4. Allow oil to cool while observing temperature. The
temperature switch should open at about 219oF
(104oC).
5. Replace switch if necessary.
Groundsmaster 4500--D/4700--D
Page 5 -- 23
Electrical System (Rev. A)
Electrical
System
CAUTION
Traction Neutral Switch
The traction neutral switch is closed when the traction
pedal is in the 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.
1
2
Figure 38
1. Piston (traction) pump
2. Neutral switch
See Piston Pump Control Assembly in Chapter 4 -- Hydraulic Systems for disassembly and reassembly procedures 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--energized. The diodes plug into the wiring harness at various
locations (see Wire Harness Drawings in Chapter 9 -Electrical Diagrams).
2
3
Diode Test
1
The diodes (Fig. 39) can be individually tested using a
digital multimeter (diode test or ohms setting) and the
table to the right.
Electrical System (Rev. A)
Figure 39
1. Diode
2. Male terminal
3. Female terminal
Multimeter
Red Lead (+)
on Terminal
Multimeter
Black Lead (--)
on Terminal
Continuity
Female
Male
YES
Male
Female
NO
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.
H
G
D1--D
F
D1--A
D1--C
The diodes can be individually tested using a digital
multimeter (ohms setting) and the table to the right. If
any of the diodes are damaged, the diode circuit board
must be replaced.
D1--D
D1--C
D1--A
Diode Circuit Board Test
D1--B
E
D1--B
D
C
B
A
CIRCUIT BOARD
DIODE DIAGRAM
Groundsmaster 4500--D/4700--D
Red Lead (+)
on
Terminal
Black Lead (--)
on
Terminal
Continuity
H
A
YES
A
H
NO
G
B
YES
B
G
NO
F
C
YES
C
F
NO
E
D
YES
D
E
NO
Page 5 -- 25
Electrical System (Rev. A)
Electrical
System
Figure 40
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 electrical components required for safe operation. This Module is located under the console cover.
1
Inputs from the neutral, parking brake, PTO, start (ignition), 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.
2
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 operation of machine switches by monitoring the LED’s of
the module. If a Module LED does not illuminate (e.g. the
in seat input LED does not illuminate with the seat occupied 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 troubleshooting of the Standard Control Module.
Figure 41
1. Control panel
2. Standard control module
6
1
7
2
8
3
9
4
10
5
11
Figure 42
1.
2.
3.
4.
5.
Electrical System (Rev. A)
Page 5 -- 26
Power input LED
Start input LED
Engine run output LED
Start output LED
PTO output LED
6.
7.
8.
9.
10.
11.
Neutral input LED
Park brake off input LED
PTO switch input LED
In seat input LED
High temp input LED
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 Storage
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.
4. Store battery in a cool atmosphere to avoid quick deterioration of the battery charge.
5. To help prevent the battery from freezing, make sure
it is fully charged (see Battery Service).
3. Leave cables disconnected if the battery is stored on
the machine.
Battery Care
3. Battery cables must be tight on terminals to provide
good electrical contact.
WARNING
Connecting cables to the wrong post could result in personal injury and/or damage to the
electrical system.
WARNING
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. Unplug charger from electrical outlet before connecting or disconnecting charger leads to or
from battery posts.
IMPORTANT: Do not remove fill caps while cleaning.
4. If 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 water. Do not fill cells above the fill line.
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 solution 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 petroleum jelly to prevent corrosion.
Groundsmaster 4500--D/4700--D
Page 5 -- 27 Rev. D
Electrical System (Rev. A)
Electrical
System
1. Battery electrolyte level must be properly maintained. The top of the battery must be kept clean. lf the
machine is stored in a location where temperatures are
extremely high, the battery will run down more rapidly
than if the machine is stored in a location where temperatures are cool.
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.
3
CAUTION
When working with batteries, use extreme caution 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 batteries.
Electrolyte Specific Gravity
Fully charged: 1.265 corrected to 80oF (26.7oC)
Discharged: less than 1.240
Figure 43
1. Negative cable
2. Positive cable
Battery Specifications
BCI Group Size 24
650 CCA at 0o F (--17.8o C)
Reserve Capacity of 105 minutes at 80oF (26.7oC)
3. Battery strap
D. Check that the cover seal is not broken away. Replace the battery if the seal is broken or leaking.
E. Check the electrolyte level in each cell. If the level
is below the tops of the plates in any cell, fill all cells
with distilled water between the minimum and maximum fill lines. Charge at 15 to 25 amps for 15 minutes to allow sufficient mixing of the electrolyte.
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 be 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 repaired.
2. Conduct a hydrometer test of the battery electrolyte.
IMPORTANT: Make sure the area around the cells is
clean before opening the battery caps.
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
of the battery which might indicate a loose or missing
filler cap, overcharging, loose terminal post, or overfilling. Also, check battery case for dirt and oil. Clean
the battery with a solution of baking soda and water,
then rinse it with clean water.
Electrical System (Rev. A)
2
1
Page 5 -- 28
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 temperature of the cell.
B. Temperature correct each cell reading. For each
10oF (5.5oC) above 80oF (26.7oC) add 0.004 to the
specific gravity reading. For each 10oF (5.5oC) below 80oF (26.7oC) subtract 0.004 from the specific
gravity reading.
Example: Cell Temperature
100oF
Cell Gravity
1.245
100oF minus 80oF equals 20oF
(37.7oC minus 26.7oC equals 11.0oC)
20oF multiply by 0.004/10oF equals 0.008
(11oC multiply by 0.004/5.5oC equals 0.008)
ADD (conversion above)
0.008
Correction to 80oF (26.7oC)
1.253
Groundsmaster 4500--D/4700--D
H. Using the table below, determine the minimum
voltage for the cell temperature reading:
Minimum
Voltage
Battery Electrolyte
Temperature
9.6
70oF (and up)
21.1oC (and up)
9.5
60oF
15.6oC
9.4
50oF
10.0oC
3. Perform a high--discharge test with an adjustable
load tester.
9.3
40oF
4.4oC
9.1
30oF
--1.1oC
This is one of the most reliable means of testing a battery
as it simulates the cold--cranking test. A commercial battery load tester is required to perform this test.
8.9
20oF
--6.7oC
8.7
10oF
--12.2oC
8.5
0 oF
--17.8oC
I. If the test voltage is below the minimum, replace
the battery. If the test voltage is at or above the minimum, return the battery to service.
CAUTION
Follow the manufacturer’s instructions when using 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. If the battery has been charged, apply a 150 amp
load for 15 seconds to remove the surface charge.
Use a battery load tester following the manufacturer’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 terminals following the manufacturer’s instructions.
Connect a digital multimeter to the battery terminals.
F. Apply a test load of one half the Cranking Performance (see Battery Specifications) rating of the battery for 15 seconds.
G. Take a voltage reading at 15 seconds, then remove the load.
Groundsmaster 4500--D/4700--D
Charging
To minimize possible damage to the battery and allow
the battery to be fully charged, the slow charging method is presented here. This charging method can be accomplished with a constant current battery charger
which is available in most shops.
CAUTION
Follow the manufacturer’s instructions when using 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
Level
Specific
Gravity
Open Circuit
Voltage
100%
1.265
12.68
75%
1.225
12.45
50%
1.190
12.24
25%
1.155
12.06
0%
1.120
11.89
Page 5 -- 29
Electrical System (Rev. A)
Electrical
System
C. If the difference between 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 battery. Charge at the recommended rate and time given 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.
2. Determine the charging time and rate using the
manufacturer’s battery charger instructions or the
following table.
Battery
Reserve
Capacity
(Minutes)
3. Following the manufacturer’s instructions, connect the charger cables to the battery. Make sure a good
connection is made.
4. Charge the battery following the manufacturer’s
instructions.
Battery Charge Level
(Percent of Fully Charged)
75%
50%
25%
0%
80 or less
3.8 hrs
@
3 amps
7.5 hrs
@
3 amps
11.3 hrs
@
3 amps
15 hrs
@
3 amps
81 to 125
5.3 hrs
@
4 amps
10.5 hrs
@
4 amps
15.8 hrs
@
4 amps
21 hrs
@
4 amps
126 to
170
5.5 hrs
@
5 amps
11 hrs
@
5 amps
16.5 hrs
@
5 amps
22 hrs
@
5 amps
171 to
250
5.8 hrs
@
6 amps
11.5 hrs
@
6 amps
17.3 hrs
@
6 amps
23 hrs
@
6 amps
above
250
6 hrs
12 hrs
18 hrs
24 hrs
@
@
@
@
10 amps 10 amps 10 amps 10 amps
5. Occasionally check the temperature of the battery
electrolyte. If the temperature exceeds 125oF (51.6oC)
or the electrolyte is violently gassing or spewing, the
charging rate must be lowered or temporarily stopped.
6. Three hours prior to the end of the charging, measure 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.
CAUTION
Do not charge a frozen battery because it can explode and cause injury. Let the battery warm to
60oF (15.5o 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 electrical spark away from the battery. Do not smoke.
Nausea may result if the gases are inhaled. Unplug the charger from the electrical outlet before
connecting or disconnecting the charger leads
from the battery posts.
Electrical System (Rev. A)
Page 5 -- 30
Groundsmaster 4500--D/4700--D
Chapter 6
Axles, Planetaries, and Brakes
Table of Contents
Rear Axle Assembly . . . . . . . . . . . . . . . . . . . . . . . .
Bevel Gear Case and Axle Case . . . . . . . . . . . . .
Differential Shafts . . . . . . . . . . . . . . . . . . . . . . . . . .
Axle Shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Input Shaft/Pinion Gear . . . . . . . . . . . . . . . . . . . . .
Differential Gear . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pinion Gear to Ring Gear Engagement . . . . . . . .
12
14
18
19
20
22
25
Axles, Planetaries,
and Brakes
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SERVICE AND REPAIRS . . . . . . . . . . . . . . . . . . . . . . 4
Brake Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Brake Inspection and Repair . . . . . . . . . . . . . . . . . . 6
Planetary Wheel Drive Assembly . . . . . . . . . . . . . . 8
Planetary Wheel Drive Service . . . . . . . . . . . . . . . 10
Groundsmaster 4500--D/4700--D
Page 6 -- 1
Axles, Planetaries, and Brakes (Rev. B)
Specifications
Item
Specification
Wheel lug nut torque (front and rear)
85 to 100 ft--lb (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
mounting screw torque
75 to 85 ft--lb (101 to 115 N--m)
Rear wheel toe--in
.125 in (3.2 mm)
Tire pressure (front and rear)
20 psi (1.4 bar)
Planetary gear drive lubricant
Planetary gear lube capacity (each wheel)
SAE 85W--140 wt. gear lube
16 fl oz (.47 l)
Rear axle lubricant
Rear axle gear lube capacity
SAE 85W--140 wt. gear lube
80 fl oz (2.37 l)
Axles, Planetaries, and Brakes (Rev. B)
Page 6 -- 2
Groundsmaster 4500--D/4700--D
Adjustments
Axles, Planetaries,
and Brakes
See Traction Unit Operator’s Manual for adjustment
procedures for Groundsmaster 4500--D and Groundsmaster 4700--D axles, planetaries, and brakes.
