4700

Form No.
02104SL Rev E
Groundsmaster® 4500-D/4700-D
Original Instructions (EN)

Revision History
Revision Date Description
-- 2002 Initial Issue.
A 2003 Updated Engine chapter.
B 2005 Updated Hydraulic chapter.
C 2007 Updated Electrical chapter.
D 2007 Updated Hydraulic chapter.
E 03/2018 Added revision history.
© THE TORO COMPANY 2018

This document and all information contained herein is the sole property of The Toro Company (and/or its affiliated companies). No
intellectual property rights are granted by the delivery of this document or the disclosure of its content. This document shall not be
reproduced by a third party without the express written consent of The Toro Company (and/or the appropriate affiliated company).
Reader Comments
The Toro Company Technical Assistance Center maintains a continuous effort to improve the quality
and usefulness of its publications. To do this effectively, we encourage user feedback.
Please comment on the completeness, accuracy, organization, usability, and readability of this manual
by an e-mail to servicemanuals@toro.com
or Mail to:
Technical Publication Manager, Commercial

The Toro Company
8111 Lyndale Avenue South
Bloomington, MN 55420-1196
Phone: +1 952-887-8495
NOTES _
PART NO. 02104SL (Rev. E)
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.
This safety symbol means DANGER, WARNING,
REFER TO THE TRACTION UNIT AND CUTTING or CAUTION, PERSONAL SAFETY INSTRUC-
UNIT OPERATOR’S MANUALS FOR OPERATING, TION. When you see this symbol, carefully read
MAINTENANCE, AND ADJUSTMENT INSTRUC- the instructions that follow. Failure to obey the
TIONS. Space is provided in Chapter 2 of this book to instructions may result in personal injury.
insert the Operator’s Manuals and Parts Catalogs for
your machine. Replacement Operator’s Manuals and NOTE: A NOTE will give general information about the
Parts Catalogs are available on the internet at correct operation, maintenance, service, testing, or re-
www.Toro.com or by sending complete Model and Seri- pair of the machine.
al Number to:
IMPORTANT: The IMPORTANT notice will give im-
The Toro Company portant instructions which must be followed to pre-
Attn. Technical Publications vent damage to systems or components on the
8111 Lyndale Avenue South machine.
Bloomington, MN 55420--1196
The Toro Company reserves the right to change product

specifications or this publication without notice.
E The Toro Company - 2002, 2003, 2005, 2007, 2018

This page is intentionally blank.
Groundsmaster 4500--D/4700--D
Table Of Contents
Safety
Chapter 1 -- Safety Chapter 5 -- Electrical System
General Safety Instructions . . . . . . . . . . . . . . . . . . 1 -- 2 Electrical Schematics and Electrical Harness and

Jacking Instructions . . . . . . . . . . . . . . . . . . . . . . . . . 1 -- 4 Connectors Drawings . . . . . . . . . . . . . . . . . . . . . . 5 -- 2
Safety and Instruction Decals . . . . . . . . . . . . . . . . 1 -- 5 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 -- 2
and Maintenance
Product Records
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 -- 3
Chapter 2 -- Product Records and Maintenance Electrical System Quick Checks . . . . . . . . . . . . . . 5 -- 6
Component Testing . . . . . . . . . . . . . . . . . . . . . . . . . 5 -- 7
Product Records . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 -- 1 Service and Repairs . . . . . . . . . . . . . . . . . . . . . . . 5 -- 27
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 -- 1
Equivalents and Conversions . . . . . . . . . . . . . . . . 2 -- 2 Chapter 6 -- Axles, Planetaries, and Brakes
Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . 2 -- 3
Diesel Engine
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 -- 2
Chapter 3 -- Kubota Diesel Engine Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 -- 3
Kubota
Service and Repairs . . . . . . . . . . . . . . . . . . . . . . . . 6 -- 4
General Information . . . . . . . . . . . . . . . . . . . . . . . . 3 -- 2
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 -- 3 Chapter 7 -- Chassis
Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 -- 4
Service and Repairs . . . . . . . . . . . . . . . . . . . . . . . . 3 -- 5 General Information . . . . . . . . . . . . . . . . . . . . . . . . 7 -- 1
KUBOTA WORKSHOP MANUAL, DIESEL ENGINE, Service and Repairs . . . . . . . . . . . . . . . . . . . . . . . . 7 -- 2
Hydraulic
V2003--T SERIES
System
Chapter 8 -- Cutting Units
Chapter 4 -- Hydraulic System
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 -- 2
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 -- 2 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 -- 3
General Information . . . . . . . . . . . . . . . . . . . . . . . . 4 -- 3 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 -- 4
Hydraulic Schematics . . . . . . . . . . . . . . . . . . . . . . . 4 -- 6 Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 -- 5
Hydraulic Flow Diagrams . . . . . . . . . . . . . . . . . . . . 4 -- 8 Service and Repairs . . . . . . . . . . . . . . . . . . . . . . . . 8 -- 8
Electrical
System
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 -- 20
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 -- 22 Chapter 9 -- Electrical Diagrams
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 -- 25
Service and Repairs . . . . . . . . . . . . . . . . . . . . . . . 4 -- 52 Electrical Schematics . . . . . . . . . . . . . . . . . . . . . . . 9 -- 3
Circuit Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 -- 9
Wire Harness Drawings . . . . . . . . . . . . . . . . . . . . 9 -- 14
Axles, Planetaries,
and Brakes
Chassis
Cutting Units
Diagrams
Electrical
Chapter 1
Safety
Safety
Table of Contents
GENERAL SAFETY INSTRUCTIONS . . . . . . . . . . . . 2 JACKING INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . 4
Before Operating . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 SAFETY AND INSTRUCTION DECALS . . . . . . . . . . 5
While Operating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Maintenance and Service . . . . . . . . . . . . . . . . . . . . 3
Groundsmaster 4500--D/4700--D Page 1 -- 1 Safety

General Safety Instructions
The GROUNDSMASTER 4500-D/4700--D was tested or death. To reduce the potential for injury or death, com-
and certified by TORO for compliance with the ply with the following safety instructions.
B71.4-1999 specifications of the American National
Standards Institute. Although hazard control and acci-
dent prevention partially are dependent upon the design
and configuration of the machine, these factors are also WARNING
dependent upon the awareness, concern, and proper
To reduce the potential for injury or death,
training of the personnel involved in the operation, trans-
comply with the following safety instructions.
port, maintenance, and storage of the machine. Improp-
er use or maintenance of the machine can result in injury
Before Operating
1. Read and understand the contents of the Operator’s 3. Assure interlock switches are adjusted correctly so
Manual before starting and operating the machine. Be- engine cannot be started unless traction pedal is in
come familiar with the controls and know how to stop the NEUTRAL and cutting units are DISENGAGED.
machine and engine quickly. A replacement Operator’s
Manual is available on the Internet at www.Toro.com or 4. Since diesel fuel is highly flammable, handle it care-
by sending the complete model and serial number to: fully:
The Toro Company A. Use an approved fuel container.

