Toro Groundsmaster 4500-d User manual

FormNo.19245SLRevA

Groundsmaster®4500-D/4700-D

(Models30885,30887,30893,30893TE,

30899and30899TE)

8111LyndaleAvenueSouth

Bloomington,MN55420

OriginalInstructions(EN)

Contactusatwww.Toro.com.

AllRightsReserved

RevisionHistory

RevisionDateDescription

A04/2020Initialissue.

RevisionHistoryPage2Groundsmaster®4500-D/4700-D

19245SLRevA

ReaderComments

TheToroCompanyT echnicalAssistanceCentermaintainsacontinuous

efforttoimprovethequalityandusefulnessofitspublications.Todothis

effectively,weencourageuserfeedback.Pleasecommentonthecompleteness,

accuracy,organization,usability,andreadabilityofthismanualbyane-mail

to[email protected]

orMailto:

TechnicalPublicationManager,Commercial

TheToroCompany

8111LyndaleAvenueSouth

Bloomington,MN55420-1196

Phone:+1952-887-8495

Groundsmaster®4500-D/4700-DPage3ReaderComments

19245SLRevA

NOTES

NOTESPage4Groundsmaster®4500-D/4700-D

19245SLRevA

Preface

Thepurposeofthispublicationistoprovidetheservicetechnicianwith

informationfortroubleshooting,testingandrepairofmajorsystemsand

componentsontheGroundsmaster4500−D(Models30885,30893and

30893TE)andGroundsmaster47000−D(Models30887,30899and30899TE).

RefertotheOperator’sManualsforinstalling,operating,maintenance,and

adjustmentinstructions.KeepacopyoftheOperator’sManualsandParts

CatalogsforyourmachineanditsaccessorieswiththisServiceManualfor

reference.AdditionalcopiesoftheOperator’sManualsandPartsCatalogsare

availableatwww.toro.com.

TheToroCompanyreservestherighttochangetheproductspecicationsor

thispublicationwithoutnotice.

DANGER

Thissafetysymbolmeansdanger.Whenyouseethissymbol,

carefullyreadtheinstructionsthatfollow.Failuretoobeythe

instructionscouldkillorcauseseriouspermanentinjuryordisability.

WARNING

Thissafetysymbolmeanswarning.Whenyouseethissymbol,

carefullyreadtheinstructionsthatfollow.Failuretoobeythe

instructionscanresultinseriousinjury.

CAUTION

Thissafetysymbolmeanscaution.Whenyouseethissymbol,

carefullyreadtheinstructionsthatfollow.Failuretoobeythe

instructionscanresultinminortomoderateinjury.

IMPORTANT

TheImportantnoticewillgivetheimportantinstructionswhichyou

mustfollowtopreventdamagetothesystemsorcomponentson

themachine.

Note:ANotewillgivethegeneralinformationaboutthecorrectoperation,

maintenance,service,testing,orrepairofthemachine.

Groundsmaster®4500-D/4700-DPage5Preface

19245SLRevA

ServiceProcedureIcons

ThefollowingiconsappearthroughoutthisServiceManualtobringattentionto

specicimportantdetailsofaserviceprocedure.

CriticalProcess

Thisiconisusedtohighlight:

•installingsafetyequipment(shields,guards,seatbelts,brakesandR.O.P .S.

components)thatmayhavebeenremoved.

•dimensionsorsettingsthatmustbemaintainedforpropermachineoperation.

•aspecicfastenertighteningsequence.

•componentorientationthatmaynotbeobvious.

CriticalTorque

Thisiconisusedtohighlightanassemblytorquerequirementthatisdifferentthan

whatisrecommendedintheStandardT orqueTables;refertoStandardT orque

forDry,ZincPlated,andSteelFasteners(InchSeries)(page2–11)orStandard

TorqueforDry,ZincPlated,andSteelFasteners(MetricFasteners)(page2–12).

FluidSpecications

Thisiconisusedtohighlightuidspecicationsandcapacitiesthatareless

common,andmaynotappearonthemachineservicedecalorinthemachine

Operator’sManual.

Note:RefertotheservicedecalonthemachineandthemachineOperator’s

Manualforcommonlyuseduidspecicationsandcapacities.