Groundsmaster 4500--D/4700--D
Page 6 -- 3
Axles, Planetaries, and Brakes (Rev. B)
Service and Repairs
Brake Assembly
1
2
18
3
6
17
17
19
15
14
RIGHT
FRONT
1.
2.
3.
4.
5.
6.
7.
9
16
13
12
11
8
5
10
75 to 85 ft--lb
(101 to 115 N--m)
Flange head screw
Splined brake shaft
Planetary assembly
Tire and wheel assembly
Lug nut
Retaining ring
Spring plate
7
4
85 to 100 ft--lb
(115 to 135 N--m)
8.
9.
10.
11.
12.
13.
Axles, Planetaries, and Brakes (Rev. B)
Figure 1
Compression spring
Jam nut
LH Brake assembly
Flange head screw
Hex plug
Piston motor
Page 6 -- 4
14.
15.
16.
17.
18.
19.
Flat washer
Cap screw
O--ring
O--ring
RH brake assembly
Brake cable
Groundsmaster 4500--D/4700--D
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 wheel drive/brake assembly
(see Traction Unit Operator’s Manual).
CAUTION
When changing attachments, tires, or performing 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 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 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 machine with jack stands or solid wood blocks.
4. Remove wheel assembly.
3. Install flange head screws (11) to secure brake assembly to frame. Tighten screws in a crossing pattern to
a torque from 75 to 85 ft--lb (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).
WARNING
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--lb (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 assembly with SAE 85W--140 gear lube (see Traction Unit
Operator’s Manual).
9. Check and adjust brake cables for proper brake operation (see Traction Unit Operator’s Manual).
5. Remove hydraulic wheel motor (see Front Wheel
Motors in Service and Repairs section of Chapter 4 -Hydraulic System).
3
6. Disconnect brake cable from pull rod on brake.
2
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. Remove brake assembly.
1
Figure 2
1. Splined brake shaft step
2. Hydraulic motor end
3. Planetary assembly end
8. Remove splined brake shaft.
1
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).
2
3
1. Install splined brake shaft into brake assembly.
2. Install brake assembly onto frame, aligning splined
brake shaft with input shaft on planetary wheel drive.
Groundsmaster 4500--D/4700--D
Figure 3
1. Brake housing
2. Check plug
Page 6 -- 5
3. Drain plug
Axles, Planetaries, and Brakes (Rev. B)
Axles, Planetaries,
and Brakes
Remove Brake Assembly (Fig. 1)
Brake Inspection and Repair
3
2
1
4
5
6
7
8
9
15
14
10
13
12
1.
2.
3.
4.
5.
11
Brake housing (LH shown)
Seal
Pull rod
Clevis pin
Link
6.
7.
8.
9.
10.
Figure 4
Hitch pin
Stationary disc
Rotating disc
Retaining ring
Gasket
11.
12.
13.
14.
15.
Rotating actuator
Extension spring
Ball
Plug
O--ring
Brake Inspection and Repair (Fig. 4)
6. Remove seal (2) from brake housing.
1. Scrape gasket material (10) from brake housing and
planetary wheel drive mounting surfaces.
7. Wash parts in cleaning solvent. Inspect components
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).
4. Remove extension springs (12).
9. Use a new gasket (10) when installing brake assembly 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
Axles, Planetaries,
and Brakes
This page is intentionally blank.
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)
1
2
18
3
6
17
17
15
14
RIGHT
FRONT
1.
2.
3.
4.
5.
6.
9
16
13
12
11
8
5
10
75 to 85 ft--lb
(101 to 115 N--m)
Flange head screw
Splined brake shaft
Planetary assembly
Tire and wheel assembly
Lug nut
Retaining ring
7
4
85 to 100 ft--lb
(115 to 135 N--m)
7.
8.
9.
10.
11.
12.
Figure 5
Spring plate
Compression spring
Jam nut
LH Brake assembly
Flange head screw
Hex plug
13.
14.
15.
16.
17.
18.
Planetary Wheel Drive Removal
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 planetary wheel drive/brake assembly
(see Traction Unit Operator’s Manual).
Axles, Planetaries, and Brakes (Rev. B)
Piston motor
Flat washer
Cap screw
O--ring
O--ring
RH brake assembly
CAUTION
When changing attachments, tires, or performing 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 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 supported by blocks or
jack stands, the machine may move or fall,
which may result in personal injury.
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 machine with jack stands or solid wood blocks.
1
4. Remove front wheel assembly.
5. Remove flange head screws that secure brake assembly to planetary assembly (see Brake Assembly).
2
6. Support planetary assembly to prevent it from falling.
Loosen and remove flange head screws that secure
planetary assembly to frame. Remove planetary assembly from machine.
3
Planetary Wheel Drive Installation
Figure 6
1. Position planetary assembly to machine. Install
flange head screws that secure planetary assembly.
Torque screws from 75 to 85 ft--lb (101 to 115 N--m).
1. Brake housing
2. Check plug
3. Drain plug
2. Install brake assembly to planetary (see Brake Assembly).
WARNING
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--lb (115 to 135 N--m).
Axles, Planetaries,
and Brakes
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 assembly with SAE 85W--140 gear lube (see Traction Unit
Operator’s Manual). Capacity is approximately 16 oz.
(.47 l) per wheel.
6. Check and adjust brake cables for proper brake operation (see Traction Unit Operator’s Manual).
Groundsmaster 4500--D/4700--D
Page 6 -- 9
Axles, Planetaries, and Brakes (Rev. B)
Planetary Wheel Drive Service
3
118 to 144 in--lb
(13.3 to 16.3 N--m)
4
7
8
9
11
12
1
13
2
5
14
15
16
6
10
28
20
27
19
18
26
17
25
24
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
Spindle
Boot seal
Oil seal
Bearing cone
Bearing cup
Wheel stud
Socket head screw
Lock washer
Housing
Dowel pin
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
23
22
21
29
Figure 7
Bearing cup
Bearing cone
O--ring
Bearing shim
Snap ring
Ring gear
Retaining ring
Plug
End cap
O--ring
21.
22.
23.
24.
25.
26.
27.
28.
29.
Thrust plug
Thrust washer
Retaining ring
Primary gear
Drive shaft
Primary carrier
Secondary gear
Secondary carrier
O--ring
6. Remove socket head screws (7) and remove ring
gear (16).
Planetary Wheel Drive Disassembly (Figure 7)
1. Remove retaining ring (17).
7. Remove snap ring (15) and bearing shim (14).
2. Remove end cap (19) and o--ring (20).
3. Remove thrust plug (21) and thrust washer (22).
8. Use a puller to remove spindle (1) from housing (9).
Remove bearing cone (12).
4. Remove retaining ring (23), primary gear (24), and
drive shaft (25).
9. Remove and discard all seals.
5. Remove primary carrier (26), secondary gear (27),
and secondary carrier (28).
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).
NOTE: Steps 6 -- 10 are necessary only if inspecting or
replacing bearings and/or seals.
Axles, Planetaries, and Brakes (Rev. B)
Page 6 -- 10
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.
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).
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 housing (9) to spindle (1).
6. Press bearing cone (12) onto spindle and secure
with bearing shim (14) and snap ring (15).
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 examined for improper assembly or damaged components.
Axles, Planetaries,
and Brakes
7. Install o--ring (13), then secure ring gear (16) to
housing (9) with socket head screws (7) and lock washers (8). Torque screws from 118 to 144 in--lb (13.3 to
16.3 N--m).
Groundsmaster 4500--D/4700--D
Page 6 -- 11
Axles, Planetaries, and Brakes (Rev. B)
Rear Axle Assembly
6
7
70 ft--lb (94 N--m) maximum
8
1
3
5
4
2
16
15
14
13 12
11
10
9
24
22
23
17
5
RIGHT
21
20
85 to 100 ft--lb
(115 to 135 N--m)
19
FRONT
18
Figure 8
1.
2.
3.
4.
5.
6.
7.
8.
Steering cylinder
Needle bearing
External snap ring
External snap ring
Thrust washer
Flat washer
Lock nut
Grease fitting
9.
10.
11.
12.
13.
14.
15.
16.
Cap screw
Flat washer
Piston motor
O--ring
Pinion gear
Gear
Cap screw
Lock washer
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 Traction Unit Operator’s Manual).
CAUTION
Tire and wheel assembly
Lug nut
Hex plug
O--ring
Drive axle assembly
Axle pivot pin
Stop pin
Hydraulic fitting
3. Chock front wheels and jack up rear of machine (see
Jacking Instructions in Chapter 1 -- Safety). Support machine 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 Chapter 4 -- Hydraulic System).
6. Remove hydraulic hoses from steering cylinder.
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 machine may move or fall, which may result in personal injury.
Axles, Planetaries, and Brakes (Rev. B)
17.
18.
19.
20.
21.
22.
23.
24.
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.
Page 6 -- 12
Groundsmaster 4500--D/4700--D
10.If needed for further axle disassembly, remove steering cylinder from axle (see Steering Cylinder in Service
and Repairs section of Chapter 4 -- Hydraulic System).
11. If 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. Inspect the pin and bushings for wear or damage. Replace
components as necessary.
9. Fill axle with SAE 85W--140 weight gear lube (see
Traction Unit Operator’s Manual).
10.Check rear wheel toe--in and adjust if 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.
Install Rear Axle
4
2
3
5
1. If removed, install steering cylinder to axle assembly
(see Steering Cylinder in Service and Repairs section of
Chapter 4 -- Hydraulic System).
1
2. If removed, install the tie rod to rear axle (Fig. 9).
Tighten ball joint castle nuts and install new cotter pins.
6
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.
Figure 9
1. Tie rod
2. Dust cover
3. Cotter pin
4. Castle nut
5. Tie rod end
6. Steering arm (LH)
6. Install hydraulic motor to axle assembly (see Rear
Axle Motor in Service and Repairs section of Chapter 4
-- Hydraulic System).
1
7. Install hydraulic hoses to steering cylinder and input
gear case.