Attn. Technical Publications
B. Do not remove fuel tank cap while engine is hot or
8111 Lyndale Avenue South
running.
Bloomington, Minnesota 55420--1196
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 D. Fill fuel tank outdoors and only to within an inch of
or damaged, repair or replace it before operating the the top of the tank, not the filler neck. Do not overfill.
machine. Also tighten any loose nuts, bolts or screws to
ensure machine is in safe operating condition. E. Wipe up any spilled fuel.
While Operating
1. Sit on the seat when starting and operating the ma- 5. Before getting off the seat:
chine.
A. Ensure that traction pedal is in neutral.
2. Before starting the engine:
B. Set parking brake.
A. Engage the parking brake.
C. Disengage cutting units and wait for blades to
B. Make sure traction pedal is in neutral and the stop.
PTO switch is OFF (disengaged).
D. Stop engine and remove key from switch.
C. After engine is started, release parking brake and
keep foot off traction pedal. Machine must not move. E. Toro recommends that anytime the machine is
If movement is evident, the traction pedal linkage is parked (short or long term), the cutting units should
adjusted incorrectly; therefore, shut engine off and be lowered to the ground. This relieves pressure
adjust traction pedal linkage until machine does not from the lift circuit and eliminates the risk of cutting
move when traction pedal is released. units accidentally lowering to the ground.
3. Do not run engine in a confined area without ade- F. Do not park on slopes unless wheels are chocked
quate ventilation. Exhaust fumes are hazardous and or blocked.
could possibly be deadly.
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
Maintenance and Service
Safety
1. Before servicing or making adjustments, lower 10.Do not overspeed the engine by changing governor
decks, stop engine, set parking brake, and remove key setting. To assure safety and accuracy, check maximum
from the switch. engine speed.
2. Make sure machine is in safe operating condition by 11. Shut engine off before checking or adding oil to the
keeping all nuts, bolts and screws tight. crankcase.
3. Never store the machine or fuel container inside 12.Disconnect battery before servicing the machine.
where there is an open flame, such as near a water heat- Disconnect negative battery cable first and positive
er or furnace. cable last. If battery voltage is required for troubleshoot-
ing or test procedures, temporarily connect the battery.
4. Make sure all hydraulic line connectors are tight, and Reconnect positive cable first and negative cable last.
all hydraulic hoses and lines are in good condition be-
fore applying pressure to the system. 13.Battery acid is poisonous and can cause burns.
Avoid contact with skin, eyes, and clothing. Protect your
5. Keep body and hands away from pin hole leaks in hy- face, eyes, and clothing when working with a battery.
draulic lines that eject high pressure hydraulic fluid. Use
cardboard or paper to find hydraulic leaks. Hydraulic 14.Battery gases can explode. Keep cigarettes, sparks,
fluid escaping under pressure can penetrate skin and and flames away from the battery.
cause injury. Fluid accidentally injected into the skin
must be surgically removed within a few hours by a doc- 15.At the time of manufacture, the machine conformed
tor familiar with this form of injury or gangrene may re- to the safety standards for riding mowers. To assure op-
sult. timum performance and continued safety certification of
the machine, use genuine Toro replacement parts and
6. Before disconnecting or performing any work on the accessories. Replacement parts and accessories made
hydraulic system, all pressure in system must be re- by other manufacturers may result in non-conformance
lieved by stopping engine and lowering cutting units to with the safety standards, and the warranty may be
the ground. voided.
7. If major repairs are ever needed or assistance is de- 16.When changing attachments, tires, or performing
sired, contact an Authorized Toro Distributor. other service, use correct blocks, hoists, and jacks.
Make sure machine is parked on a solid level floor such
8. To reduce potential fire hazard, keep engine area as a concrete floor. Prior to raising the machine, remove
free of excessive grease, grass, leaves and dirt. Clean any attachments that may interfere with the safe and
protective screen on machine frequently. proper raising of the machine. Always chock or block
wheels. Use jack stands or solid wood blocks to support
9. If engine must be running to perform maintenance or the raised machine. If the machine is not properly sup-
an adjustment, keep hands, feet, clothing, and other ported by blocks or jack stands, the machine may move
parts of the body away from cutting units and other mov- or fall, which may result in personal injury (see Jacking
ing parts. Keep bystanders away. Instructions).

Jacking Instructions
CAUTION
When changing attachments, tires, or perform-
ing other service, use correct blocks, hoists,
and jacks. Make sure machine is parked on a
solid level surface such as a concrete floor.
1
Prior to raising machine, remove any attach-
ments that may interfere with the safe and prop-
er 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 2
not properly supported by blocks or jack
stands, the machine may move or fall, which Figure 1
may result in personal injury. 1. Frame 2. Front tire (RH shown)
Jacking the Front End (Fig. 1)
1. Set parking brake and chock both rear tires to pre-

vent 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 in-

side of the front tire. 2 1 2
3. Jack front of machine off the ground.
Figure 2
4. Position jack stands or hardwood blocks under the 1. Rear axle 2. Rear tire
frame as close to the wheels as possible to support the
machine.
Jacking the Rear End (Fig. 2)
1. Set parking brake and chock both front tires to pre-

vent 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 and Instruction Decals
Safety
Numerous safety and instruction decals are affixed to
the Groundsmaster 4500--D/4700--D. If any decal be-
comes illegible or damaged, install a new decal. Decal
part numbers are listed in your Parts Catalog.


Chapter 2
Product Records and Maintenance
and Maintenance
Product Records
Table of Contents
PRODUCT RECORDS . . . . . . . . . . . . . . . . . . . . . . . . . 1 Standard Torque for Dry, Zinc Plated, and
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Steel Fasteners (Inch Series) . . . . . . . . . . . . . . . 4
EQUIVALENTS AND CONVERSIONS . . . . . . . . . . . 2 Standard Torque for Dry, Zinc Plated, and
Decimal and Millimeter Equivalents . . . . . . . . . . . . 2 Steel Fasteners (Metric Fasteners) . . . . . . . . . . . 5
U.S. to Metric Conversions . . . . . . . . . . . . . . . . . . . 2 Other Torque Specifications . . . . . . . . . . . . . . . . . . 6
TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . 3 Conversion Factors . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Fastener Identification . . . . . . . . . . . . . . . . . . . . . . . 3
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 ac-
cessories have been installed to your machine, insert
the Installation Instructions, Operator’s Manuals and
Parts Catalogs for those options at the end of this chap-
ter.
Maintenance
Maintenance procedures and recommended service in-
tervals for the Groundsmaster 4500--D/4700--D are cov-
ered in the Operator’s Manual. Refer to that publication
when performing regular equipment maintenance.
Groundsmaster 4500--D/4700--D Page 2 -- 1 Product Records and Maintenance

Rev. D
Equivalents and Conversions
0.09375
Product Records and Maintenance Page 2 -- 2 Groundsmaster 4500--D/4700--D

Rev. D
Torque Specifications
Recommended fastener torque values are listed in the As noted in the following tables, torque values should be
following tables. For critical applications, as determined reduced by 25% for lubricated fasteners to achieve
by Toro, either the recommended torque or a torque that the similar stress as a dry fastener. Torque values may
is unique to the application is clearly identified and spe- also have to be reduced when the fastener is threaded
cified in this Service Manual. into aluminum or brass. The specific torque value
and Maintenance
Product Records
should be determined based on the aluminum or brass
These Torque Specifications for the installation and material strength, fastener size, length of thread en-
tightening of fasteners shall apply to all fasteners which gagement, etc.
do not have a specific requirement identified in this Ser-
vice Manual. The following factors shall be considered The standard method of verifying torque shall be per-
when applying torque: cleanliness of the fastener, use formed by marking a line on the fastener (head or nut)
of a thread sealant (e.g. Loctite), degree of lubrication and mating part, then back off fastener 1/4 of a turn.
on the fastener, presence of a prevailing torque feature, Measure the torque required to tighten the fastener until
hardness of the surface underneath the fastener’s head, the lines match up.
or similar condition which affects the installation.
Fastener Identification
Grade 1 Grade 5 Grade 8 Class 8.8 Class 10.9
Inch Series Bolts and Screws Metric Bolts and Screws

Figure 1 Figure 2

Standard Torque for Dry, Zinc Plated, and Steel Fasteners (Inch Series)
Grade 1, 5, & SAE Grade 1 Bolts, Screws, Studs, & SAE Grade 5 Bolts, Screws, Studs, & SAE Grade 8 Bolts, Screws, Studs, &
Thread Size 8 with Thin Sems with Regular Height Nuts Sems with Regular Height Nuts Sems with Regular Height Nuts
Height Nuts (SAE J995 Grade 2 or Stronger Nuts) (SAE J995 Grade 2 or Stronger Nuts) (SAE J995 Grade 5 or Stronger Nuts)
in--lb in--lb N--cm in--lb N--cm in--lb N--cm
# 6 -- 32 UNC 15 + 2 170 + 20 23 + 2 260 + 20

10 + 2 13 + 2 147 + 23
# 6 -- 40 UNF 17 + 2 190 + 20 25 + 2 280 + 20
# 8 -- 32 UNC 29 + 3 330 + 30 41 + 4 460 + 45

13 + 2 25 + 5 282 + 30
# 8 -- 36 UNF 31 + 3 350 + 30 43 + 4 485 + 45
# 10 -- 24 UNC 42 + 4 475 + 45 60 + 6 675 + 70

18 + 2 30 + 5 339 + 56
# 10 -- 32 UNF 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 on the fastener size, the aluminum or base material
by 25% for lubricated fasteners. Lubricated fasteners strength, length of thread engagement, etc.
are defined as threads coated with a lubricant such as
oil, graphite, or thread sealant such as Loctite. NOTE: The nominal torque values listed above for
Grade 5 and 8 fasteners are based on 75% of the mini-
NOTE: Torque values may have to be reduced when mum proof load specified in SAE J429. The tolerance is
installing fasteners into threaded aluminum or brass. approximately + 10% of the nominal torque value. Thin
The specific torque value should be determined based height nuts include jam nuts.