PrefacePage6Groundsmaster®4500-D/4700-D

19245SLRevA

TableofContents
Preface................................................................................................................5
Chapter1:Safety............................................................................................1–1
SafetyInstructions.......................................................................................1–2
SafetyandInstructionalDecals....................................................................1–9
Chapter2:SpecicationsandMaintenance....................................................2–1
Specications...............................................................................................2–2
TorqueSpecications...................................................................................2–8
ShopSupplies............................................................................................2–14
SpecialT ools..............................................................................................2–16
Chapter3:Troubleshooting.............................................................................3–1
GEARS–TheSystematicApproachtoDening,DiagnosingandSolving
Problems......................................................................................................3–2
GeneralHydraulicSystemProblems............................................................3–3
TractionCircuitProblems..............................................................................3–4
MowCircuitProblems...................................................................................3–5
SteeringCircuitProblems.............................................................................3–7
LiftCircuitProblems......................................................................................3–8
EngineCoolingFanCircuitProblems............................................................3–9
OperatorAdvisories....................................................................................3–10
MachineFaultCodes..................................................................................3–12
StartingProblems.......................................................................................3–27
GeneralRunandTransportProblems.........................................................3–28
CuttingDeckOperatingProblems...............................................................3–29
CuttingDeckLift/LowerProblems...............................................................3–30
AftercutAppearance...................................................................................3–32
Chapter4:YanmarDieselEngine....................................................................4–1
GeneralInformation.....................................................................................4–2
ServiceandRepairs.....................................................................................4–9
Chapter5:HydraulicSystem...........................................................................5–1
GeneralInformation.....................................................................................5–3
HydraulicSchematic...................................................................................5–12
HydraulicFlowDiagrams............................................................................5–14
Testing........................................................................................................5–43
Adjustments...............................................................................................5–86
ServiceandRepairs...................................................................................5–87
Chapter6:ElectricalSystem...........................................................................6–1
GeneralInformation.....................................................................................6–2
Adjustments................................................................................................6–19
ElectricalSystemQuickChecks..................................................................6–23
ComponentT esting.....................................................................................6–25
ServiceandRepairs...................................................................................6–69
Chapter7:Axles,PlanetariesandBrakes.......................................................7–1
GeneralInformation.....................................................................................7–2
Adjustments..................................................................................................7–3
ServiceandRepairs.....................................................................................7–4
Chapter8:Chassis..........................................................................................8–1
GeneralInformation.....................................................................................8–2
ServiceandRepairs.....................................................................................8–3
Chapter9:CuttingDecks................................................................................9–1
GeneralInformation.....................................................................................9–2
Adjustments.................................................................................................9–3
ServiceandRepairs.....................................................................................9–4
AppendixA......................................................................................................A–1
ElectricalDrawingDesignations....................................................................A–2
HydraulicSchematic-Groundsmaster4500-D.............................................A–3
HydraulicSchematic-Groundsmaster4700-D.............................................A–4
Groundsmaster®4500-D/4700-DPage7Preface
19245SLRevA

ElectricSchematic-Groundsmaster4500-D/4700-D(Models30885and

30887)..........................................................................................................A–5

ElectricSchematic-Groundsmaster4500-D/4700-D(Models30893,

30893TE,30899and30899TE)....................................................................A–6

OptionalOperatorCabElectricalSchematic-Groundsmaster

4500-D/4700-D.............................................................................................A–7

MainWireHarness-Groundsmaster4500-D/4700-D..................................A–8

MainWireHarness-Groundsmaster4500-D/4700-D..................................A–9

SeatandConsoleWireHarness-Groundsmaster4500-D/4700-D............A–10

SeatandConsoleWireHarness-Groundsmaster4500-D/4700-D.............A–11

PowerCenterWireHarness-Groundsmaster4500-D/4700-D..................A–12

PowerCenterWireHarness-Groundsmaster4500-D/4700-D..................A–13

Deck6and7WireHarness-Groundsmaster4700-D................................A–14

Deck6and7WireHarness-Groundsmaster4700-D................................A–15

EngineWireHarnessDrawing-Groundsmaster4500−D/4700−D

(Models30885and30887).........................................................................A–16

EngineWireHarnessDrawing-Groundsmaster4500−D/4700−D

(Models30885and30887).........................................................................A–17

EngineWireHarnessDrawing-Groundsmaster4500−D/4700−D(Models

30893,30893TE,30899and30899TE)......................................................A–18

EngineWireHarnessDrawing-Groundsmaster4500−D/4700−D(Models

30893,30893TE,30899and30899TE)......................................................A–19