2
WARNING
Failure to maintain proper wheel lug nut
torque could result in failure or loss of wheel
and may result in personal injury.
Figure 10
1. Steering stop bolt
2. Bevel gear case (LH)
8. Install wheels to axle. Torque wheel lug nuts from 85
to 100 ft--lb (115 to 135 N--m). Lower machine to ground.
Groundsmaster 4500--D/4700--D
Page 6 -- 13
Axles, Planetaries, and Brakes (Rev. B)
Axles, Planetaries,
and Brakes
5. Install flat washer and lock nut onto pivot pin. Lock
nut should be tightened enough to allow pivot pin to rotate (70 ft--lb (94 N--m) maximum).
Bevel Gear Case and Axle Case
The following procedures assume the rear axle assembly has been removed from the machine.
35 to 41 ft--lb
(47 to 56 N--m)
Removal
1
1. Remove the mounting screws, nuts, and lock washers. Remove the bevel gear case/axle case assembly
and O-ring from the axle support (Fig. 11).
4
6
5
2
2. Mark both right and left bevel gear case/axle case
assemblies.
3
35 to 41 ft--lb
(47 to 56 N--m)
IMPORTANT: Do not interchange right and left
bevel gear case/axle case assemblies.
1.
2.
3.
4.
Cap screw
Lock nut
Lock washer
Axle support
Figure 11
5. Bevel gear case/axle
case assembly
6. O-ring
3. Remove the axle cover mounting screws. Remove
the axle cover from the axle case as an assembly
(Fig. 12).
17 to 20 ft--lb
(23 to 27 N--m)
1
4
3
2
Figure 12
1. Axle case
2. Axle cover assembly
4. Remove the axle case support mounting screws, the
axle case support, and the support shims (Fig. 13).
3. Mounting screw
4. O-ring
Thread--locking
Compound
3
2
57 to 67 ft--lb
(77 to 91 N--m)
4
1
1. Axle case
2. Axle case support
Axles, Planetaries, and Brakes (Rev. B)
Page 6 -- 14
Figure 13
3. Mounting screw
4. Support shim
Groundsmaster 4500--D/4700--D
5. Remove the knuckle pin mounting screws and the
knuckle pin. Remove the gasket and any remaining gasket material from either mating surface (Fig. 14).
6. While holding the bevel gear case, tap the upper end
of the bevel gear shaft out of the upper bearing and upper bevel gear.
2
1
17 to 20 ft--lb
(23 to 27 N--m)
3
4
Thread--locking
Compound
7. Pull the bevel gear case from the axle case and remove the upper bevel gear, and collar from the gear
case.
5
8. Remove the axle case cover screws, cover, and the
O-ring from the axle case.
14
7
15
8
9. Remove the plug and sealing washer from the center
of the axle case cover. While holding the axle case cover, lightly tap the lower end of the bevel gear shaft out of
the lower bearing and lower bevel gear.
11
6
10.Remove and discard bevel gear shaft seal from axle
case (Fig. 14).
13
9
12
10
17 to 20 ft--lb
(23 to 27 N--m)
Knuckle pin
Mounting screw
O--ring
Bevel gear case
Upper bearing
Bevel gear shaft
Collar
Upper bevel gear
Figure 14
9.
10.
11.
12.
13.
14.
15.
Lower bevel gear
Lower bearing
Axle case
Axle case cover
O-ring
Shaft seal
Bushing
Axles, Planetaries,
and Brakes
1.
2.
3.
4.
5.
6.
7.
8.
Inspection
1. Measure the knuckle pin O.D. and the axle case support bushing I.D. to determine the bushing to pin clearance (Fig. 15). Replace components as necessary.
1
2
BUSHING TO 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 I.D.
(Factory Spec.):
0.984 to 0.987 in. (25.00 to 25.08 mm)
2. Inspect all gears, shafts, bearings, cases, and covers for damage and wear. Replace components as necessary.
Groundsmaster 4500--D/4700--D
1. Knuckle pin
Page 6 -- 15
Figure 15
2. Axle case support
Axles, Planetaries, and Brakes (Rev. B)
Installation
1. Coat new shaft seal with grease and install in axle
case as shown (Fig. 16).
3
2
1
1. Axle case
2. Bevel gear case
2. Install the lower bevel gear, and bevel gear shaft in
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 N--m).
Figure 16
3. Shaft seal
7
8
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).
6
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).
5
3
2
1
4
1.
2.
3.
4.
Axles, Planetaries, and Brakes (Rev. B)
Page 6 -- 16
Axle case cover
Lower bevel gear
Bevel gear shaft
Lower bearing
Figure 17
5.
6.
7.
8.
Upper bevel gear
Collar
Upper bearing
Knuckle pin
Groundsmaster 4500--D/4700--D
5. Determine necessary quantity of support shims.
4
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 clearance (vertical endplay) between axle case support
and knuckle pin. If binding of components is noted
before screws are fully tightened, add additional support shims. Torque screws from 57 to 67 ft--lb (77 to
91 N--m).
C. Use dial indicator to measure vertical endplay of
axle case (Fig. 18).
AXLE CASE ASSEMBLY ENDPLAY:
0.001 to 0.008 in. (0.02 to 0.20 mm)
57 to 67 ft--lb
(77 to 91 N--m)
1
VERTICAL
ENDPLAY
6
5
2
3
1. Axle case support
2. Axle case
3. Bevel gearcase
3
D. Adjust endplay by increasing or reducing number
of axle case support shims.
Figure 18
4. Dial indicator
5. Knuckle pin
6. Support shim location
2
1
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.
4
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).
7. Temporarily install the bevel gear case/axle case assembly on the axle support. Position a dial indicator at
the tooths center. Prevent the axle from turning and
measure the upper bevel gear to differential shaft gear
backlash (Fig. 19).
Figure 19
1. Axle support
2. Upper bevel gear
3. Differential shaft gear
UPPER BEVEL GEAR BACKLASH:
0.004 to 0.016 in. (0.10 to 0.40 mm)
4. Dial indicator
5. Axle bearing shims
4
5
1
8. Adjust backlash by increasing or reducing axle bearing 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.
2
3
Figure 20
1. Axle cover assembly
2. Lower bevel gear
3. Axle gear
Groundsmaster 4500--D/4700--D
Page 6 -- 17
4. Dial indicator
5. Axle bearing shims
Axles, Planetaries, and Brakes (Rev. B)
Axles, Planetaries,
and Brakes
5
IMPORTANT: Correct engagement between bevel
gears is critical to axle performance and durability.
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 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 bearing shim thickness (see Axle Shafts in this section of this
manual).
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).
Differential Shafts
The following procedures assume the rear axle assembly has been removed from the machine.
35 to 41 ft--lb
(47 to 56 N--m)
Removal
1
IMPORTANT: Do not interchange right and left differential shaft assemblies.
1. Remove the mounting screws, nuts, and lock washers. Remove the bevel gear case/axle case assembly
and O-ring from the axle support (Fig. 21).
4
4. Drive the differential shaft out of the bearings. Remove the bearings and bearing shims.
5
2
3
7
35 to 41 ft--lb
(47 to 56 N--m)
2. Mark and pull the differential shaft assembly from the
axle support.
3. Remove the retaining ring and bevel gear (Fig 22).
6
1.
2.
3.
4.
Cap screw
Lock nut
Lock washer
Axle support
Figure 21
5. Bevel gear/axle case
assembly
6. O-ring
7. Stud
5. Inspect all gears, shafts, bearings, and cases for
damage and wear. Replace components as necessary.
Installation
1. Press bearings onto differential shaft. Place correct
combination of bearing shims in axle support and drive
differential shaft and bearing assembly into axle support.
6
3
5
4
2. Install bevel gear and retaining ring.
2
1
3. Coat new O-ring with grease. Align differential shaft
splines with differential gear assembly and slide differential shaft assembly onto axle support.
4. Install bevel gear case/axle case assembly (see
Bevel Gear Case/Axle Case Assembly in this section of
this manual).
Axles, Planetaries, and Brakes (Rev. B)
1. Retaining ring
2. Bevel gear
3. Differential shaft
Page 6 -- 18
Figure 22
4. Bearing
5. Bearing shims
6. O-ring
Groundsmaster 4500--D/4700--D
Axle Shafts
The following procedures assume the rear axle assembly has been removed from the machine.
17 to 20 ft--lb
(23 to 27 N--m)
1
Removal
4
3
1. Remove the axle cover mounting screws. Remove
the axle cover from the axle case as an assembly
(Fig. 23).
2. Use a bearing 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 discard the axle shaft seal.
4. Inspect all gears, shafts, bearings, spacers, and
cases for damage and wear. Replace components as
necessary.
2
Figure 23
1. Axle case
2. Axle cover assembly
3. Mounting screw
4. O-ring
Installation
1
1. Coat new axle shaft seal with grease and install in
axle cover as shown (Fig. 25).
2
2. Press the axle cover and bearing assembly onto the
axle shaft. Press only on the inner race of the cover
bearing (Fig. 25).
4
3
5
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).
1. Bearing
2. Bevel gear
3. Shims
Figure 24
4. Spacer
5. Retaining ring
1
4
2
3
1. Axle shaft seal
2. Axle cover
Groundsmaster 4500--D/4700--D
Page 6 -- 19
Figure 25
3. Bearing
4. Axle shaft
Axles, Planetaries, and Brakes (Rev. B)
Axles, Planetaries,
and Brakes
3. Install retaining ring, spacer, and correct combination of bearing shims. Install bevel gear and bearing.
Input Shaft/Pinion Gear
1
35 to 41 ft--lb
(47 to 56 N--m)
9
7
8
6
5
3
2
18
17
4
18
15
10
9
16
14
10
13
11
35 to 41 ft--lb
(47 to 56 N--m)
12
Figure 26
1.
2.
3.
4.
5.
6.
Nut
Lockwasher
Stud
Locknut
Stake washer
Oil seal
7.
8.
9.
10.
11.
12.
O-ring
Seal collar
Bearing
O-ring
Input shaft/Pinion gear
Bearing case
13.
14.
15.
16.
17.
18.
Shim
Screw
Gear case
Gasket
Cover plate
Dowel pin
The following procedures assume the rear axle assembly has been removed from the machine.
NOTE: Replacement input shaft/pinion gear (11) is only
available in matched set with differential ring gear.
Removal
Installation
1. Remove the cover plate, gasket, and gear case assembly from the axle assembly. Remove the gasket and
any remaining gasket material.
NOTE: When installing bearing cones onto the input
shaft/pinion gear, press only on the inner race of the
bearing cone.