Standard Torque for Dry, Zinc Plated, and Steel Fasteners (Metric Fasteners)
Class 8.8 Bolts, Screws, and Studs with Class 10.9 Bolts, Screws, and Studs with
Thread Size Regular Height Nuts Regular Height Nuts
(Class 8 or Stronger Nuts) (Class 10 or Stronger Nuts)
and Maintenance
Product Records
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 on the fastener size, the aluminum or base material
by 25% for lubricated fasteners. Lubricated fasteners strength, length of thread engagement, etc.
are defined as threads coated with a lubricant such as
oil, graphite, or thread sealant such as Loctite.
NOTE: The nominal torque values listed above are
NOTE: Torque values may have to be reduced when based on 75% of the minimum proof load specified in
installing fasteners into threaded aluminum or brass. SAE J1199. The tolerance is approximately + 10% of the
The specific torque value should be determined based nominal torque value.

Other Torque Specifications
SAE Grade 8 Steel Set Screws Wheel Bolts and Lug Nuts
Recommended Torque Thread Size Recommended Torque**

Thread Size
Square Head Hex Socket 7/16 -- 20 UNF 65 + 10 ft--lb 88 + 14 N--m
Grade 5
1/4 -- 20 UNC 140 + 20 in--lb 73 + 12 in--lb
1/2 -- 20 UNF 80 + 10 ft--lb 108 + 14 N--m
5/16 -- 18 UNC 215 + 35 in--lb 145 + 20 in--lb Grade 5
3/8 -- 16 UNC 35 + 10 ft--lb 18 + 3 ft--lb M12 X 1.25 80 + 10 ft--lb 108 + 14 N--m

Class 8.8
1/2 -- 13 UNC 75 + 15 ft--lb 50 + 10 ft--lb
M12 X 1.5 80 + 10 ft--lb 108 + 14 N--m
Class 8.8
** For steel wheels and non--lubricated fasteners.

Thread Cutting Screws Thread Cutting Screws
(Zinc Plated Steel) (Zinc Plated Steel)
Type 1, Type 23, or Type F Thread Threads per Inch

Size Baseline Torque*
Thread Size Baseline Torque* Type A Type B
No. 6 -- 32 UNC 20 + 5 in--lb No. 6 18 20 20 + 5 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 * Hole size, material strength, material thickness & finish
must be considered when determining specific torque
3/8 -- 16 UNC 200 + 100 in--lb values. All torque values are based on non--lubricated
fasteners.
Conversion Factors
in--lb X 11.2985 = N--cm N--cm X 0.08851 = in--lb
ft--lb X 1.3558 = N--m N--m X 0.7376 = ft--lb

Chapter 3
Kubota Diesel Engine

Table of Contents
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . 2 Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Engine Removal . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Engine Run Solenoid . . . . . . . . . . . . . . . . . . . . . . . . 4 Engine Installation . . . . . . . . . . . . . . . . . . . . . . . . 14
SERVICE AND REPAIRS . . . . . . . . . . . . . . . . . . . . . . 5 Pump Adapter Plate . . . . . . . . . . . . . . . . . . . . . . . . 16
Diesel Engine
Air Filter System . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 KUBOTA WORKSHOP MANUAL, DIESEL ENGINE,
Kubota
Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 V2003--T SERIES
Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Check Fuel Lines and Connections . . . . . . . . . . . 8
Drain and Clean Fuel Tank . . . . . . . . . . . . . . . . . . 8
Fuel Tank Removal . . . . . . . . . . . . . . . . . . . . . . . . 9
Fuel Tank Installation . . . . . . . . . . . . . . . . . . . . . . . 9
Groundsmaster 4500--D/4700--D Page 3 -- 1 Kubota Diesel Engine (Rev. A)

General Information
This Chapter gives information about specifications and tools are described in the Kubota Workshop Manual,
repair of the diesel engine used in the Groundsmaster Diesel Engine, V2003--T. The use of some specialized
4500--D/4700--D. test equipment is explained. However, the cost of the
test equipment and the specialized nature of some re-
General maintenance procedures are described in your pairs may dictate that the work be done at an engine re-
Traction Unit Operator’s Manual. Information on engine pair facility.
troubleshooting, testing, disassembly and reassembly
is identified in the Kubota Workshop Manual, Diesel En- Service and repair parts for Kubota engines are sup-
gine, V2003--T that is included at the end of this section. plied through your Authorized Toro Distributor. If no
parts list is available, be prepared to provide your distrib-
Most repairs and adjustments require tools which are utor with the Toro model and serial number.
commonly available in many service shops. Special
Kubota Diesel Engine (Rev. A) Page 3 -- 2 Groundsmaster 4500--D/4700--D

Specifications
Item Description
Make / Designation Kubota, 4--Cycle, 4 Cylinder,

Water Cooled, Turbocharged, Diesel Engine
Horse Power 58 HP (43.3 kW) @ 2600 RPM
Bore mm (in.) 83.0 (3.27)
Stroke mm (in.) 92.4 (3.64)
Diesel Engine
Total Displacement cc (cu. in.) 1999 (122.12)
Kubota
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) 184 (406)

Adjustments
Engine Run Solenoid
1. When ignition switch is in the RUN position, the en-
gine run solenoid should energize and position the fuel 4 3 2
stop lever to within 1/16” (1.6 mm) of stop on the injec-
tion pump.
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) 3. Swivel
2. Lever 4. Lock nut
Figure 2
1. Run solenoid (OFF) 3. Injection pump stop
2. Solenoid lever

Service and Repairs
Air Filter System
7 8
10
Diesel Engine
Kubota
11 4
1
RIGHT
2
9 15
FRONT
12
3 13
5
6 11 14
VACUATOR
DIRECTION
16
Figure 3
1. Air cleaner hose 7. Hose clamp 12. Air cleaner body
2. Hose clamp 8. Air cleaner hose 13. Filter element
3. Air cleaner assembly 9. Hose clamp 14. Filter element
4. Service indicator 10. Cap screw 15. Air cleaner cover
5. Air cleaner strap 11. Flat washer 16. Vacuator valve
6. Lock nut
Removal
4
1. Remove air cleaner components as needed using
Figure 3 as a guide.
1
Installation
IMPORTANT: Any leaks in the air filter system will 3 5

cause serious engine damage. Make sure daily that
all air cleaner components are in good condition
and are properly secured during reassembly.
1. Assemble air filter system using Figure 3 as a guide.
2. When installing air cleaner hose (8) between air 2

cleaner and turbo--charger (Fig. 4):
Figure 4
A. Make sure that hose does not contact engine 1. Air cleaner hose 4. Air cleaner body
valve cover. To modify clearance, move and/or rotate 2. Engine valve cover 5. Muffler bracket
air cleaner body in air cleaner strap. Verify that tabs 3. Air cleaner strap
in strap mesh fully with slots in air cleaner body.
B. Position hose to allow 5/16” (7.9 mm) clearance

between air cleaner hose and muffler bracket.

Exhaust System
1
14
3
11
16 to 22 ft--lb
(21 to 29 N--m)
4 2
16 to 22 ft--lb
5
(21 to 29 N--m) 12
11
7
8
9
7 8
6
RIGHT 10
6
FRONT
13
16 to 22 ft--lb
(21 to 29 N--m)
Figure 5
1. Muffler 6. Lock nut 11. Flange nut
2. Muffler bracket/lift tab 7. Cap screw 12. Flange head screw
3. Exhaust tailpipe 8. Flat washer 13. Engine mount
4. Flange head screw 9. Spacer 14. Muffler clamp
5. Exhaust gasket 10. Rubber hanger

Removal
3
CAUTION
The muffler and exhaust pipe may be hot. To
avoid possible burns, allow the engine and ex-
haust system to cool before working on the muf-
fler. 2
4
1. Park machine on a level surface, lower cutting units,
stop engine, engage parking brake, and remove key
from the ignition switch.
Diesel Engine
2. Remove muffler and/or muffler bracket from the en-
Kubota
gine as necessary using Figure 5 as a guide. 1
Installation
Figure 6
NOTE: Make sure muffler flange and exhaust manifold
sealing surfaces are free of debris or damage that may
prevent a tight seal.
1. Install new gasket if original gasket is damaged or

torn.
IMPORTANT: Failure to follow the suggested muf-

fler fastener sequence may result in premature muf-
fler 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 brack-

et.
C. Flange head screws that secure muffler flange to

engine.
D. Flange nuts that secure muffler bracket to en-

gine.
3. Adjust tailpipe so it has equal clearance between

frame and engine before tightening muffler clamp.