WireHarnessDiagram-Two−PostROPSExtension.................................A–20

WireHarnessDiagram-Two−PostROPSExtension.................................A–21

AdditionalReferenceMaterials

YanmarTNV(Tier4i)SeriesServiceManual

YanmarTNV(Tier4i)SeriesTroubleshootingManual

YanmarTNV(Tier4)SeriesServiceManual

YanmarTNV(Tier4)SeriesTroubleshootingManual

DanfossKAndLFrameVariableMotorsServiceManual

DanfossSteeringUnitTypeOSPMServiceManual

DanfossMP1ClosedCircuitAxialPistonPumpsServiceManual

PrefacePage8Groundsmaster®4500-D/4700-D

19245SLRevA

Chapter1

Safety

TableofContents

SafetyInstructions................................................................................................................................1–2

BeforeOperatingtheMachine...........................................................................................................1–3

WhileOperatingtheMachine.............................................................................................................1–4

MaintenanceandService...................................................................................................................1–5

JackingInstructions...........................................................................................................................1–7

SafetyandInstructionalDecals............................................................................................................1–9

Groundsmaster®4500-D/4700-DPage1–1Safety

19245SLRevA

SafetyInstructions

TheGroundsmaster4500-Dand4700-DaretestedandcertiedbyToro

forcompliancewithexistingsafetystandardsandspecications.Although

hazardcontrolandaccidentpreventionpartiallyaredependentuponthedesign

andcongurationofthemachine,thesefactorsarealsodependentupon

theawareness,concernandpropertrainingofthepersonnelinvolvedinthe

operation,transport,maintenanceandstorageofthemachine.Improperuseor

maintenanceofthemachinecanresultininjuryordeath.

WARNING

Toreducethepotentialofinjuryordeath,complywiththefollowing

safetyinstructionsaswellasinformationfoundintheOperator’s

ManualsandtheOperatorandSafetyTrainingVideosfoundon

www.toro.com.

Safety:SafetyInstructionsPage1–2Groundsmaster®4500-D/4700-D

19245SLRevA

BeforeOperatingtheMachine

•ReviewandunderstandthecontentsoftheOperator’sManualsbefore

startingandoperatingthemachine.Becomefamiliarwiththecontrolsand

knowhowtostopthemachineandenginequickly.Additionalcopiesofthe

Operator’sManualsareavailableatwww.toro.com.

•Neverallowchildrentooperatethemachine.Neverallowadultstooperate

themachinewithoutproperinstructions.

•Becomefamiliarwiththecontrolsandknowhowtostopthemachineand

tractorenginequickly.

•Keepalltheshields,safetydevices,anddecalsinplace.Ifashield,safety

device,ordecalisillegibleordamaged,repairorreplaceitbeforeoperating

themachine.

•Alwayswearsubstantialshoes.Donotoperatemachinewhilewearing

sandals,tennisshoesorsneakers.Donotwearloosettingclothingwhich

couldgetcaughtinmovingpartsandcausepersonalinjury.

•Wearingsafetyglasses,safetyshoes,longpantsandahelmetisadvisable

andrequiredbysomelocalsafetyandinsuranceregulations.

•Makesureworkareaisclearofobjectswhichmightbepickedupandthrown

bytheattachments.

•Keepeveryone,especiallychildrenandpets,awayfromtheareasof

operation.

•Ensurethattheinterlockswitchesareadjustedcorrectlysotheengine

cannotbestartedunlesstractionpedalisinNEUTRALandcuttingdecksare

DISENGAGED.

•Sincethefuelishighlyammable;handleitcarefully.

–Useanapprovedfuelcontainer.

–Donotremovecapfromfueltankwhenengineishotorrunning.

–Donotsmokewhilehandlingfuel.

–Fillfueltankoutdoorsandnohigherthantothebottomoflterscreen.Do

notoverllfueltank.

–Wipeupanyspilledfuel.

Groundsmaster®4500-D/4700-DPage1–3Safety:SafetyInstructions

19245SLRevA

WhileOperatingtheMachine

1.Sitontheseatwhenstartingandoperatingthemachine.

2.Beforestartingtheengine:

A.Applytheparkingbrake.

B.MakesuretractionpedalisinneutralandthePTOswitchisOFF

(disengaged).

3.Afterengineisstarted,releaseparkingbrakeandkeepfootofftractionpedal.

Machinemustnotmove.Ifmovementisevident,theremaybeaproblem

withtractionpedalcalibrationorthepiston(traction)pumpthatneedstobe

correctedbeforeusingthemachine.

