Toro Groundsmaster 4500-D, 4700-D (Model 30856, 30868) Service Repair Manual

Table of Content – Groundsmaster 4500-D, 4700-D (Model 30856, 30868)

Title Page
Revision History
Reader Comments
Preface
1 – Safety
General Safety Instructions
Before Operating
While Operating
Maintenance and Service
Jacking Instructions
Safety and Instruction Decals
2 – Product Records and Maintenance
Product Records
Equivalents and Conversions
Torque Specifications
Maintenance
3 – Kubota Diesel Engine
General Information
Specifications
Adjustments
Engine Run Solenoid
Service and Repairs
Air Filter System
Exhaust System
Fuel System
Radiator
Engine
Pump Adapter Plate
Kubota V2003-T Workshop Manual
4 – Hydraulic System
Specifications
General Information
Hydraulic Hoses
Hydraulic Fitting Installation
Towing Traction Unit
Check Hydraulic Fluid
Hydraulic Schematics
GM 4500-D Hydraulic Schematic
GM 4700-D Hydraulic Schematic
Hydraulic Flow Diagrams
Traction Circuit
Lower Cutting Units
Raise Cutting Units
Mow Circuit
Cutting Deck Blade Braking
Steering Circuit
Special Tools
Troubleshooting
Testing
TEST NO. 1: Traction Circuit Charge Pressure
Before Performing Hydraulic Tests
TEST NO. 2: Traction Circuit Relief Pressure
TEST NO. 3: Cutting Deck Circuit Pressure
TEST NO. 4: Cutting Deck Gear Pump Flow
TEST NO. 5: Cutting Deck Manifold Relief Pressure
TEST NO. 6: Cutting Deck Motor Case Drain Leakage
TEST NO. 7: Steering Circuit Relief Pressure
TEST NO. 8: Lift, Lower Circuit Relief Pressure
TEST NO. 9: Steering and Lift, Lower Gear Pump Flow
TEST NO. 10: Counterbalance (RV1) Pressure
TEST NO. 11: Rear Traction Circuit (RV5) Relief Pressure
TEST NO. 12: Traction Circuit Reducing Valve (PR1) Pressure
TEST NO. 13: Traction Assist (RV2) Pressure
Service and Repairs
General Precautions for Removing and Installing Hydraulic System Components
Check Hydraulic Lines and Hoses
Flush Hydraulic System
Charge Hydraulic System
Gear Pump
Gear Pump Service
Piston (Traction) Pump
Piston (Traction) Pump Service
Piston Pump Manual Servo Control Assembly
Hydraulic Control Manifolds: 2 Wheel, 4 Wheel Drive, Filtration and Charge, Power Down and Traction Assist
Hydraulic Control Manifold Service: 2 Wheel, 4 Wheel Drive Control
Hydraulic Control Manifold Service: Filtration and Charge Control
Hydraulic Control Manifold Service: Power Down and Traction Assist (GM 4500–D)
Hydraulic Control Manifold Service: Power Down and Traction Assist (GM 4700–D)
Hydraulic Control Manifold: Deck Drive (GM 4500–D)
Hydraulic Control Manifold Service: Deck Drive (GM 4500–D)
Hydraulic Control Manifold: Deck Drive (GM 4700-D)
Hydraulic Control Manifold Service: Deck Drive (GM 4700–D)
Rear Axle Motor
Front Wheel Motors
Rear Axle, Front Wheel Motor Service
Cutting Deck Motor
Cutting Deck Motor Service
Lift, Lower Control Valve (GM 4500–D)
Lift, Lower Control Valve Service (GM 4500–D)
Lift, Lower Control Valve (GM 4700–D)
Lift, Lower Control Valve Service (G 4700–D)
Steering Valve
Steering Valve Service
Lift Cylinders: Decks #1, #4, and #5
Lift Cylinders: Decks #2 and #3
Lift Cylinders: Decks #6 and #7 (GM 4700–D)
Lift Cylinder Service
Steering Cylinder
Steering Cylinder Service
Hydraulic Reservoir
Hydraulic Oil Cooler
5 – Electrical System
Electrical Schematic and Electrical Harness and Connectors Drawings
Special Tools
Troubleshooting
Starting Problems
General Run and Transport Problems
Cutting Unit Operating Problems
Electrical System Quick Checks
Battery Test (Open Circuit Test)
Check Operation of Interlock Switches
Component Testing
Ignition Switch
Fuses
Indicator Lights
PTO and Hi–Lo Speed Control Switches
Seat Switch
Parking Brake Switch
Cutting Deck Position Switch
Cutting Deck Lift, Lower Switch
Ramp–up Module
Hour Meter
Glow Relay
Start, Neutral, Seat, Cutting Deck, Parking Brake, and High Temperature Relays
Hydraulic Valve Solenoids
Engine Run Solenoid
Fuel Pump
Glow Controller
Temperature Sender
Temperature Gauge
High Temperature Shutdown Switch
Traction Neutral Switch
Diode Assemblies
Diode Circuit Board
Standard Control Module (S.N 230000001 and up)
Service and Repairs
Battery Storage
Battery Care
Battery Service
6 – Axles, Planetaries, and Brakes
Specifications
Adjustments
Service and Repairs
Brake Assembly
Brake Inspection and Repair
Planetary Wheel Drive Assembly
Planetary Wheel Drive Service
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
7 – Chassis
General Information
Cutting Deck Identification
Service and Repairs
Steering Tower
Lift Arms for Cutting Decks #1, #4, and #5
Lift Arms for Cutting Decks #2 and #3
Lift Arms for Cutting Decks #6 and #7 (Groundsmaster 4700–D only)
Hood
8 – Cutting Units
Specifications
Troubleshooting
Special Tools
Adjustments
Blade Stopping Time
Blade Plane Inspection and Adjustment
Service and Repairs
Blade Spindle Assembly
Blade Spindle Service
Rear Roller
Rear Roller Service (Non-Greasable Bearings)
Rear Roller Service (Greasable Bearings with Retaining Ring)
Rear Roller Service (Greasable Bearings with Bearing Nut)
Front Roller Service
Cutting Deck Carrier Frame
9 – Electrical Diagrams
Schematic GM4500-D (S.N below 220999999)
Schematic GM4500-D (S.N 230000001 to 260000600)
Schematic GM4500-D (S.N 260000601 and up)
Schematic GM4700-D (S.N below 220999999)
Schematic GM4700-D (S.N 230000001 to 260000600)
Schematic GM4700-D (S.N 260000601 and up)
Glow Plug Circuit
Crank Circuit
Run (Transport) Circuit
Run (Mow) Circuit
Main Harness Diagram (S.N below 220999999)
Main Wire Harness (S.N below 220999999)
Main Harness Diagram (S.N 230000001 to 260000600)
Main Wire Harness (S.N 230000001 to 260000600)
Main Harness Diagram (S.N 260000601 and up)
Main Wire Harness (S.N 230000601 and up)
Console Harness Diagram (S.N below 220999999)
Console Wire Harness (S.N below 220999999)
Console Harness Diagram (S.N 230000001 to 260000600)
Console Wire Harness (S.N 230000001 to 260000600)
Console Harness Diagram (S.N 260000601 and up)
Console Wire Harness (S.N 260000601 and up)
Engine Harness Diagram (S.N below 220999999)
Engine Wire Harness (S.N below 220999999)
Engine Harness Diagram (S.N 230000001 and up)
Engine Wire Harness (S.N 230000001 and up)
Deck 6 and 7 Harness Diagram GM4700-D