Fuel System
16
6
3
7
4
RIGHT 2 8
5
FRONT
17
9
10
11
14
12
13 15
Figure 7
1. Suction fitting 7. Bushing 13. Cap screw (4 used)
2. Fuel line clamp 8. Fuel level gauge 14. Hose clamp
3. Fuel hose 9. Grommet 15. Draincock
4. Return fitting 10. Fuel tank 16. Hose clamp
5. Fuel hose 11. Tank mount grommet (4 used) 17. Frame
6. Fuel tank cap 12. Flat washer (4 used)
Check Fuel Lines and Connections
DANGER Check fuel lines and connections periodically as recom-

mended in the Traction Unit Operator’s Manual. Check
Because diesel fuel is highly flammable, use cau- lines for deterioration, damage, leaking, or loose con-
tion when storing or handling it. Do not smoke nections. Replace hoses, clamps, and connections as
while filling the fuel tank. Do not fill fuel tank necessary.
while engine is running, hot, or when machine is
in an enclosed area. Always fill fuel tank outside Drain and Clean Fuel Tank
and wipe up any spilled diesel fuel before start-
ing the engine. Store fuel in a clean, safety--ap- Drain and clean the fuel tank periodically as recom-
proved container and keep cap in place. Use die- mended in the Traction Unit Operator’s Manual. Also,
sel fuel for the engine only; not for any other drain and clean the fuel tank if the fuel system becomes
purpose. contaminated or if the machine is to be stored for an ex-
tended period. To clean fuel tank, flush tank out with
clean diesel fuel. Make sure tank is free of contaminates
and debris.
Fuel Tank Removal Fuel Tank Installation
1. Park machine on a level surface, lower cutting units, 1. Install fuel tank to frame using Figure 7 as a guide.
from the ignition switch. 2. Connect fuel hoses to the suction and return fittings
in top of tank.
2. Disconnect fuel hoses from the suction and return fit-
tings in top of tank. 3. Make sure that draincock is closed.
3. Use draincock to empty fuel tank into a suitable con- 4. Fill fuel tank (see Traction Unit Operator’s Manual).
tainer.
4. Remove fuel tank using Figure 7 as a guide.
Diesel Engine
Kubota

Radiator
2 1 29 36
3 28
4 15 3
5 37
RIGHT 39
6 35
7
FRONT 8 34
9
10
11
15
12
13
14
27
25 26 18
33
32
31
30
15
38
40
24
15
23 22
15
16 21
17 9 10
18 19 18 20
Figure 8
1. Hydraulic fitting 15. Flange nut 28. O--ring
2. Oil cooler 16. Tank bracket 29. O--ring
3. Flange nut 17. Flat washer 30. Oil cooler mount plate
4. Radiator bracket 18. Flange head screw 31. Oil cooler clamp
5. Bulb seal 19. Coolant reservoir 32. Flat washer
6. Air cleaner hose 20. Reservoir cap 33. Cap screw
7. Hood seal bracket 21. Flange head screw 34. Wire form clamp
8. Radiator 22. Flange nut 35. Cap screw
9. Reservoir hose 23. Bulb seal 36. Washer
10. Hose clamp 24. Bottom cover 37. Oil cooler bracket (top)
11. Radiator cap 25. Flange head screw 38. Bulb seal
12. Radiator fan shroud 26. Washer head screw 39. Foam seal
13. Clamp 27. Spacer 40. Foam seal
14. Radiator hose

Removal 4. Attach radiator fan shroud to the radiator with flange
screws and flat washers. Make sure that clearance be-
1. Park machine on a level surface, lower cutting units, tween shroud and fan is at least .180” (4.6 mm) at all
stop engine, engage parking brake, and remove key points.
5. Connect reservoir hose to the vent tube.
2. Remove hood from the machine (see Traction Unit
Operator’s Manual). 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).
Do not open radiator cap or drain coolant if the
radiator or engine is hot. Pressurized, hot cool- 9. Install hood on the machine.
Diesel Engine
ant can escape and cause burns.
Kubota
Ethylene--glycol antifreeze is poisonous. Dis-
pose 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 1
housing (Figures 9 and 10).
4. Disconnect hoses (upper and lower) from the radia- 2

tor.
3
5. Remove air cleaner hose.
6. Disconnect reservoir hose from the vent tube.
7. Detach radiator fan shroud from the radiator by re- Figure 9

moving four flange head screws and flat washers. Posi- 1. Oil filter housing 3. Coolant draincock
tion shroud away from radiator. 2. Coolant drain hose
8. Pivot rear screen and oil cooler away from radiator

(see Traction Unit Operator’s Manual).
9. Remove flange head screws and lock nuts securing 1

the radiator to the support frame. Pull radiator from the
2
machine.
10.Plug any radiator or hose openings to prevent con-

tamination.
Installation
1. Remove any plugs used during the removal proce-

dure.
2. Position radiator to the support frame. Secure radia- Figure 10

tor to the support frame with lock nuts and flange head 1. Coolant drain hose 2. Coolant draincock
screws.
3. Pivot and secure oil cooler and rear screen (see

Traction Unit Operator’s Manual).

Engine
16 to 22 ft--lb
(21 to 29 N--m)
12
13
15 14
16
17
16 to 22 ft--lb 15
(21 to 29 N--m) 22
18
19 23
20
21
11
1
2 25
24
RIGHT
6
7 9
8 10
FRONT
3
4
5
4
Figure 11
1. Engine 10. Bolt 18. Lock nut
2. Flange head screw 11. LH engine mount 19. RH engine mount
3. Rubber engine support 12. Muffler bracket/lift tab 20. Cap screw
4. Flange nut 13. Flange nut 21. RH engine mount
5. Rebound washer 14. Cap screw 22. Fusible link
6. LH engine mount 15. Flat washer 23. Engine wire harness
7. Lock washer 16. Spacer 24. Cap screw
8. Cap screw 17. Rubber hanger (exhaust) 25. Lift tab
9. Lock washer

Engine Removal

stop engine, engage parking brake, and remove key 2
from the ignition switch. Raise hood. 3
2. Remove battery strap and cover. Disconnect nega-

tive battery cable first and then positive battery cable.
Remove battery from machine.
1
CAUTION 3
Do not open radiator cap or drain coolant if the
Diesel Engine
radiator or engine is hot. Pressurized, hot cool-
ant can escape and cause burns. Figure 12
Kubota
1. Alternator 3. Coolant hose
2. Temperature sender
Ethylene--glycol antifreeze is poisonous. Dis-
pose of coolant properly, or store it in a properly
labeled container away from children and pets.
3. Drain coolant from radiator into a suitable container

1
(see Radiator Removal). Disconnect coolant hoses
from the radiator (Fig. 12).
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.
Figure 13
4. Remove exhaust system from engine (see Muffler 1. Engine run solenoid 2. Solenoid harness
Removal).
5. Remove air cleaner system from engine (see Air

Cleaner Removal). 1
6. Note location of cable ties used to secure wires. Dis-
connect 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.
B. The engine run solenoid (Fig. 13). 2
C. The high temperature shutdown switch and glow Figure 14

1. Glow plug connection 3. Engine lift tab
plug connection (Fig. 14). 2. High temp shutdown
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 pres-

sure switch located on alternator side of engine (near
electric starter) (Fig. 16).

7. Disconnect fuel line from injection pump (Fig. 17).
Cap fuel line and injector pump fuel inlet to prevent con-
tamination.
8. Disconnect throttle cable from the speed control le-

ver by removing the washer and lock nut. Loosen jam 4
nut and take cable from mounting bracket (Fig. 17).
9. Remove coolant reservoir and bracket from fan

shroud. 5
10.Remove four flange head screws and flat washers 1

securing the fan shroud to the radiator.
2
11. Disconnect two wires from neutral switch on hydrau-
lic traction pump.
3
IMPORTANT: Support hydraulic pump assembly to
Figure 15
prevent it from falling and being damaged.
1. Battery cable (+) 4. Engine wire harness
2. Battery cable (--) 5. Fusible link harness
12.Remove hydraulic pump assembly from engine (see 3. Engine to frame ground
Pump Assembly in Chapter 4 -- Hydraulic Systems).
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. 2
14) lift tabs on engine.
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 Figure 16

other person guides the engine out of the ma- 1. Electric starter 3. Oil pressure switch
chine. 2. Fusible link connection
IMPORTANT: Make sure not to damage the engine,

fuel lines, hydraulic lines, electrical harness, or oth-
er parts while removing the engine. 3 4
16.Slowly remove engine from the machine.
17.If necessary, remove engine mounts from the engine

2 5
using Figure 11 as a guide.
Engine Installation 1
1. If removed, install engine mounts to the engine using
Figure 11 as a guide. Figure 17
1. Engine run solenoid 4. Cable jam nut
2. Connect hoist or lift to the front (Fig. 11) and rear (Fig. 2. Fuel line 5. Cable washer/lock nut
14) lift tabs on engine. 3. Throttle cable
3. Position fan shroud around the engine fan.