2. Remove the retaining rings and the driven gear from
the input shaft/pinion gear.
1. If the inner bearing cone was removed, press a new
bearing cone all the way onto the input shaft/pinion gear.
3. Remove input shaft/pinion gear assembly from the
gear case. Remove the shims and bearing case Orings.
2. Place the shaft and bearing assembly in the bearing
case and install the outer bearing cone.
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)
NOTE: The bearings must be completely seated.
There should be no input shaft/pinion gear end play.
3. Coat a 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.
Page 6 -- 20
Groundsmaster 4500--D/4700--D
6. Set the bearing preload by securing the bearing case
in a vise. Thread a M12 x 1.5 hex head cap screw into
the splined end of the input shaft/pinion gear and slowly
tighten the locknut until 4 to 6 in-lb (0.4 to 0.7 N--m) of
force is required to rotate the input shaft/pinion gear in
the bearing case.
0.04 in. (1.0 mm)
7. Secure the lock nut with the stake washer.
2
1
8. Use a depth gauge to measure the distance from the
end face of the input shaft/pinion gear to the mating surface of the bearing case. Subtract the “Design Cone
Center Distance” 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)
3
1. Oil seal
2. Bearing case
Figure 27
3. Seal garter spring
NOTE: Bearing case shims are available in 0.004 in.
(0.1 mm) and 0.008 in. (0.2 mm) thickness.
9. Coat new 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-lb (47
to 56 N--m).
Design
Cone Center
Distance
1
10.Insert a screwdriver through the drain plug hole to
hold ring gear and measure the pinion gear to ring gear
backlash (Fig. 29).
2
11. Adjust backlash by increasing or reducing gear case
shim thickness.
Axles, Planetaries,
and Brakes
PINION GEAR TO RING GEAR BACKLASH:
0.004 to 0.016 in. (0.10 to 0.40 mm)
Figure 28
1. Input shaft/pinion gear
2. Bearing case
12.Check pinion gear to ring gear engagement (see Pinion Gear to Ring Gear Engagement in this section of this
manual).
1
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.
3
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
2
4
1. Axle case
2. Screwdriver
Page 6 -- 21
Figure 29
3. Dial indicator
4. Input shaft/pinion gear
Axles, Planetaries, and Brakes (Rev. B)
Differential Gear
The following procedures assume the rear axle assembly has been removed from the machine.
35 to 41 ft--lb
(47 to 56 N--m)
5
Removal
1
2
6
1. Remove bevel gear case/axle case assemblies (see
Bevel Gear Case/Axle Case Assembly in this section of
this manual).
IMPORTANT: Do not interchange right and left differential shafts assemblies.
7
4
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.
3
35 to 41 ft--lb
(47 to 56 N--m)
1.
2.
3.
4.
Gear Case
Pinion Gear
Axle support (left)
Axle support (right)
Figure 30
5. Case screw
6. Differential gear
7. O-ring
5. Remove the differential gear assembly, bearings,
and adjusting shims from the axle case.
2
6. Drive the spring pin from the differential case with a
punch and hammer. Discard the spring pin (Fig. 31).
1
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.
Figure 31
1. Differential case
2. Spring pin
1
3
2
5
22 to 25 ft--lb
(30 to 34 N--m)
Thread--locking
Compound
7
1.
2.
3.
4.
Axles, Planetaries, and Brakes (Rev. B)
Page 6 -- 22
4
2
4
5
3
6
Figure 32
Differential pinion shaft
Pinion gear
Pinion washer
Side gear
5. Side gear shims
6. Ring gear
7. Differential case
Groundsmaster 4500--D/4700--D
Inspection
1. Measure the differential side gear O.D. and the differential case I.D. 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)
1
SIDE GEAR O.D. (Factory Spec.):
1.335 to 1.337 in. (33.91 to 33.95 mm)
DIFFERENTIAL CASE I.D. (Factory Spec.):
1.339 to 1.341 in. (34.00 to 34.06 mm)
2
2. Measure the differential pinion shaft O.D. and the
pinion gear I.D. to determine the pinion shaft to pinion
gear clearance (Fig. 34). Replace components as necessary.
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)
1. Side gear
PINION GEAR I.D. (Factory Spec.):
0.551 to 0.552 in. (13.10 to 14.02 mm)
Figure 33
2. Differential case
Axles, Planetaries,
and Brakes
3. Inspect all gears, shafts, bearings, cases, and covers for damage and wear. Replace components as necessary.
1
2
1. Pinion shaft
Groundsmaster 4500--D/4700--D
Page 6 -- 23
Figure 34
2. Pinion gear
Axles, Planetaries, and Brakes (Rev. B)
Installation
3
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
1
2. Apply molybdenum 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 washers in their original location in the differential case. Temporarily install the differential pinion shaft.
Figure 35
1. Vise
2. Differential gear case
3. Dial indicator
More than 35% total tooth contact
5. Secure the differential case in a soft jawed vise. Position a dial indicator on a tooth of the differential pinion
gear. Press the pinion and side gear against the differential case and measure the pinion gear to side gear backlash (Fig. 35).
PINION GEAR TO SIDE GEAR BACKLASH:
0.004 to 0.016 in. (0.10 to 0.40 mm)
1/3 to 1/2 of entire width
from small end of tooth
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) thickness.
7. Apply gear marking compound, such as DyKemR
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 differential pinion gear to side gear
backlash if any changes are made.
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-lb (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 differential 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).
11. After backlash and tooth contact have been adjusted, 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
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 following procedure.
PROFILE
TOP LAND
GEAR TOOTH DEFINITIONS (Fig. 37):
Toe -- the portion of the tooth surface at the end towards the center.
TOE
HEEL
Heel -- the portion of the gear tooth at the outer end.
LENGTHWISE
BEARING
ARC
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 DyKemR
Steel Blue.
ROOT
Figure 37
2. Install the input shaft/pinion gear assembly into axle
case.
More than 35% 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 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 end (Fig. 38).
1/3 to 1/2 of entire width
from small end of tooth
4
Axles, Planetaries,
and Brakes
Figure 38
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 bearing shims) (Fig. 39).
3
NOTE: Bearing case shims are available in 0.004 in.
(0.10 mm) and 0.008 in. (0.20 mm) thickness.
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.
Study the different contact patterns (Figs. 40 and 41)
and correct gear engagement as necessary.
2
NOTE: When making changes, note that two variables
are involved (see Gear Pattern Movement Summary in
this section of this manual).
Example: If the pinion gear to ring gear backlash is set
correctly to specifications and the bearing case shim is
changed to adjust tooth contact, it may be necessary to
readjust backlash to the correct specification before
checking the contact pattern.
Groundsmaster 4500--D/4700--D
1
Figure 39
1. Input shaft/pinion gear
2. Bearing case shims
3. Differential gear case
Page 6 -- 25
4. Differential bearing
shims
Axles, Planetaries, and Brakes (Rev. B)
Gear Pattern Movement Summary
Heel Contact
Base Contact
Every gear has a characteristic pattern. The illustrations
show typical patterns only and explain how patterns shift
as gear location is changed.
1. If contact is toward the heel or base of the gear (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.
C. Repeat until proper tooth contact and pinion gear
to ring gear backlash are correct.
Toe Contact
Tip Contact
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, Planetaries, and Brakes (Rev. B)
Page 6 -- 26
Groundsmaster 4500--D/4700--D
Chapter 7
Chassis
Table of Contents
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . .
Cutting Deck Identification . . . . . . . . . . . . . . . . . . . .
SERVICE AND REPAIRS . . . . . . . . . . . . . . . . . . . . . .
Steering Tower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lift Arms For Cutting Decks #1, #4, and #5 . . . . .
1
1
2
2
4
Lift Arms For Cutting Decks #2 and #3 . . . . . . . . . 6
Lift Arms For Cutting Decks #6 and #7
(Groundsmaster 4700--D only) . . . . . . . . . . . . . . 8
Hood . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
General Information
Cutting Deck Identification
Cutting decks on the Groundsmaster 4500--D and
4700--D are identified as shown in Figure 1.
#4 Deck
#6 Deck
(GM4700)
#1 Deck
#2
Deck
#5 Deck
#3
Deck
#7 Deck
(GM4700)
Chassis
CUTTING DECK LOCATIONS
Figure 1
Groundsmaster 4500--D/4700--D
Page 7 -- 1
Chassis
Service and Repairs
Steering Tower
20 to 26 ft--lb
(28 to 35 N--m)
1
20
21
22 19 18 45 44
2
3
23
5
4
24
25
26
6
11
7
31
27
29
8
48
47
46
9
10
28
11
30
13
42
41
32
24
RIGHT
33
34
35
FRONT
38
15
39
40
43
14
13
12
16
34
17
36 37
Figure 2
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
Steering wheel cover
Hex nut
Steering wheel
Parking brake knob
Dust cover
Flange head screw
Friction disc
Spring pin
Cotter pin
Cable
Flat washer
Lock nut
Spring washer
Tube
Lever bracket
Steering column
Chassis
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
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
33.
34.
35.
36.
37.
38.
39.
40.
41.
42.
43.
44.
45.
46.
47.
48.
Cotter pin
Flat washer
Parking brake rack
Hydraulic fitting
O--ring
O--ring
Switch plate
Carriage bolt
Flat washer
Lock nut
Parking brake proximity switch
Screw
Flat washer
Lock washer
Nut
Ignition key
Groundsmaster 4500--D/4700--D
Disassembly
Assembly
1. Park machine on a level surface, lower cutting units,
stop engine, engage parking brake, and remove key
from the ignition switch.
1. Assemble steering tower using Figure 2 as a guide.
Chassis
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
30
38
6
37
5
4
3
2 1
7
8
9
36
10
32
2
13
15 14
34
33
5
RIGHT
11
12
32
10
4
14
16
35
17
31
FRONT
19
32
29
28
25
18
26
27
19
24
23
22 21
16
20
Figure 3
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
Lock nut
Flange nut
Lift arm (#1 deck)
Lift cylinder pin
Flange head screw
Hydraulic fitting
Cap screw
Lift cylinder (#4 and #5 decks)
Lift cylinder (#1 deck)
Thrust washer
Lock nut
Pivot pin
Slotted roll pin
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
Lift cylinder pin
Flange nut
Washer head screw
Skid plate
Lift arm (#4 deck)
Cap screw
Carrier frame shaft
Lynch pin
Thrust washer
Carriage bolt
Switch bracket
Proximity switch
Proximity switch plate
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 cutting deck from lift arm (see Cutting Unit
Operator’s Manual).
Chassis
27.
28.
29.
30.
31.
32.
33.
34.
35.
36.