4.Donottouchengine,radiatororexhaustsystemwhileengineisrunningor

soonafteritisstopped.Theseareascouldbehotenoughtocauseburns.

5.Donottouchtheengine,muferorexhaustpipewhileengineisrunningor

soonafterithasstoppedbecausetheseareasarehotenoughtocauseburns.

6.Beforegettingofftheseat:

A.Ensurethattractionpedalisinneutral.

B.Fullyloweranddisengagecuttingdecks.Waitforbladestostop.

C.Applytheparkingbrake.

D.Stopengineandremovekeyfromswitch.

7.Tororecommendsthatanytimethemachineisparked(shortorlongterm),

thecuttingdecksshouldbeloweredtotheground.Thisrelieveshydraulic

pressurefromthedeckliftcircuitandeliminatestheriskofthecuttingdecks

unexpectedlyloweringtotheground.

8.Donotparkonslopesunlesswheelsarechockedorblocked.

Safety:SafetyInstructionsPage1–4Groundsmaster®4500-D/4700-D

19245SLRevA

MaintenanceandService

1.TheTractionUnitandCuttingDeckOperator’sManualprovideinformation

regardingtheoperation,generalmaintenanceandmaintenanceintervalsfor

yourGroundsmastermachine.Refertothesepublicationsforadditional

informationwhenservicingthemachine.

2.Beforeservicingormakingadjustments,lowerdecks,stopengine,apply

parkingbrakeandremovekeyfromtheignitionswitch.

3.Makesuremachineisinsafeoperatingconditionbykeepingallnuts,bolts

andscrewstight.

4.Neverstorethemachineorfuelcontainerinsidewherethereisanopen

ame,suchasnearawaterheaterorfurnace.

5.Makesureallhydraulicconnectorsaretightandallhydraulichosesandlines

areingoodconditionbeforeapplyingpressuretothehydraulicsystem.

6.Keepbodyandhandsawayfrompinholeleaksinhydrauliclinesthateject

highpressurehydraulicuid.Usecardboardorpapertondhydraulicleaks.

Hydraulicuidescapingunderpressurecanpenetrateskinandcauseinjury.

Fluidaccidentallyinjectedintotheskinmustbesurgicallyremovedwithina

fewhoursbyadoctorfamiliarwiththisformofinjuryorgangrenemayresult.

7.Beforedisconnectingorperforminganyworkonthehydraulicsystem,all

pressureinsystemmustberelievedbyloweringcuttingdeckstotheground

andstoppingengine.

8.Ifmajorrepairsareeverneededorassistanceisdesired,contactan

AuthorizedT oroDistributor.

9.Toreducepotentialrehazard,keepengineareafreeofexcessivegrease,

grass,leavesanddirt.Cleanprotectivescreenonmachinefrequently.

10.Ifenginemustberunningtoperformmaintenanceoranadjustment,keep

hands,feet,clothingandotherpartsofthebodyawayfromcuttingdecksand

othermovingparts.Keepbystandersaway.

11.T oassuresafetyandaccuracy,checkmaximumenginespeed.

12.Shutengineoffbeforecheckingoraddingoiltothecrankcase.

13.Disconnectbatterybeforeservicingthemachine.Disconnectnegativecable

rstandpositivecablelast.Ifbatteryvoltageisrequiredfortroubleshooting

ortestprocedures,temporarilyconnectthebattery.Reconnectpositivecable

rstandnegativecablelast.

14.Batteryacidispoisonousandcancauseburns.Avoidcontactwithskin,

eyesandclothing.Protectyourface,eyesandclothingwhenworkingwitha

battery.

15.Batterygasescanexplode.Keepcigarettes,sparksandamesawayfrom

thebattery.

16.Atthetimeofmanufacture,themachineconformedtothesafetystandards

forridingmowers.T oassureoptimumperformanceandcontinued

safetycerticationofthemachine,usegenuineTororeplacementparts

andaccessories.Replacementpartsandaccessoriesmadebyother

manufacturersmayresultinnon-conformancewiththesafetystandardsand

thewarrantymaybevoided.

17.Whenchangingattachments,tiresorperformingotherservice,usecorrect

supports,hoistsandjacks.Makesuremachineisparkedonasolidlevel

surfacesuchasaconcreteoor.Priortoraisingthemachine,remove

anyattachmentsthatmayinterferewiththesafeandproperraisingofthe

machine.Alwayschockorblockwheels.Useappropriatejackstandsto

supporttheraisedmachine.Ifthemachineisnotproperlysupportedbyjack

stands,themachinemaymoveorfall,whichmayresultinpersonalinjury

(seeJackingInstructions(page1–7)).