13.Install air cleaner assembly to the engine (see Air
CAUTION Cleaner Installation).
14.Install exhaust system to machine (see Muffler

One person should operate lift or hoist while the Installation).
other person guides the engine into the machine.
15.Connect coolant hoses to the radiator. Make sure ra-
IMPORTANT: Make sure not to damage the engine, diator drain is shut. Fill radiator and reservoir with cool-
fuel lines, hydraulic lines, electrical harness, or oth- ant.
er parts while installing the engine.
16.Check position of wires, fuel lines, hydraulic hoses,
4. Slowly lower engine into the machine. and cables for proper clearance with rotating, high tem-
perature, and moving components.
5. Align engine mounts to the rubber engine supports.
Secure engine with cap screws, rebound washers, and 17.Position battery to machine. Connect positive bat-
Diesel Engine
flange head nuts. tery cable first and then negative battery cable. Secure
Kubota
battery to machine with cover and strap.
6. Secure fan shroud to the radiator with four flange
head screws and flat washers. Make sure that clearance 18.Check and adjust engine oil as needed (see Traction
between shroud and fan is at least .180” (4.6 mm) at all Unit Operator’s Manual).
points.
19.Check and adjust hydraulic oil as needed (see Trac-
7. Install coolant reservoir bracket and reservoir to fan tion Unit Operator’s Manual).
shroud.
20.Bleed fuel system (see Traction Unit Operator’s
8. Connect throttle cable to the speed control lever with Manual).
washer and lock nut. Install cable to mounting bracket
(Fig. 17). Adjust throttle cable (see Traction Unit Opera- 21.Operate hydraulic controls to properly fill hydraulic
tor’s Manual). 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 pres-

sure switch located on alternator side of engine (near
electric starter) (Fig. 16).

Pump Adapter Plate
17 to 21 ft--lb 2
(23 to 28 N--m)
3
6
7
5
2
8
9
RIGHT 17 to 21 ft--lb
(23 to 28 N--m)
10
11
FRONT
10
35 to 43 ft--lb
12 (48 to 58 N--m)
Figure 18
1. Engine 5. Plate pin (2 used) 9. Spring center coupling
2. Lock washer 6. Dowel (2 used) 10. Lock washer
3. Cap screw (4 used) 7. Coupling spacer 11. Cap screw (6 used)
4. Pump adapter plate 8. Shoulder bolt (2 used) 12. Cap screw (9 used)

Disassembly
1. Hydraulic pump assembly needs to be removed from

engine before coupling can be serviced (see Pump As-
sembly 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
1. Position coupling spacer to engine and align mount- 3 4
ing holes. Use two shoulder bolts and lockwashers in the
positions shown in Figure 19 to secure the spacer to the
Diesel Engine
half threaded holes in engine flywheel. Torque shoulder
1
Kubota
bolts from 17 to 21 ft--lb (23 to 28 N--m).
2. Install four cap screws and lockwashers to coupling

spacer and flywheel. Torque cap screws from 17 to 21 Figure 19
ft--lb (23 to 28 N--m). 1. Coupling spacer 3. Cap screw position
2. Shoulder bolt position 4. Dowel position
3. Place dowels in locating holes of coupling spacer

(Fig. 19).
4. Position spring center coupling (coil springs toward Hydraulic Engine Side
engine (Fig. 20)) over dowels. Secure coupling to cou- Pump Side
pling 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.
Spring Center
Coupling
Figure 20


Chapter 4
Hydraulic System
Table of Contents
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Flush Hydraulic System . . . . . . . . . . . . . . . . . . . . . 53
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . 3 Charge Hydraulic System . . . . . . . . . . . . . . . . . . . 54
Hydraulic Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Gear Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Hydraulic Fitting Installation . . . . . . . . . . . . . . . . . . . 3 Gear Pump Service . . . . . . . . . . . . . . . . . . . . . . . . . 58
Towing Traction Unit . . . . . . . . . . . . . . . . . . . . . . . . . 5 Piston (Traction) Pump . . . . . . . . . . . . . . . . . . . . . . 62
Check Hydraulic Fluid . . . . . . . . . . . . . . . . . . . . . . . 5 Piston (Traction) Pump Service . . . . . . . . . . . . . . 64
HYDRAULIC SCHEMATICS . . . . . . . . . . . . . . . . . . . . 6 Piston Pump Manual Servo Control Assembly . . 68
GM 4500--D Hydraulic Schematic . . . . . . . . . . . . . 6 Hydraulic Control Manifolds: 2 Wheel/4 Wheel
GM 4700--D Hydraulic Schematic . . . . . . . . . . . . . 7 Drive, Filtration and Charge, Power Down and
HYDRAULIC FLOW DIAGRAMS . . . . . . . . . . . . . . . . 8 Traction Assist . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Traction Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Hydraulic Control Manifold Service:
Hydraulic
Lower Cutting Units . . . . . . . . . . . . . . . . . . . . . . . . . 10 2 Wheel/4 Wheel Drive Control . . . . . . . . . . . . . 72
System
Raise Cutting Units . . . . . . . . . . . . . . . . . . . . . . . . . 12 Hydraulic Control Manifold Service:
Mow Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Filtration and Charge Control . . . . . . . . . . . . . . . 74
Cutting Deck Blade Braking . . . . . . . . . . . . . . . . . . 16 Hydraulic Control Manifold Service: Power Down
Steering Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 and Traction Assist (GM 4500--D) . . . . . . . . . . . 75
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Hydraulic Control Manifold Service: Power Down
Hydraulic Pressure Test Kit . . . . . . . . . . . . . . . . . . 20 and Traction Assist (GM 4700--D) . . . . . . . . . . . 76
Hydraulic Tester (Pressure and Flow) . . . . . . . . . 20 Hydraulic Control Manifold: Deck Drive
Hydraulic Test Fitting Kit . . . . . . . . . . . . . . . . . . . . . 21 (GM 4500--D) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Measuring Container . . . . . . . . . . . . . . . . . . . . . . . 21 Hydraulic Control Manifold Service: Deck
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . 22 Drive (GM 4500--D) . . . . . . . . . . . . . . . . . . . . . . . 79
TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Hydraulic Control Manifold: Deck Drive
Test No. 1: Traction Circuit Charge Pressure . . . 26 (GM 4700--D) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Test No. 2: Traction Circuit Relief Pressure . . . . 28 Hydraulic Control Manifold Service: Deck
Test No. 3: Cutting Deck Circuit Pressure . . . . . . 30 Drive (GM 4700--D) . . . . . . . . . . . . . . . . . . . . . . . 81
Test No. 4: Cutting Deck Gear Pump Flow . . . . . 32 Rear Axle Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Test No. 5: Cutting Deck Manifold Front Wheel Motors . . . . . . . . . . . . . . . . . . . . . . . . 84
Relief Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 Rear Axle/Front Wheel Motor Service . . . . . . . . . 86
Test No. 6: Cutting Deck Motor Case Cutting Deck Motor . . . . . . . . . . . . . . . . . . . . . . . . . 89
Drain Leakage . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 Cutting Deck Motor Service . . . . . . . . . . . . . . . . . . 90
Test No. 7: Steering Circuit Relief Pressure . . . . 38 Lift/Lower Control Valve (GM 4500--D) . . . . . . . . 94
Test No. 8: Lift/Lower Circuit Relief Pressure . . . 40 Lift/Lower Control Valve Service (GM 4500--D) . 96
Test No. 9: Steering and Lift/Lower Lift/Lower Control Valve (GM 4700--D) . . . . . . . . 98
Gear Pump Flow . . . . . . . . . . . . . . . . . . . . . . . . . 42 Lift/Lower Control Valve Service (GM 4700--D) 100
Test No. 10: Counterbalance (RV1) Pressure . . 44 Steering Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
Test No. 11: Rear Traction Circuit (RV5) Relief Steering Valve Service . . . . . . . . . . . . . . . . . . . . . 104
Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 Lift Cylinders: Decks #1, #4, and #5 . . . . . . . . . 106
Test No. 11: Traction Circuit Reducing Valve Lift Cylinders: Decks #2 and #3 . . . . . . . . . . . . . 108
(PR1) Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . 48 Lift Cylinders: Decks #6 and #7 (GM 4700--D) . 110
Test No. 13: Traction Assist (RV2) Pressure . . . . 50 Lift Cylinder Service . . . . . . . . . . . . . . . . . . . . . . . 112
SERVICE AND REPAIRS . . . . . . . . . . . . . . . . . . . . . 52 Steering Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . 114
General Precautions for Removing and Steering Cylinder Service . . . . . . . . . . . . . . . . . . 116
Installing Hydraulic System Components . . . . 52 Hydraulic Reservoir . . . . . . . . . . . . . . . . . . . . . . . 118
Check Hydraulic Lines and Hoses . . . . . . . . . . . . 52 Hydraulic Oil Cooler . . . . . . . . . . . . . . . . . . . . . . . 119
Groundsmaster 4500--D/4700--D Page 4 -- 1 Hydraulic System (Rev. A)