37.
38.
Lock nut
Bumper support bracket
Bumper
Lift arm (#5 deck)
Lock nut
Flange bushing
Front carrier frame
Grease fitting
Deck carrier frame
Grease fitting
O--ring
O--ring
3. If lift arm for either deck #4 or #5 (Fig. 4) is to be removed, tag and remove hydraulic hoses from the deck
motor (Fig. 5). Slide hoses out of the hose retaining loop
on the lift arm.
4. Remove lift cylinder pin that secures lift cylinder to lift
arm.
5. Loosen and remove lock nut from lift arm pivot pin.
Page 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.
#4 Deck
#1 Deck
#5 Deck
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
#6 Deck
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.
(GM4700)
#2
Deck
#3
Deck
#7 Deck
(GM4700)
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.
CUTTING DECK LOCATIONS
Figure 4
NOTE: Install thrust washer on deck pivot shaft before
installing cutting deck on pivot shaft.
1
4. Position and install cutting deck to lift arm (see Cutting Unit Operator’s Manual).
5. If lift 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.
4
3
2
6. Lubricate lift arm and lift cylinder grease fittings after
assembly is complete (see Traction Unit Operator’s
Manual).
Figure 5
1. Pressure “in” hose
2. Pressure “out” hose
3. Case drain hose
4. Hose retaining loop
Chassis
7. 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 -- 5
Chassis
Lift Arms for Cutting Decks #2 and #3
5
29
3
4
1
2
20
19
30
15
17
16
18
15
29
14
21
RIGHT
31
29
25
30
FRONT
6
Thread--locking
Compound
7
10
8
24
13
28
27
11
26
23
13
22
12
9
Figure 6
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
Flange nut
Bulkhead bracket
Hydraulic t--fitting
Flange head screw
Lock nut
Slotted roll pin
Pivot pin
Bumper
Thrust washer
Rebound washer
Deck pivot shaft
Chassis
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
Lift arm (#2 deck shown)
Flange bushing
Flange nut
Retaining ring
Lift cylinder
Grease fitting
Lock nut
Hydraulic fitting
Lift cylinder pin
Thrust washer
Page 7 -- 6
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
Flange head screw
Lift cylinder pin
Cap screw
Hydraulic fitting
Cap screw
Lift arm rotation stop
Set screw
O--ring
O--ring
Grease fitting
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.
#4 Deck
#1 Deck
#5 Deck
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.
#6 Deck
(GM4700)
4. Loosen and remove lock nut from pivot pin.
#2
Deck
#3
Deck
#7 Deck
(GM4700)
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
bushings and pivot pin for damage or wear.
Figure 7
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 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 Cutting Unit Operator’s Manual).
Chassis
NOTE: The lift arms for cutting decks #2 and #3 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 strength thread--locking compound (e.g. Loctite blue) to set screws and retighten 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)
1
2
3
41
34
4
40
6
5
4
27
1
31
6
33
7
8
9
10
30
37
36
34
32
14
13
1
11
12
39
15
20
19
18
17
16
39
RIGHT
FRONT
1
27
38
28
35
22
21
10 23
15 29
24
25
26
42
Figure 8
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
Retaining ring
Flat washer
Cap screw
Hydraulic fitting
Lift cylinder
Plastic roller
Lock nut
Grease fitting
Rear link
Lift link
Carriage screw
Neutral switch plate
Switch bracket
Carriage bolt
Chassis
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
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
Page 7 -- 8
29.
30.
31.
32.
33.
34.
35.
36.
37.
38.
39.
40.
41.
42.
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
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.
#4 Deck
#1 Deck
#5 Deck
2. Remove cutting deck from lift arm (see Cutting Unit
Operator’s Manual).
3. Remove pin that secures lift links (10) to lift arm.
#6 Deck
4. Loosen and remove lock nut from pivot pin.
(GM4700)
#2
Deck
#3
Deck
#7 Deck
(GM4700)
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.
7. Clean lift arm and pivot pin. Inspect lift arm flange
bushings and pivot pin for damage or wear.
CUTTING DECK LOCATIONS
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 in pivot pin with slot in support arm 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 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 Cutting Unit Operator’s Manual).
Chassis
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 -- 9
Chassis
Hood
8
6
32
2
1
31
48
49
9
7
9
10
13
11
3
4
51
5
18
17
16
14
10
15
44
46
12
19
21
20 50
22
23
24
25
26
27
46
47
28
45
29
30
17
13
37
36
RIGHT
38
39
40
41
42
FRONT
43
35
34
33
22
Figure 10
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
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
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
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
35.
36.
37.
38.
39.
40.
41.
42.
43.
44.
45.
46.
47.
48.
49.
50.
51.
Hood receiver retainer
Spring washer
Hood receiver spacer
Axle stop
Flat washer
Hood latch
Pop rivet
Cap screw
Cap screw
Draw latch
Hood lock pin
Pop rivet
Latch plate
Foam seal
Foam seal
Foam seal
Pop rivet
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.
1
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).
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).
Figure 11
1.
3. Check hood alignment for correct operation of hood
latches and dust seals.
Hood latch
1
2
Figure 12
2. Lanyard
Chassis
1. Hood lock pin
Groundsmaster 4500--D/4700--D
Page 7 -- 11
Chassis
This page is intentionally blank.
Chassis
Page 7 -- 12
Groundsmaster 4500--D/4700--D
Chapter 8
Cutting Units
Table of Contents
2
3
3
4
5
5
6
SERVICE AND REPAIRS . . . . . . . . . . . . . . . . . . . . . . 8
Blade Spindle Assembly . . . . . . . . . . . . . . . . . . . . . 8
Blade Spindle Service . . . . . . . . . . . . . . . . . . . . . . 10
Rear Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Rear Roller Service (Non--Greasable Bearings) 13
Rear Roller Service (Greasable Bearings with
Retaining Ring) . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Rear Roller Service (Greasable Bearings with
Bearing Nut) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Front Roller Service . . . . . . . . . . . . . . . . . . . . . . . . 18
Cutting Deck Carrier Frame . . . . . . . . . . . . . . . . . . 20
Cutting Units
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
Page 8 -- 1
Rev. D
Cutting Units (Rev. B)
Specifications
MOUNTING: All cutting units are supported by independent 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 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 adjustment 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.
DISCHARGE: Clippings are discharged from the rear of
the mowing decks. Pre--drilled mounting holes allow attachment of optional mulching baffle.
CUTTING UNIT LIFT: Cutting units on the Groundsmaster 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 supported with two front rollers and one, full width, rear roller.
WEIGHT: Complete cutting unit weighs 190 lb (86 kg).
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 standard blade is not ideal.
Cutting Units (Rev. B)
Page 8 -- 2
Groundsmaster 4500--D/4700--D
Troubleshooting
There are a number of factors that can contribute to unsatisfactory quality of cut, some of which may be turf
conditions. Turf conditions such as excessive thatch,
“sponginess”, uneven ground conditions, or attempting
to cut off too much grass height may not always be overcome by adjusting the machine. It is important to remember that the lower the height--of--cut, the more
critical these factors are.
Remember that the “effective” or actual height--of--cut
depends on cutting unit weight, counterbalance setting,
and turf conditions. Effective height--of--cut will be different than the bench set height--of--cut.
Factors That Can Affect Quality of Cut
Factor
Possible Problem/Correction
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 the same
height--of--cut. Adjust cutting units as specified in the
Cutting Unit Operator’s Manual.
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.
All rollers should rotate freely. Replace bearings if worn
or damaged.
9. Grass Conditions.
Mow when grass is dry for best cutting results.
Groundsmaster 4500--D/4700--D
Page 8 -- 3
Cutting Units (Rev. B)
Cutting Units
Adjust height--of--cut setting to remove only 1 inch (2.5
cm) or 1/3 of the grass blade when cutting.
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
TOR4065
TOR4066
TOR4067
TOR4068
TOR4869
TOR4071
TOR4072
TOR4073
TOR4074
Spanner Wrench
Inner Oil Seal Installer
Bearing Installer
Shaft Support Tool
Inner Seal Installer
Outer Seal Installer
Outer Oil Seal Installer
Shaft Seal Protector
Handle
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 rear
roller that has greasable bearings and a bearing lock nut
used to retain the bearings.
Bearing Installation
Washer
115--0852 Inner Seal Tool
115--0853 Bearing/Outer Seal Tool
107--8133 Bearing Installation Washer
Bearing/Outer Seal
Tool
Inner Seal
Tool
Figure 3
Cutting Units (Rev. B)
Page 8 -- 4
Rev. D
Groundsmaster 4500--D/4700--D
Adjustments
CAUTION
Never install or work on the cutting units or lift
arms with the engine running. Always stop engine 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 a complete
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.
Cutting Units
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.
Groundsmaster 4500--D/4700--D
Page 8 -- 5
Cutting Units (Rev. B)
Blade Plane Inspection and Adjustment
If a solid 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 cutting 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.
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.
7. Adjust right and/or left height--of--cut brackets by repeating 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).
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.
FRONT OF DECK
12 o’clock
9 o’clock
3 o’clock
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.
6 o’clock
REAR OF DECK
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.
Figure 1
3. Install height--of--cut bracket to deck frame with remaining shims assembled below the height--of--cut
bracket.
1
NOTE: Socket head bolt and spacer for front bracket
are held together with Loctite to prevent spacer from falling inside the deck frame.
4. Secure front height--of--cut bracket to deck frame
with socket head bolt/spacer and flange nut.
2
5. Verify 12 o’clock height. Re--adjust if needed.
Figure 2
1. Height--of--cut bracket
Cutting Units (Rev. B)
Page 8 -- 6
2. Shims
Groundsmaster 4500--D/4700--D
Cutting Units
This page is intentionally blank.
Groundsmaster 4500--D/4700--D
Page 8 -- 7
Cutting Units (Rev. B)
Service and Repairs
CAUTION
Never install or work on the cutting units or lift
arms with the engine running. Always stop engine and remove key first.
Blade Spindle Assembly
1
2
13
12
3
11
4
5
RIGHT
6
FRONT
7
85 to 110 ft--lb
(115 to 149 N--m)
8
9
10
Figure 3
1.
2.
3.
4.
5.
Flange nut
Socket head screw (motor mounting)
Spindle plate
Cutting deck
O--ring
Cutting Units (Rev. B)
6.
7.
8.
9.
Spindle assembly
Cap screw
Cutting blade
Anti--scalp cup
Page 8 -- 8
10.
11.
12.
13.