Groundsmaster®4500-D/4700-DPage1–5Safety:SafetyInstructions

19245SLRevA

MaintenanceandService(continued)

18.Whenweldingonmachine,disconnectallbatterycablestopreventdamage

tomachineelectronicequipment.Disconnectnegativebatterycablerstand

positivecablelast.Also,disconnectwireharnessconnectorfrombothofthe

TECcontrollers,disconnectandremovetheengineECManddisconnectthe

terminalconnectorfromthealternator.Attachweldergroundcablenomore

thantwo(2)feet(0.6meters)fromtheweldinglocation.

19.Makesuretodisposeofpotentiallyharmfulwaste(e.g.fuel,oil,engine

coolant,lters,battery)inanenvironmentallysafemanner.Followalllocal

codesandregulationswhenrecyclingordisposingofwaste.

Safety:SafetyInstructionsPage1–6Groundsmaster®4500-D/4700-D

19245SLRevA

JackingInstructions

CAUTION

Whenchangingattachments,tiresorperformingotherservice,use

correctjacksandsupports.Makesuremachineisparkedonasolid,

levelsurfacesuchasaconcreteoor.Priortoraisingmachine,

removeanyattachmentsthatmayinterferewiththesafeandproper

raisingofthemachine.Alwayschockorblockwheels.Usejack

standstosupporttheraisedmachine.Ifthemachineisnotproperly

supportedbyjackstands,themachinemaymoveorfall,whichmay

resultinpersonalinjury.

JackingtheFrontEnd

g036670

Figure1

1.Applyparkingbrakeandchockbothreartirestopreventthemachinefrom

moving.

Note:Donotplacejack,jackstandsorblocksunderthewheelmotors.

Wheelmotorscanbedamagedifusedforjackingorsupportpoints.

2.Positionjacksecurelyundertheframe,justtotheinsideofthefronttire.

3.Jackfrontwheelofftheground.

4.Positionappropriatejackstandsundertheframeasclosetothewheelas

possibletosupportthemachine.

Groundsmaster®4500-D/4700-DPage1–7Safety:SafetyInstructions

19245SLRevA

JackingtheRearEnd

g036671

Figure2

1.Applyparkingbrakeandchockbothfronttirestopreventthemachinefrom

moving.

2.Placejacksecurelyunderthecenterofrearaxle.

3.Jackrearofmachineofftheground.

4.Positionappropriatejackstandsundertherearaxletosupportthemachine.

Safety:SafetyInstructionsPage1–8Groundsmaster®4500-D/4700-D

19245SLRevA

SafetyandInstructionalDecals

Numeroussafetyandinstructiondecalsareafxedtothetractionunitand

cuttingunitsofyourGroundsmaster.Ifanydecalbecomesillegibleordamaged,

installanewdecal.DecalpartnumbersarelistedinyourPartsCatalog.Order

replacementdecalsfromAuthorizedT oroDistributor.

Groundsmaster®4500-D/4700-DPage1–9Safety:SafetyandInstructionalDecals

19245SLRevA

Safety:SafetyandInstructionalDecalsPage1–10Groundsmaster®4500-D/4700-D

19245SLRevA

Chapter2

SpecicationsandMaintenance

TableofContents

Specications.......................................................................................................................................2–2

OverallDimensions............................................................................................................................2–2

Engine(Models30893,30893TE,30899and30899TE)....................................................................2–3

Engine(Models30885and30887)....................................................................................................2–4

HydraulicSystem...............................................................................................................................2–5

Axles,PlanetariesandBrakes...........................................................................................................2–6

CuttingDecks.....................................................................................................................................2–7

TorqueSpecications...........................................................................................................................2–8

CalculatingtheT orqueValuesWhenUsingaDrive-AdapterWrench.................................................2–9

IdentifyingtheFastener....................................................................................................................2–10

StandardT orqueforDry,ZincPlated,andSteelFasteners(InchSeries)..........................................2–11

StandardT orqueforDry,ZincPlated,andSteelFasteners(MetricFasteners).................................2–12

OtherTorqueSpecications.............................................................................................................2–13

ConversionFactors..........................................................................................................................2–13

ShopSupplies....................................................................................................................................2–14

SpecialTools......................................................................................................................................2–16

Groundsmaster®4500-D/4700-DPage2–1SpecicationsandMaintenance

19245SLRevA