Specifications
Item Description
Piston (Traction) Pump Variable displacement piston pump

System Relief Pressure: Forward 5000 PSI (345 bar)
System Relief Pressure: Reverse 5000 PSI (345 bar)
Charge Pressure 260 PSI (17.9 bar)
Gear Pump 3 section, positive displacement gear type pump

Cutting Deck Relief Pressure 3500 PSI (241.5 bar)
Steering Relief Pressure 1180 PSI (81.4 bar)
Lift/Lower Relief Pressure 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 2 Micron (nominal) spin--on cartridge type

In--line Suction Strainer 100 mesh (in reservoir)
Hydraulic Reservoir 7.5 gal. (28.4 l)
Hydraulic Oil See Traction Unit Operator’s Manual
Hydraulic System (Rev. A) Page 4 -- 2 Groundsmaster 4500--D/4700--D

General Information
Hydraulic Hoses
Hydraulic hoses are subject to extreme conditions such
as pressure differentials during operation and exposure
to weather, sun, chemicals, very warm storage condi- WARNING
tions, or mishandling during operation and mainte-
Before disconnecting or performing any work
nance. These conditions can cause damage or
on hydraulic system, relieve all pressure in
premature deterioration. Some hoses are more suscep-
system. Stop engine; lower or support all at-
tible to these conditions than others. Inspect the hoses
tachment(s).
frequently for signs of deterioration or damage.
When replacing a hydraulic hose, be sure that the hose Keep body and hands away from pin hole leaks
is straight (not twisted) before tightening the fittings. or nozzles that eject hydraulic fluid under high
This can be done by observing the imprint on the hose. pressure. Use paper or cardboard, not hands,
Use two wrenches; hold the hose straight with one to search for leaks. Hydraulic fluid escaping
wrench and tighten the hose swivel nut onto the fitting under pressure can have sufficient force to
with the other wrench. penetrate the skin and cause serious injury. If
fluid is injected into the skin, it must be surgi-
cally removed within a few hours by a doctor
Hydraulic
System
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. Nut
Body
2. Make sure the O--ring is installed and properly Sleeve

seated in the groove. It is recommended that the O--ring
be replaced any time the connection is opened. 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.
5. Mark the nut and fitting body. Hold the body with a Figure 1
wrench. Use another wrench to tighten the nut to the cor-
rect Flats From Finger Tight (F.F.F.T.). The markings on
the nut and fitting body will verify that the connection has
been tightened.
Final
Position
Size F.F.F.T.
Mark Nut
4 (1/4 in. nominal hose or tubing) 0.75 + 0.25 and Body
6 (3/8 in.) 0.75 + 0.25
8 (1/2 in.) 0.75 + 0.25 Initial
Extend Line Position
10 (5/8 in.) 1.00 + 0.25
12 (3/4 in.) 0.75 + 0.25
16 (1 in.) 0.75 + 0.25 Finger Tight After Proper Tightening
Figure 2

SAE Straight Thread O--Ring Port -- Non--adjustable

free of burrs, nicks, scratches, or any foreign material.
2. Always replace the O--ring seal when this type of fit-

ting 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. Figure 3
5. Tighten the fitting to the correct Flats From Finger
Tight (F.F.F.T.). Fitting Size Installation Torque
Size F.F.F.T. 4 9--10 ft--lb (12--13 N--m)
4 (1/4 in. nominal hose or tubing) 1.00 + 0.25 6 20--21 ft--lb (27--28 N--m)
6 (3/8 in.) 1.50 + 0.25 8 35--37 ft--lb (47--50 N--m)
8 (1/2 in.) 1.50 + 0.25
10 (5/8 in.) 1.50 + 0.25 10 60--66 ft--lb (81--89 N--m)
12 (3/4 in.) 1.50 + 0.25
16 (1 in.) 1.50 + 0.25 12 81--87 ft--lb (110--117 N--m)
16 121--131 ft--lb (164--177 N--m)
NOTE: Installation torque values for non--adjustable fit-
tings are listed in Figure 4. These torque values should Figure 4
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.
SAE Straight Thread O--Ring Port -- Adjustable

free of burrs, nicks, scratches, or any foreign material.
2. Always replace the O--ring seal when this type of fit-

ting 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 Back--up Washer
the back up washer is not loose and is pushed up as far
as possible (Step 1). O--Ring
5. Install the fitting into the port and tighten finger tight Figure 5
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 1 Step 3
(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). Step 2 Step 4
Size F.F.F.T.
4 (1/4 in. nominal hose or tubing) 1.00 + 0.25

6 (3/8 in.) 1.50 + 0.25
8 (1/2 in.) 1.50 + 0.25
10 (5/8 in.) 1.50 + 0.25 Figure 6
12 (3/4 in.) 1.50 + 0.25
16 (1 in.) 1.50 + 0.25

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, 1

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 tow-
ing.
See Traction Unit Operator’s Manual for additional tow-

ing procedures.
Figure 7
1. By--pass valve location
Check Hydraulic Fluid

The Groundsmaster 4500--D and 4700--D hydraulic
Hydraulic
System
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 1
checking procedure and oil recommendations.
Figure 8
1. Hydraulic reservoir cap

2200
PSI
Hydraulic System (Rev. A)

Hydraulic Schematics
Page 4 -- 6
Groundsmaster 4500--D
Hydraulic Schematic
All solenoids are shown as
de--energized
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Page 4 -- 7
Hydraulic Schematic
All solenoids are shown as
de--energized

Hydraulic
System
2200
PSI

Hydraulic Flow Diagrams
Page 4 -- 8
Traction Circuit (GM 4500--D Forward 4WD Shown)
Working Pressure
Low Pressure (Charge)
Return or Suction
Flow
Traction Circuit
The traction circuit piston pump is a variable displace- Charge pressure is limited by a relief valve located in the
ment pump that is directly coupled to the engine fly- filtration and charge control manifold. Charge pressure
wheel. Pushing the top of the traction pedal engages a can be measured at the charge circuit pressure test port
hydraulic servo valve which controls the variable dis- on the filtration and charge control manifold.
placement piston pump swash plate to create a flow of
oil. This oil is directed to the front wheel and rear axle The 4WD/2WD control manifold provides hydraulic flow
motors. Operating pressure on the high pressure side of management in a variety of situations. Pressure testing
the closed traction circuit loop is determined by the of this control manifold can be performed at a test port
amount of load developed at the fixed displacement on the manifold.
wheel and axle motors. As the load increases, circuit
pressure can increase to relief valve settings: 5000 PSI 1. Four wheel drive (mow) and two wheel drive (trans-
in both forward and reverse. If pressure exceeds the re- port) operation is controlled by a solenoid valve (SV) lo-
lief setting, oil flows through the relief valve to the low cated in the 4WD/2WD control manifold. When in
pressure side of the closed loop traction circuit. The transport (2WD), the solenoid valve (SV) is energized
traction circuit provides operation in either mow (four and directs charge pressure to shift control valves PD1
wheel drive) or transport (two wheel drive). and PD2. The shifted valves block hydraulic flow to the
rear axle motor in both forward and reverse directions
Traction circuit pressure (forward and reverse) can be when in transport (2WD).
measured at test ports located on the traction circuit hy-
Hydraulic
draulic tubes of the machine. 2. A pressure reducing valve (PR1) in the 4WD/2WD
System
control manifold lowers pressure to the rear axle motor
The traction pump and wheel motors use a small when the machine is operated in reverse. The lower
amount of hydraulic fluid for internal lubrication. Fluid is pressure prevents rear tire scuffing and provides added
designed to leak across pump and motor parts into the pressure to the front wheels during reverse operation.
case drain. This leakage results in the loss of hydraulic
fluid from the closed loop traction circuit that must be re- 3. An adjustable relief valve (RV5) in the 4WD/2WD
placed. control manifold reduces rear axle motor pressure
created in down--hill, dynamic braking conditions.
The gear pump section (P3) that supplies oil to the steer-
ing and lift/lower circuits also provides charge oil for the To enhance traction control, the lift/lower circuit is
traction circuit. The gear pump is driven directly off the equipped with a counterbalance system. An adjustable
traction pump. It provides a constant supply of charge oil counterbalance valve (RV1) located in the power down
to the traction circuit to make up for oil that is lost due to and traction assist control manifold transfers cutting unit
internal leakage in the traction pump and motors. weight to the machine to improve traction. Additionally,
the counterbalance system has a secondary relief valve
Charge pump flow is directed through the oil filter and to (RV2) that provides additional cutting unit weight trans-
the low pressure side of the closed loop traction circuit. fer when traction circuit pressure increase is sensed by
A filter bypass valve allows charge oil flow to the closed directional valve (PD3) located in the power down and
loop if the filter becomes plugged. traction assist control manifold.