Blade bolt
Rubber flap (if equipped)
Flap plate (if equipped)
Pop rivet (steel) (if equipped)
Groundsmaster 4500--D/4700--D
Removal
2
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 hydraulic motor to the cutting unit (Fig. 4). Remove hydraulic motor and O--ring from deck.
1
1
3. Cover top of spindle to prevent contamination.
Spindle plug (Toro Part No. 94--2703) can be used to
cover spindle.
4. Start the engine and raise the cutting unit. Stop engine 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).
Figure 4
1. Socket head screw
2. Hydraulic motor
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 assembly 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 cutting deck and spindle 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).
Cutting Units
3. Position O--ring to top of spindle housing. Install hydraulic motor to the cutting unit with two socket head
screws.
Groundsmaster 4500--D/4700--D
Page 8 -- 9
Cutting Units (Rev. B)
Blade Spindle Service
Disassembly
2
1. Remove blade spindle from cutting deck (see Blade
Spindle Removal).
6
4
130 to 160 ft--lb
(177 to 216 N--m)
2. Loosen and remove spindle nut from top of spindle
shaft.
11
10
3. Press the spindle shaft out of the spindle housing using an arbor press. The shaft spacer remains on the
spindle shaft as the shaft is being removed.
9
12
8
7
4. Remove seals from spindle housing.
1
5. Allow the bearings, inside spacer and spacer ring to
drop out of the spindle housing.
4
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.
5
3
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 necessary to replace the original snap ring. If a spindle
housing is being replaced, new bearings with their
matched spacer set and snap ring must be installed.
Replacement bearings are sold only with a matched
spacer set and snap ring. These parts cannot be
purchased separately.
Figure 5
1.
2.
3.
4.
5.
6.
Spindle housing
Spindle plug
Spindle shaft
Oil seal
Shaft spacer
Spindle nut
7.
8.
9.
10.
11.
12.
Grease fitting
Bearing
Spacer ring
Spacer set (2 piece)
Bearing
Large snap ring
PRESS
4
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.
3
1
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 that the assembly is correct by supporting the
first bearing cup and pressing the second against it (Fig.
6).
2
5
6
Figure 6
1. Bearing cups
2. Large snap ring
3. Large spacer
4. Arbor press
5. Support
6. Arbor press base
4. Pack the bearing cones with grease. Apply a film of
grease on lips of seals.
Cutting Units (Rev. B)
Page 8 -- 10
Groundsmaster 4500--D/4700--D
5. Install lower bearing and seal into bottom of spindle
housing. Note: The bottom seal must have the lip facing
out (down) (Fig. 7).
2
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. Lubricate 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
130 to 160 ft--lb (177 to 216 N--m).
1
Figure 7
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.
Cutting Units
11. Install blade spindle to cutting deck (see Blade
Spindle Installation).
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 fittings in the roller
shaft ends. The third design has grease fittings incorporated into the roller fasteners. Removal and installation
of the rear roller from the cutting deck is the same, regardless of roller type.
10
6
5
4
9
7
1
8
6
7
Removal (Fig. 8)
3
1. Park machine on a 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, remove fasteners securing left and right scraper rod
brackets to roller mounts. Remove scraper rod assembly.
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.
2
Figure 8
1.
2.
3.
4.
5.
Deck frame
Rear roller assembly
Flange head screw
Flange head screw
Roller mount
6.
7.
8.
9.
10.
Cap screw
Scraper plate
Roller scraper
Cap screw (if equipped)
Grease fitting
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 Operator’s
Manual).
Cutting Units (Rev. B)
Page 8 -- 12
Rev. D
Groundsmaster 4500--D/4700--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.
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.
3. Using the tool as a template, locate, mark, and drill
two 7/64 inch (.109 inch diameter) holes in outer face of
seal.
2
3
4
4. Screw two No. 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.
5
1
Figure 9
1. Roller
2. Roller shaft
3. Bearing
4. Retaining ring
5. Oil seal
.188” dia. (2)
Bearing Removal (Fig. 9)
.625” dia.
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.
.625”
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 and tapping on roller shaft.
.625”
Tap 1/4--20
UNC (2)
1.05”
1.05”
Figure 10
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.
Cutting Units
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
Cutting Units (Rev. B)
Rear Roller Service (Greasable Bearings with Retaining Ring)
9
8
7
2
10
4
6
1
1
2
3
4
5
3
5
10
9
7
8
6
Figure 11
1.
2.
3.
4.
Roller shaft
Outer seal
Retaining ring
Outer oil seal
Cutting Units (Rev. B)
5.
6.
7.
Grease fitting
Washer
Inner seal
Page 8 -- 14
Rev. D
8. Ball bearing
9. Inner oil seal
10. Roller tube
Groundsmaster 4500--D/4700--D
Roller Disassembly (Fig. 11)
3. Use tool TOR4068 to install inner seal.
1. Remove retaining ring from both ends of roller.
4. Use tool TOR4069 to install outer seal.
2. Hit end of roller shaft with a soft face hammer to remove seals and bearing from one end of roller. Hit other
end of roller shaft to remove seals and bearing from other end of roller. Be careful not to drop roller shaft.
5. Install retaining ring so that side with sharp edges
faces end of roller (out).
3. Discard seals and bearings.
7. Use tool TOR4067 to install washer.
Roller Assembly (Fig. 11)
8. Put opposite end of roller facing up and support bottom end with tool TOR4067. Repeat steps 3 - 7.
NOTE: A soft face hammer can be used with the special
tools listed (see Special Tools) to assemble the roller,
however use of a press is recommended.
1. Use installation tool TOR4065 and handle TOR4073
to install inner oil seal into each end of roller tube.
6. Use tool TOR4071 to install outer oil seal.
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.
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 outside 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.
Cutting Units
D. Use tool TOR4067 to install second ball bearing.
Groundsmaster 4500--D/4700--D
Page 8 -- 15
Rev. D
Cutting Units (Rev. B)
Rear Roller Service (Greasable Bearings with Bearing Nut)
Disassembly (Fig. 12)
2
1. Remove bearing lock nut from each end of roller
shaft.
50 to 60 ft--lb
(68 to 81 N--m)
3
4
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 roller tube by tapping on opposite end of shaft. Remove
shaft from roller tube.
5
6
7
1
2
4
3
5
3. Carefully remove inner seal from both ends of roller
tube taking care to not damage tube surfaces.
6
4. Discard removed seals and bearings.
Loctite #242
5. Clean roller shaft and all surfaces on the inside of the
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
1. Install inner seals into roller tube making sure that
seal lip (and garter spring) faces end of tube. Use inner
seal tool (see Special Tools) and soft face hammer to fully seat seals against roller shoulder (Fig. 13). Apply a
small amount of grease around the lip of both inner seals
after installation.
7
Figure 12
1.
2.
3.
4.
Roller tube
Roller shaft
Inner seal
Bearing
5. Outer seal
6. Bearing lock nut
7. Set screw
1
2
3
IMPORTANT: During assembly process, frequently
check that bearings rotate freely and do not bind. If
any binding is detected, consider component removal 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.
Figure 13
1. Roller tube
2. Inner seal
3. Inner seal tool
1
B. Apply a small amount of grease around the lip of
both outer seals.
2
3
4
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 sure to not crush the installed outer seal.
Again, make sure that bearing still freely rotates.
Cutting Units (Rev. B)
Figure 14
1. Roller tube
2. Inner seal
3. Bearing
Page 8 -- 16
Rev. D
4. Washer
5. Bearing/outer seal tool
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:
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--lbs (0.68 N--m) resistance.
1
3
2
4
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.
5
Figure 15
1. Roller tube
2. Inner seal
3. Bearing
1
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 rotate after seal installation.
4. Outer seal
5. Bearing/outer seal tool
2
E. Using the same process, install second outer
seal making sure to not crush the installed outer seal.
Again, make sure that shaft and bearings still freely
rotate.
3
4
5
6
Figure 16
IMPORTANT: Make sure that all grease is removed
from shaft threads to prevent bearing lock nut loosening.
1. Roller tube
2. Roller shaft
3. Inner seal
5. Thoroughly clean threads on both ends of roller
shaft.
1
4. Bearing
5. Washer
6. Bearing/outer seal tool
2
3
4
5
6
6. Install bearing lock nut onto each end of the roller
shaft. Make sure that outer seals are not damaged during nut installation. Torque lock nuts from 50 to 60 ft--lb
(68 to 81 N--m).
7. If set screw was removed from either end of roller
shaft, apply Loctite #242 (or equivalent) to threads of removed set screw and install into roller shaft. Tighten set
screw until it bottoms in shaft and is recessed in shaft.
Figure 17
1. Roller tube
2. Roller shaft
3. Inner seal
4. Bearing
5. Outer seal
6. Bearing/outer seal tool
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
Rev. D
Cutting Units (Rev. B)
Cutting Units
NOTE: If original bearing lock nut(s) are being used,
apply Loctite #242 (or equivalent) to threads of lock
nut(s).
Front Roller Service
Disassembly (Fig. 18)
1. Remove roller mounting bolt.
2. Remove roller assembly from carrier frame.
1
3. To remove bearings and spacer:
A. Insert punch through end of roller and drive opposite bearing out by alternating taps to opposite side of
inner bearing race. There should be a lip of inner race
exposed for this process.
2
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)
80 ft--lb
(108 N--m)
3
4
2
Figure 18
1. Mounting bolt
2. Bearing
3. Spacer
4. Front roller
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.
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 pressing equally on inner and outer races until the inner
race comes in contact with the spacer.
3. Verify that there is no more than a .060 inch (1.5 mm)
gap between roller assembly and the roller mount brackets 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
N--m).
2. Install roller assembly into deck frame.
Cutting Units (Rev. B)
Page 8 -- 18
Rev. D
Groundsmaster 4500--D/4700--D
Cutting Units
This page is intentionally blank.
Groundsmaster 4500--D/4700--D
Page 8 -- 19
Rev. D
Cutting Units (Rev. B)
Cutting Deck Carrier Frame
Decks #2 and #3
Decks #1, #4, and #5
9
8
3
1
7
6
1
5
Decks #6 and #7
3
4
14
2
13
RIGHT
3
FRONT
12
1
11
10
Figure 19
1.
2.
3.
4.
5.
Carrier frame
Lynch pin
Thrust washer
Pivot shaft
Lift arm (#4 shown)
Cutting Units (Rev. B)
6.
7.
8.
9.
10.
Cap screw
Rebound washer
Pivot shaft
Lift arm (#2 shown)
Lock nut
Page 8 -- 20
Rev. D
11.
12.
13.
14.
Flat washer
Compression spring
Pivot shaft
Lift arm (#6 shown)
Groundsmaster 4500--D/4700--D
Installation
1
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).
