Toro Groundsmaster 4500-D, 4700-D (Model 30857, 30858) Service Repair Manual

Table of Content – Groundsmaster 4500-D, 4700-D (Model 30857, 30858)

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
Maintenance
Equivalents and Conversions
Torque Specifications
3 – Kubota Diesel Engine
Specifications
General Information
Stopping the Engine
Service and Repairs
Air Filter System
Exhaust System
Fuel System
Radiator
Engine
Pump Adapter Plate
Kubota Diesel Engine Workshop Manual
4 – Hydraulic System
Specifications
General Information
Operator’s Manual
Towing Traction Unit
Check Hydraulic Fluid
Relieving Hydraulic System Pressure
Traction Circuit Component Failure
Hydraulic Hoses
Hydraulic Hose and Tube Installation (O–Ring Face Seal Fitting)
Hydraulic Fitting Installation (SAE Straight Thread O–Ring Fitting into Component Port)
Hydraulic Schematics
GM4500
GM4700
Hydraulic Flow Diagrams
Traction Circuit: Low Speed
Traction Circuit: High Speed
Lower Cutting Decks: GM4500
Lower Cutting Decks: GM4700
Raise Cutting Decks: GM4500
Raise Cutting Decks: GM4700
Mow Circuit
Cutting Deck Blade Braking
Steering Circuit
Engine Cooling Fan Circuit
Special Tools
Hydraulic Pressure Test Kit
Hydraulic Tester (Pressure and Flow)
Hydraulic Test Fitting Kit
Measuring Container
O–ring Kit
High Pressure Hydraulic Oil Filter
Troubleshooting
General Hydraulic System Problems
Traction Circuit Problems
PTO Problems
Steering Circuit Problems
Lift, Lower Circuit Problems
Engine Cooling Fan Circuit Problems
Testing
Traction Circuit Charge Pressure (Using Pressure Gauge)
Traction Circuit Relief Pressure (Using Pressure Gauge)
Rear Traction Circuit Relief (RV) Pressure (Using Pressure Gauge)
Traction Circuit Reducing Valve (PR) Pressure (Using Pressure Gauge)
Cutting Deck Circuit Pressure (Using Pressure Gauge)
Cutting Deck Circuit Relief Pressure (Using Tester with Pressure Gauges and Flow Meter)
Cutting Deck Motor Case Drain Leakage (Using Tester with Pressure Gauges and Flow
Gear Pump P1 and P2 Flow (Cutting Deck Circuits) (Using Tester with Pressure Gauges
Steering Circuit Relief Pressure (Using Pressure Gauge)
Lift, Lower Circuit Relief Pressure (Using Pressure Gauge)
Gear Pump P3 Flow (Steering and Lift, Lower Circuits) (Using Tester with Pressure
Cooling Fan Circuit (Using Pressure Gauge and Phototac)
Gear Pump P4 Flow (Cooling Fan Circuit) (Using Tester with Pressure Gauges and Flow
Service and Repairs
General Precautions for Removing and Installing Hydraulic System Components
Flush Hydraulic System
Charge Hydraulic System
Gear Pump
Gear Pump Service
Piston (Traction) Pump
Piston (Traction) Pump Service
4WD, 2WD and Filtration, Charge Control Manifolds
4WD, 2WD Control Manifold Service
Filtration, Charge Control Manifold Service
Rear Axle Motor
Front Wheel Motors
Rear Axle and Front Wheel Motor Service
Cutting Deck Motor
Cutting Deck Motor Service
Deck Control Manifold
Deck Control Manifold Service (GM 4500–D)
Deck Control Manifold Service (GM 4700–D)
Steering Control Valve
Steering Control Valve Service
Steering Cylinder
Steering Cylinder Service
Engine Cooling Fan Motor
Engine Cooling Fan Motor Service
Fan Control Manifold
Fan Control Manifold Service
Lift Control Manifold
Lift Control Manifold Service (GM 4500–D)
Lift Control Manifold Service (GM 4700–D)
Lift Circuit Junction Manifold
Lift Cylinders: Decks #1, #4 and #5
Lift Cylinders: Decks #2 and #3
Lift Cylinders: Decks #6 and #7 (GM 4700–D)
Lift Cylinder Service
Hydraulic Reservoir
Hydraulic Oil Cooler
Eaton Piston Pump Repair Information
Eaton Piston Motor Repair Information
Danfoss Steering Unit Service Repair Manual
5 – Electrical System
General Information
Operator’s Manual
Toro Electronic Controllers (TEC)
CAN–bus Communications (Groundsmaster 4700–D
Electrical Drawings
Special Tools
Multimeter
Skin–Over Grease
Battery Hydrometer
Diagnostic Display
Troubleshooting
Diagnostic Display
Starting Problems
General Run and Transport Problems
Cutting Deck Operating Problems
Electrical System Quick Checks
Check Operation of Interlock Switches
Glow Plug System Test
Charging System Test
Battery Test (Open Circuit Test)
Component Testing
Ignition Switch
Fuses
Indicator Lights
PTO Switch
Cutting Deck Lift Switches
Hi–Low Speed and Headlight Switches
Engine Cooling Fan Switch
Seat Switch
Parking Brake Switch
Cutting Deck Position Switch
Hour Meter
Temperature Gauge
Glow and Main Power Relays
Start Relay
Hydraulic Solenoid Valve Coils
Engine Coolant and Hydraulic Oil Temperature Senders
Fuel Pump
Temperature Sender
Traction Neutral Switch
Service and Repairs
Battery Storage
Battery Care
Battery Service
Hydraulic Solenoid Valve Coil
6 – Axles, Planetaries and Brakes
Specifications
General Information
Operator’s Manual
Adjustments
Planetary Drive Endplay (OPH-2 series planetary drives)
Service and Repairs
Brake Assembly
Brake Inspection and Repair
Planetary Drive Assembly
OPH-2 Series Planetary Drive Service
VA02 Series Planetary Drive Service
Rear Axle Assembly
Rear Axle Service
Bevel Gear Case and Axle Case
Differential Shafts
Axle Shafts
Input Shaft, Pinion Gear
Differential Gear
Pinion Gear to Ring Gear Engagement
7 – Chassis
General Information
Operator’s Manual
Cutting Deck Identification
Service and Repairs
Steering Column
Console Arm
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)
Operator Seat
Operator Seat Service
Operator Seat Suspension
Hood
8 – Cutting Decks
Specifications
General Information
Operator’s Manual
Troubleshooting
Factors That Can Affect Quality of Cut
Special Tools
Rear Roller Bearing and Seal Installation Tools
Spindle Plug
Adjustments
Blade Stopping Time
Service and Repairs
Blade Spindle Assembly
Blade Spindle Service
Rear Roller
Rear Roller Service
Front Roller Service
Cutting Deck Carrier Frame
9 – Foldout Drawings
Hydraulic Schematics (2)
Electrical Schematics (3)
Main Wire Harness
Main Wire Diagram
Seat and Console Wire Harness
Seat and Console Wire Diagram
Power Center Wire Harness
Power Center Wire Diagram
Deck 6 and 7 Wire Harness
Deck 6 and 7 Wire Diagram