Rev. D
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Page 4 -- 10
Groundsmaster 4500--D/GM--4700--D
Lower Cutting Units (GM 4500--D Shown)
Working Pressure
Return or Suction
Flow
Lower Cutting Units
A three section gear pump is coupled to the piston (trac- To lower a side cutting unit on the Groundsmaster
tion) pump. The gear pump section (P3) farthest from 4700--D (deck #6 or #7), the appropriate lift lever on the
the piston pump supplies hydraulic flow to both the lift/ lift/lower control valve is pushed to allow valve shift in the
lower control valve and the steering control valve. Hy- lift/lower control. This valve change causes a shift in the
draulic flow from this pump section is delivered to the sequence valve located in the power down and traction
circuits through a proportional flow divider. This pump assist manifold and also allows a passage for oil flow
section takes its suction from the hydraulic reservoir. from the rod end of the lift cylinder. Oil flow to the piston
Maximum lift/lower circuit pressure (2200 PSI) is limited end of the lift cylinder causes the cylinder shaft to ex-
by a relief valve in the power down and traction assist tend, and lowers the cutting unit. Oil from the rod end of
control manifold (RV7). the cylinders returns to the traction charge circuit. When
the lift lever is released, the lift cylinder is held in posi-
On the Groundsmaster 4500--D, a single lift lever is used tion.
to lift and lower the five cutting decks. The Groundsmas-
ter 4700--D has three lift levers to control the cutting An adjustable counterbalance valve (RV1) maintains
decks: the center lever is for the five center decks, the back pressure on the deck lift cylinders. This counterbal-
left lever controls the left, rear deck (#6), and the right ance pressure transfers cutting unit weight to the ma-
lever controls the right, rear deck (#7). chine 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
Hydraulic
at a port on the end of the gear pump.
System
When the cutting units are in a stationary position, flow #4 Deck #1 Deck #5 Deck
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 #2 #3
#6 Deck #7 Deck
oil flow from the rod end of the lift cylinders. The weight (GM4700) Deck Deck (GM4700)
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 cir-
cuit. The piston end of the cylinders are replenished by CUTTING DECK LOCATIONS
the charge circuit. When the lift lever is released, the lift
cylinders are held in position. Figure 9
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GM 4700--D
LOWER DECK #6 SHOWN

FROM GEAR PUMP (P3)
FROM TRACTION CIRCUIT
CHARGE CIRCUIT
Figure 10
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Page 4 -- 12
Raise Cutting Units (GM 4500--D Shown)
Working Pressure
Return or Suction
Flow
Raise Cutting Units
A three section gear pump is coupled to the piston (trac- To raise a side cutting unit on the Groundsmaster
tion) pump. The gear pump section (P3) farthest from 4700--D (deck #6 or #7), the appropriate outer lift lever
the piston pump supplies hydraulic flow to the lift/lower on the lift/lower control valve is pulled to allow valve shift
control valve and the steering control valve. Hydraulic in the lift/lower control. This valve change allows hy-
flow from this pump section is delivered to the two cir- draulic pressure to the rod end of the cylinder and
cuits through a proportional flow divider. The gear pump causes the lift cylinder shaft to retract, raising the cutting
takes its suction from the hydraulic reservoir. Maximum unit. Oil from the piston end of the cylinder returns to the
lift/lower circuit pressure (1500 PSI) is limited by a relief traction charge circuit. When the lift lever is released, the
valve in the power down and traction assist control man- lift cylinder is held in position.
ifold (RV7).
An adjustable counterbalance valve (RV1) in the power
On the Groundsmaster 4500--D, a single lift lever is used down and traction assist control manifold maintains
to lift and lower the five cutting decks. The Groundsmas- back pressure on the lift cylinders. This counterbalance
ter 4700--D has three lift levers to control the cutting pressure transfers cutting unit weight to the machine to
decks: the center lever is for the five center decks, the improve traction. Excess circuit flow is routed to the oil
left lever controls the left, rear deck, and the right lever filter and then to the traction charge circuit.
controls the right, rear deck.
Pressure to the lift/lower control valve can be monitored
Hydraulic
at a port on the end of the gear pump. #4 Deck #1 Deck #5 Deck
System
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 #6 Deck
#2 #3 #7 Deck
lift/lower control valve. This valve change allows hy- Deck Deck (GM4700)
(GM4700)
draulic 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 cyl-
inders are held in position.
CUTTING DECK LOCATIONS
Figure 11
2200
PSI
GM 4700--D
FROM GEAR PUMP (P3)
RAISE DECK #6 SHOWN

FROM TRACTION CIRCUIT
CHARGE CIRCUIT
Figure 12

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Page 4 -- 14
Mow Circuit (GM 4500--D Shown)
Working Pressure
Return or Suction
Flow
Mow Circuit
Hydraulic flow for the mow circuit is supplied by two sec- stopping rate of the blade when the solenoid valves are
tions of the gear pump (P1 and P2). Gear pump section de--energized as the PTO switch is turned OFF. Decks
(P1) supplies hydraulic flow to decks 2, 3, and 5 (also 7 #6 and #7 are controlled by solenoid valve (SV2), logic
on the GM 4700--D), while gear pump section (P2) cartridge (LC2), and brake relief cartridge (RV9).
supplies decks 1 and 4 (also 6 on the GM 4700--D).
Return oil from the deck motors is directed to the oil cool-
On the Groundsmaster 4500--D, hydraulic flow from the er and oil filter. Deck motor case drain leakage returns
two pump sections is controlled by two hydraulic to the hydraulic reservoir.
manifolds each equipped with a solenoid controlled,
proportional relief valve (PRV1/PRV2), logic cartridge Maximum mow circuit pressure is limited at each deck
(LC1), and brake relief cartridge (RV8). When the PTO manifold by the proportional relief valve (PRV1 and
switch is OFF (or if the decks are raised), the deck sole- PRV2). The deck relief valve pressure is 3500 PSI. Mow
noid valves (PRV1/PRV2) are not energized, allowing circuit pressure can be measured at port (G1) of the
hydraulic flow to by--pass the deck motors through the deck control manifold.
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 re- #4 Deck #1 Deck #5 Deck
lief cartridges (RV8) control the stopping rate of the
Hydraulic
blade when the solenoid valves are de--energized as the
System
PTO switch is turned OFF.
On the Groundsmaster 4700--D, hydraulic flow from the

two pump sections is controlled by two hydraulic man-
ifolds each equipped with a solenoid controlled, propor-
#2 #3 #7 Deck
tional relief valve (PRV1/PRV2), a solenoid valve (SV2), #6 Deck
Deck Deck
(GM4700) (GM4700)
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 low-
ered, the solenoid valves (SV2 and PRV1/PRV2) ener- CUTTING DECK LOCATIONS
gize, causing a shift of the logic cartridges (LC1 and
LC2) and allowing hydraulic flow to the deck motors. Figure 13
Brake relief cartridges (RV8 and RV9) control the
TO OIL COOLER
FROM GEAR PUMP (P1) FROM GEAR PUMP (P2)
GM 4700--D
ALL DECKS LOWERED