3
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:
2
1. Carrier frames for the front three cutting decks (#1,
#4, and #5) have a thrust washer between the carrier
frame and the lift arm. The frame is secured to the lift arm
pivot shaft with a lynch pin (Fig. 19).
2. Carrier frames for the center two cutting decks (#2
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).
Figure 20
1. Carrier frame
2. Lower hole
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).
3. Deck bracket
#4 Deck
#6 Deck
(GM4700)
#1 Deck
#5 Deck
#2
Deck
#3
Deck
#7 Deck
(GM4700)
CUTTING DECK LOCATIONS
Cutting Units
Figure 21
Groundsmaster 4500--D/4700--D
Page 8 -- 21
Rev. D
Cutting Units (Rev. B)
This page is intentionally blank.
Cutting Units (Rev. B)
Page 8 -- 22
Rev. D
Groundsmaster 4500--D/4700--D
Chapter 9
Electrical Diagrams
Table of Contents
Groundsmaster 4500--D/4700--D
Page 9 - 1
Rev. D
Electrical Diagrams (Rev. A)
Electrical
Diagrams
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 (Transport) Circuit Diagram . . . . . . . . . . . . . . 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
This page is intentionally blank.
Electrical Diagrams (Rev. A)
Page 9 - 2
Groundsmaster 4500--D/4700--D
GLOW
OVER TEMP
BU/W OR
CLUSTER GAUGE
GLOW RELAY
ALTERNATOR
W
LOW OIL PRESSURE
GN
CONTROLLER
GLOW PLUG
KUBOTA
(IN 4WD)
START RELAY K5
(OFF)
(SEAT VACANT)
DECK UP
(IN CENTER POSITION)
FRONT PTO
(DECKS 2, 3, 5)
FRONT DECK
POSITION
(DECK RAISED)
FRONT DECK
POSITION
(DECK RAISED)
FRONT PTO
(DECKS 1,4)
(NOT IN NEUTRAL)
Groundsmaster 4500--D
Electrical Schematic
Serial Number Below 220999999
All relays and solenoids
are shown as de-- energized.
All ground wires are black.
Page 9 - 3
GLOW RELAY
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.
Page 9 - 4
Rev. D
Groundsmaster 4500--D
Electrical Schematic
Serial Number Above 260000600
All relays and solenoids
are shown as de-- energized.
All ground wires are black.
Page 9 - 5
Rev. D
GLOW
OVER TEMP
LOW OIL PRESSURE
CLUSTER GAUGE
GLOW RELAY
ALTERNATOR
GN
CONTROLLER
GLOW PLUG
KUBOTA
(IN 4WD)
START RELAY K5
(OFF)
DECK UP
(IN CENTER POSITION)
LEFT PTO
(DECK 6)
(SEAT VACANT)
LEFT DECK
POSITION
(DECK RAISED)
DECK UP
(IN CENTER POSITION)
FRONT PTO
(DECKS 2, 3, 5)
FRONT DECK
POSITION
(DECK RAISED)
FRONT DECK
POSITION
(DECK RAISED)
FRONT PTO
(DECKS 1,4)
DECK UP
(IN CENTER POSITION)
(NOT IN NEUTRAL)
RIGHT PTO
(DECK 7)
RIGHT DECK
POSITION
(DECK RAISED)
Groundsmaster 4700--D
Electrical Schematic
Serial Number Below 220999999
All relays and solenoids
are shown as de-- energized.
All ground wires are black.
Page 9 - 6
Rev. D
GLOW RELAY
Groundsmaster 4700--D
Electrical Schematic
Serial Number From 230000001 to 260000600
All relays and solenoids
are shown as de-- energized.
All ground wires are black.
Page 9 - 7
Rev. D
Groundsmaster 4700--D
Electrical Schematic
Serial Number Above 260000600
All relays and solenoids
are shown as de-- energized.
All ground wires are black.
Page 9 - 8
Rev. D
GLOW
OVER TEMP
BU/W OR
CLUSTER GAUGE
GLOW RELAY
ALTERNATOR
W
LOW OIL PRESSURE
GN
NOTE: The wire harness and relays of the GM 4500-- D and GM 4700-- D
are the same. The drawing on this page uses the GM 4500-- D Schematic
(Serial Number Below 220999999) to show the operational circuits.
CONTROLLER
GLOW PLUG
KUBOTA
(IN 4WD)
START RELAY K5
(OFF)
(SEAT VACANT)
DECK UP
(IN CENTER POSITION)
FRONT PTO
(DECKS 2, 3, 5)
FRONT DECK
POSITION
(DECK RAISED)
FRONT DECK
POSITION
(DECK RAISED)
FRONT PTO
(DECKS 1,4)
(NOT IN NEUTRAL)
Groundsmaster 4500--D/4700--D
Glow Plug Circuit
Power Current
Control Current
Indicator/Gauge Current
Page 9 - 9
Rev. D
GLOW
OVER TEMP
BU/W OR
CLUSTER GAUGE
GLOW RELAY
ALTERNATOR
W
LOW OIL PRESSURE
GN
NOTE: The wire harness and relays of the GM 4500-- D and GM 4700-- D
are the same. The drawing on this page uses the GM 4500-- D Schematic
(Serial Number Below 220999999) to show the operational circuits.
CONTROLLER
GLOW PLUG
KUBOTA
(IN 4WD)
START RELAY K5
(OFF)
(SEAT OCCUPIED)
DECK UP
(IN CENTER POSITION)
FRONT PTO
(DECKS 2, 3, 5)
FRONT DECK
POSITION
(DECK RAISED)
FRONT DECK
POSITION
(DECK RAISED)
FRONT PTO
(DECKS 1,4)
(IN NEUTRAL)
Groundsmaster 4500--D/4700--D
Crank Circuit
Power Current
Control Current
Indicator/Gauge Current
Page 9 - 10
Rev. D
GLOW
OVER TEMP
BU/W OR
CLUSTER GAUGE
GLOW RELAY
ALTERNATOR
W
LOW OIL PRESSURE
GN
NOTE: The wire harness and relays of the GM 4500-- D and GM 4700-- D
are the same. The drawing on this page uses the GM 4500-- D Schematic
(Serial Number Below 220999999) to show the operational circuits.
CONTROLLER
GLOW PLUG
KUBOTA
(IN 2WD)
START RELAY K5
(OFF)
(OFF)
(SEAT OCCUPIED)
DECK UP
(IN CENTER POSITION)
FRONT PTO
(DECKS 2, 3, 5)
FRONT DECK
POSITION
(DECK RAISED)
FRONT DECK
POSITION
(DECK RAISED)
FRONT PTO
(DECKS 1,4)
(NOT IN NEUTRAL)
Groundsmaster 4500--D/4700--D
Run (Transport) Circuit
Power Current
Control Current
Indicator/Gauge Current
Page 9 - 11
Rev. D
GLOW
OVER TEMP
BU/W OR
CLUSTER GAUGE
GLOW RELAY
ALTERNATOR
W
LOW OIL PRESSURE
GN
NOTE: The wire harness and relays of the GM 4500-- D and GM 4700-- D
are the same. The drawing on this page uses the GM 4500-- D Schematic
(Serial Number Below 220999999) to show the operational circuits.
CONTROLLER
GLOW PLUG
KUBOTA
(IN 4WD)
START RELAY K5
(OFF)
(ON)
NOTE: Refer to Cutting Deck Position Switch and Cutting Deck Lift/Lower Switch in
Chapter 5 - Electrical System for information on cutting deck switch operation.
(SEAT OCCUPIED)
DECK UP
(IN CENTER POSITION)
FRONT PTO
(DECKS 2, 3, 5)
FRONT DECK
FRONT DECK
POSITION
POSITION
(DECK LOWERED) (DECK LOWERED)
FRONT PTO
(DECKS 1,4)
(NOT IN NEUTRAL)
Groundsmaster 4500--D/4700--D
Run (Mow) Circuit
Power Current
Control Current
Indicator/Gauge Current
Page 9 - 12
Rev. D
This page is intentionally blank.
Page 9 - 13
Rev. D
ORANGE
P4
GRAY
P5
BLUE/WHITE
YELLOW
INTERCONNECT TO ENGINE
PARKING BRAKE
P17
NEUTRAL SWITCH
P6
RED/BLACK
SEAT SWITCH
P15
BLACK
ALT. B+
J3
J2
BLACK
J1
BLACK
P3
BLACK
GLOW RELAY
RED/BLACK
oil pressure
WARNING LIGHTS
P1
alt ”L”
P20
FUEL PUMP
YELLOW
GREEN
YELLOW
WHITE
YELLOW
over temp.
WARNING LIGHTS
P2
glow
YELLOW
YELLOW
BLUE/WHITE
YELLOW
PINK
RED
BLACK
BLUE
BROWN
RED
STARTER B+
P18
RED
ORANGE
TAN
ORANGE
GREEN
BLUE/WHITE
RED/BLACK
BLACK
GREEN
YELLOW
P19
ORANGE
P23
GREEN
INTERCONNECT
TO CONSOLE
VIOLET
IGNITION SWITCH
YELLOW
BLACK
WHITE
J4
BLACK
BROWN
SHIELDED CABLE
GREEN
VIOLET
PINK
ORANGE
GREEN
GRAY
PINK
BLACK
BLACK
BLACK
SHIELD GROUND
BLACK
BLUE
PINK
GREEN
Page 9 - 14
Rev. D
P8
P9
CENTER DECK SWITCH #1
CENTER DECK SWITCH #2
P27
DIODE 3
P10
2 WD COIL
P30
P13
P14
INTERCONNECT TO GM 4700
CENTER DECK PTO
(2, 3, 5)
CENTER DECK PTO
(1, 4)
Groundsmaster 4500--D/4700--D
Serial Number Below 220999999
Main Wire Harness
J3
ALTERNATOR B+
P15
SEAT SWITCH
P27
DIODE 3
B
A
J2
GLOW
RELAY
P18
STARTER B+
P10
2WD COIL
1
P19
IGNITION SWITCH
2
P14
CENTER DECK (1, 4)
1
5
4
2
P30
INTERCONNECT TO 4700
P23
INTERCONNECT
TO CONSOLE
3
SP4
P2
WARNING LIGHTS
(OVER TEMP)
SP6
SP5
P1
WARNING LIGHTS
(OIL PRESSURE/ALT ”L”)
J1
GLOW
RELAY
SP2
SP7
J4
IGNITION
SWITCH
1
SP1
P23
INTERCONNECT TO ENGINE
P6
NEUTRAL SWITCH
P17
PARKING BRAKE
P13
CENTER DECK
PTO (2, 3, 5)
P3
GLOW
RELAY
P20
FUEL PUMP
2
SP3
P4
INTERCONNECT
TO ENGINE
P8
CENTER DECK
SWITCH #1
P9
CENTER DECK
SWITCH #2
Groundsmaster 4500--D/4700--D
Serial Number Below 220999999
Main Wire Harness
Page 9 - 15
Rev. D
GRAY
RED/BLACK
BLUE/WHITE
BLACK
BLACK
BLACK
BLACK
PINK
ORANGE
RED/BLACK
PINK
GREEN
PINK
WHITE
PINK
PINK
PINK
BLUE/WHITE
PINK
BROWN
RED
BLACK
BLUE
RED
BROWN
ORANGE
RED
GRAY
ORANGE
GREEN
BLUE/WHITE
BLACK
RED/BLACK
GREEN
YELLOW
ORANGE
GREEN
VIOLET
YELLOW
BLACK
WHITE
BLACK
BROWN
GREEN
TAN
BLUE
ORANGE
YELLOW
WHITE
BLACK
BROWN
BLACK
BLUE
GREEN
BLACK
CABLE SHIELD
BROWN
BLACK
Groundsmaster 4500--D/4700--D
Serial Number From 230000001 to 260000600
Main Wire Harness
Page 9 - 16
Rev. D
Groundsmaster 4500--D/4700--D
Serial Number From 230000001 to 260000600
Main Wire Harness
Page 9 - 17
Rev. D
GRAY
RED/BLACK
BLUE/WHITE
BLACK
BLACK
BLACK
BLACK
ORANGE
PINK
RED/BLACK
PINK
GREEN
PINK
WHITE
PINK
PINK
PINK
BLUE/WHITE
PINK
BROWN
RED
BLACK
BLUE
RED
BROWN
ORANGE
RED
GRAY
ORANGE
GREEN
BLUE/WHITE
BLACK
RED/BLACK
GREEN
YELLOW
ORANGE
GREEN
VIOLET
YELLOW
BLACK
WHITE
BLACK
BROWN
GREEN
TAN
BLUE
ORANGE
YELLOW
WHITE
BLACK
BROWN
BLACK
BLUE
GREEN
BLACK
CABLE SHIELD
BROWN
BLACK
Groundsmaster 4500--D/4700--D
Serial Number Above 260000600
Main Wire Harness
Page 9 - 18
Rev. D
SN 280000001
AND UP
Groundsmaster 4500--D/4700--D
Serial Number Above 260000600
Main Wire Harness
Page 9 - 19
Rev. D
PTO SWITCH
P5
K7 PARKING BRAKE
P14
VIOLET
P15
YELLOW
YELLOW
PINK
BLACK
YELLOW
K6 HIGH TEMP
BLACK
BLUE
GREEN
VIOLET
PINK
VIOLET
BLUE
BLUE
K2 RELAY
CENTER PTO
RAMP--UP MODULE
SHIELDED CABLE
BROWN
BLACK
P28
ORANGE
YELLOW
P7
GREEN
K1 RELAY
LEFT PTO
BLACK
RED
WHITE
GND
P4
YELLOW
2WD/4WD SWITCH
P3
GREEN
GLOW CONTROLLER
J1
BLACK
P2
PINK
TEMPERATURE GAUGE
BLACK
P8
BLUE
BLACK
BLACK
ORANGE
BLUE
K3 RELAY
RIGHT PTO
TAN
P9
ORANGE
GREEN
BLUE/WHITE
BLACK
BLUE
VIOLET
GREEN
YELLOW
YELLOW
ORANGE
ORANGE
GREEN
VIOLET
K5 RELAY
START
INTERCONNECT TO MAIN
HARNESS
P6
DIODE PACK
VIOLET
YELLOW
WHITE
P11
P23
PINK
WHITE
BLACK
BLACK
VIOLET
ORANGE
GREEN
YELLOW
WHITE
GRAY
YELLOW
P22
YELLOW
POWER POINT
GRAY
RED
FUSE BLOCK #1
P12
GREEN
RED
YELLOW
PINK
YELLOW
P13
OPT. FUSE BLOCK #2
P1
HOUR METER
P16
K8 SEAT
P17
K9 NEUTRAL
J2
J3
CAPACITOR
ORANGE
BROWN
YELLOW
GREEN
WHITE
RED/BLACK
VIOLET
VIOLET
VIOLET
VIOLET
BLACK
TAN
GREEN
YELLOW
RED/BLACK
P18
P19
P21
P20
DIODE 8
LEFT DECK
CENTER DECKS
RIGHT DECK
Groundsmaster 4500--D/4700--D
Serial Number Below 220999999
Console Wire Harness
Page 9 - 20
Rev. D
P9
K3 RELAY:
RIGHT PTO
P15
K7 PARKING BRAKE
1
4
2
3
P11
K5 RELAY:
START
P14
K6 HIGH TEMP
1
5
P8
K2 RELAY:
CENTER PTO
P12
FUSE BLOCK #1
P7
K1 RELAY:
LEFT PTO
3
2
P1
HOUR METER
P28
RAMP UP MODULE
J3
CAPACITOR
J2
CAPACITOR
P13
OPT. FUSE BLOCK #2
P17
K9 NEUTRAL
P21
CENTER DECKS
P16
K8 SEAT
P20
RIGHT DECK
SP8
SP1
SP7
SP3
SP9
SP6
SP4
SP5
P4
2WD/4WD SWITCH
P23
INTERCONNECT TO
MAIN HARNESS
A
B
SP2
P5
PTO SWITCH
P18
DIODE 8
P22
POWER POINT
2
1
P6
DIODE PACK
P3
GLOW CONTROLLER
3
6
2
1
5
4
P19
LEFT DECK
J1
TEMPERATURE GAUGE
P2
TEMPERATURE GAUGE
2
3
1
Groundsmaster 4500--D/4700--D
Serial Number Below 220999999
Console Wire Harness
Page 9 - 21
Rev. D
BLUE
BLACK
PINK
BLACK
PINK
GND
BLACK
BLACK
RED
WHITE
GREEN
ORANGE
SHIELDED CABLE
PINK
BROWN
TAN
PINK
BLACK
PINK
BLUE
BLUE
BLACK
BROWN
BLACK
BLACK
BLUE
BLUE
ORANGE
GRAY
VIOLET
ORANGE
GREEN
BLUE/WHITE
GREEN
PINK
BLACK
BLACK
GREEN
YELLOW
YELLOW
ORANGE
ORANGE
WHITE/BLACK
GREEN
YELLOW
PINK
RED
TAN
GRAY
PINK
BLUE
YELLOW
BLACK
WHITE
VIOLET
PINK
YELLOW
RED
GREEN
VIOLET
RED/BLACK
PINK
RED
WHITE
RED
ORANGE
BROWN
PINK
VIOLET
PINK
BLACK
ORANGE
PINK
WHITE
BLACK
GREEN
YELLOW
Groundsmaster 4500--D/4700--D
Serial Number From 230000001 to 260000600
Console Wire Harness
Page 9 - 22
Rev. D
Groundsmaster 4500--D/4700--D
Serial Number From 230000001 to 260000600
Console Wire Harness
Page 9 - 23
Rev. D
PINK
BROWN
BLACK
PINK
BLACK
BLACK
RED
WHITE
GREEN
GND
BLACK
BROWN
ORANGE
TAN
PINK
SHIELDED CABLE
PINK
BLACK
BROWN
BROWN
BROWN
BLACK
BLACK
BLACK
BLUE
ORANGE
VIOLET
BROWN
GRAY
ORANGE
GREEN
BLACK
PINK
BLACK
BLUE/WHITE
GREEN
GREEN
YELLOW
YELLOW
ORANGE
ORANGE
WHITE/BLACK
GREEN
YELLOW
PINK
RED
TAN
GRAY
PINK
BLUE
ORANGE
YELLOW
BLACK
VIOLET
YELLOW
GREEN
RED/BLACK
PINK
RED
PINK
WHITE
VIOLET
RED
RED
WHITE
BROWN
PINK
VIOLET
PINK
BLACK
YELLOW
ORANGE
GREEN
PINK
WHITE
BLACK
Groundsmaster 4500--D/4700--D
Serial Number Above 260000600
Console Wire Harness
Page 9 - 24
Rev. D
Groundsmaster 4500--D/4700--D
Serial Number Above 260000600
Console Wire Harness
Page 9 - 25
Rev. D
RUN SOLENOID
P1
OVER TEMPERATURE
J4
J5
BLUE/WHITE
BLACK
RED/BLACK
HOLD PULL GROUND
OIL PRESSURE
WHITE
FUSIBLE LINK
P2
STARTER ”G”
WHITE
GREEN
INTERCONNECT
P4
TO MAIN HARNESS
BLUE
GRAY
J3
BLACK
GROUND
BLACK
ORANGE
YELLOW
BLACK
BLUE
INTERCONNECT
P5
TO MAIN HARNESS
J2
J1
P7
J6
GLOW
TEMPERATURE SENDER
DIODE
STARTER
R
L
P6
ALTERNATOR
Groundsmaster 4500--D/4700--D
Serial Number Below 220999999
Engine Wire Harness
Page 9 - 26
Rev. D
P1
FUEL SOLENOID
J5
TEMPERATURE
SWITCH
B
J2
GLOW PLUGS
SP2
A
P5
TO MAIN HARNESS
SP1
J1
TEMPERATURE
SENDER
P4
TO MAIN HARNESS
P2
STARTER ”G”
J4
OIL PRESSURE
J6
STARTER ”S”
P6
ALTERNATOR
2
1
P7
DIODE
J3
GROUND
Groundsmaster 4500--D/4700--D
Serial Number Below 220999999
Engine Wire Harness
Page 9 - 27
Rev. D
BLUE/WHITE
BLACK
RED/BLACK
WHITE
FUSIBLE LINK
WHITE
GREEN
BLUE
GRAY
BLACK
ORANGE
PINK
BLACK
Groundsmaster 4500--D/4700--D
Serial Number Above 230000000
Engine Wire Harness
Page 9 - 28
Rev. D
Groundsmaster 4500--D/4700--D
Serial Number Above 230000000
Engine Wire Harness
Page 9 - 29
Rev. D
PINK
GREEN
PINK
VIOLET
YELLOW
PINK
BLACK
ORANGE
BLACK
VIOLET
BLACK
YELLOW
BLACK
BLACK
Groundsmaster 4700--D
Deck 6 and 7 Wire Harness
Page 9 - 30
Rev. D
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