PTO SWITCH ON
TO HYDRAULIC RESERVOIR
Figure 14
Cutting Deck Blade Braking
When the operator turns the cutting decks OFF, propor-
tional 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 re- FROM
DECK TO OIL
duced to the cutting deck motors which begins to slow MOTORS COOLER
the cutting blades and also allows the manifold relief
valve (RV) to shift.
ORIFICE
The inertia of the rotating cutting blades increases pres- TO DECK
sure of the oil return to the deck control manifold. This MOTORS
pressure increase along with the orifice in the manifold
FROM
and the shifted relief valve (RV) cause logic cartridge GEAR
(LC1) to shift (Fig. 16). The oil from the deck motors is PUMP
finally directed through the orifice and to relief valve (RV)
which bleeds the residual pressure in the circuit and al- Figure 15
lows the blades to stop in a controlled manner (Fig. 17).
FROM
DECK TO OIL
MOTORS COOLER
ORIFICE
TO DECK
MOTORS
FROM
GEAR
PUMP
Figure 16
FROM
DECK TO OIL
MOTORS COOLER
ORIFICE
TO DECK
MOTORS
FROM
GEAR
PUMP
Figure 17

Hydraulic
System

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Page 4 -- 18
Steering Circuit (GM 4500--D Right Turn Shown)
Working Pressure
Return or Suction
Flow
Steering Circuit
A three section gear pump is coupled to the piston (trac- a left turn. The rotary meter ensures that the oil flow to
tion) pump. The gear pump section (P3) supplies hy- the cylinder is proportional to the amount of the turning
draulic flow to the steering control valve and the lift/lower on the steering wheel. Fluid leaving the cylinder flows
control valve. Pump hydraulic flow is delivered to the two back through the spool valve then through the T port and
circuits through a proportional flow divider. The gear to the hydraulic reservoir.
pump takes its suction from the hydraulic reservoir.
Steering circuit pressure is limited by a relief valve lo- The steering wheel and steering control valve return to
cated in the steering control. 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. Right Turn
With the steering wheel in the neutral position (rear When a right turn is made with the engine running, the
wheels positioned straight ahead) and the engine run- turning of the steering wheel positions the spool valve so
ning, flow enters the steering control valve at the P port that flow goes through the bottom of the spool. Flow en-
and goes through the steering control spool valve, by-- tering the steering control valve at the P port goes
passing the rotary meter (V1) and steering cylinder. through the spool and is routed to two places. As in a left
Flow leaves the control valve through the PB port to the turn, most of the flow through the valve is by--passed out
oil filter and traction charge circuit. the PB port back to the oil filter and traction charge cir-
cuit. Also like a left turn, the remainder of the flow is
Hydraulic
System
Left Turn drawn through rotary meter (V1) but goes out port R.
Pressure extends the piston for a right turn. The rotary
When a left turn is made with the engine running, the meter ensures that the oil flow to the cylinder is propor-
turning of the steering wheel positions the spool valve so tional to the amount of the turning on the steering wheel.
that flow goes through the top of the spool. Flow entering Fluid leaving the cylinder flows back through the spool
the steering control valve at the P port goes through the valve then through the T port and to the hydraulic reser-
spool and is routed to two places. First, most of the flow voir.
through the valve is by--passed out the PB port back to
the oil filter and traction charge circuit. Second, the re- The steering wheel and steering control valve return to
mainder of the flow is drawn through the rotary meter the neutral position when turning is completed.
(V1) and out the L port. Pressure contracts the piston for
STEERING CYLINDER STEERING CYLINDER STEERING CYLINDER

NO PISTON MOVEMENT PISTON MOVEMENT PISTON MOVEMENT
R L R L R L
1180 1180 1180

PSI PSI PSI
T PB P STEERING T PB P STEERING T PB P STEERING

CONTROL CONTROL CONTROL
NEUTRAL POSITION LEFT TURN RIGHT TURN
Figure 18

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 4. HIGH PRESSURE GAUGE: High range gauge
fittings for use on this machine. which accommodates pressures beyond the capacity of
the low pressure gauge: 0 to 5000 PSI.
1. INLET HOSE: Hose connected from the system cir-
cuit to the inlet side of the hydraulic tester. 5. FLOW METER: This meter measures actual oil flow
in the operating circuit with a gauge rated at 15 GPM.
2. LOAD VALVE: A simulated working load is created
in the circuit by turning the valve to restrict flow. 6. OUTLET HOSE: A hose from the outlet side of the
hydraulic tester connects to the hydraulic system circuit.
3. LOW PRESSURE GAUGE: Low range gauge to pro-
vide accurate reading at low pressure: 0 to 1000 PSI.
A protector valve cuts out when pressure is about to

exceed the normal range for the gauge. The cutout
pressure is adjustable.

Rev. 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

Use this container for doing hydraulic motor efficiency
testing (motors with case drain lines only). Measure effi-
ciency of a hydraulic motor by restricting the outlet flow
from the motor and measuring leakage from the case
Hydraulic
drain line while the motor is pressurized by the hydraulic
System
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

Troubleshooting
The charts that follow contain information to assist in Refer to the Testing section of this Chapter for precau-
troubleshooting. There may possibly be more than one tions and specific test procedures.
cause for a machine malfunction.
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 Traction control linkage is faulty.
only.
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.

Traction power is lost or unit will not Brakes are engaged or sticking.
operate in either direction.
Traction control linkage is damaged or disconnected.
Hydraulic reservoir oil level is low.
Piston pump by--pass valve is open or damaged.
System charge check valve and/or system relief valve is defective.
Traction circuit pressure is low.
Front wheel motor couplers are damaged.

Rev. D
Problem Possible Causes
Machine travels too far before stop- Traction linkage is out of adjustment.
ping when the traction pedal is re-
leased. 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.

No cutting decks will operate. Electrical problem exists (see Chapter 5 -- Electrical System).
Hydraulic
Gear pump sections P1 and P2 are damaged.
System
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 oper- Electrical problem exists (see Chapter 5 -- Electrical System).
ate.
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.

Rev. D
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 Lift circuit lines or fittings are leaking.
up.
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.

Testing
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
WARNING
during various operational checks (See the Special Before disconnecting or performing any work
Tools section in this Chapter). on the hydraulic system, all pressure in the
system must be relieved and all rotating ma-
Before Performing Hydraulic Tests
chine parts must be stopped. Stop engine;
IMPORTANT: All obvious areas such as oil supply, lower or support attachments.
filter, binding linkages, loose fasteners, or improper
adjustments must be checked before assuming that 1. Clean machine thoroughly before disconnecting or
a hydraulic component is the source of the problem. disassembling any hydraulic components. Always keep
in mind the need for cleanliness when working on hy-
Precautions for Hydraulic Testing draulic equipment. Contamination will cause excessive
wear of components.
2. Put metal caps or plugs on any hydraulic lines left

CAUTION open or exposed during testing or removal of compo-
nents.
Failure to use gauges with recommended pres-
Hydraulic
sure (PSI) rating as listed in test procedures 3. The engine must be in good operating condition. Use
System
could result in damage to the gauge and possible a phototac to determine engine speed when performing
personal injury from leaking hot oil. a hydraulic test. Engine speed can affect the accuracy
of the tester readings. Check actual speed of the pump
when performing flow testing.
CAUTION 4. The inlet and the outlet hoses must be properly con-
nected and not reversed (tester with pressure and flow
All testing should be performed by two (2) capabilities) to prevent damage to the hydraulic tester or
people. One person should be in the seat to oper- components.
ate the machine, and the other should read and
record test results. 5. When using hydraulic tester with pressure and flow
capabilities, open load valve completely in the tester to
minimize the possibility of damaging components.
CAUTION 6. Install fittings finger tight and far enough to make

sure that they are not cross--threaded before tightening
them with a wrench.
Operate all hydraulic controls to relieve system
pressure and avoid injury from pressurized hy- 7. Position tester hoses to prevent rotating machine
draulic oil. Controls must be operated with the
parts from contacting and damaging the hoses or tester.
ignition switch in OFF. Remove key from the igni-
tion switch.
8. Check oil level in the hydraulic reservoir. After con-
necting test equipment, make sure tank is full.
WARNING 9. Check control linkages for improper adjustment,

binding, or broken parts.
Keep body and hands away from pin hole leaks
10.All hydraulic tests should be made with the hydraulic
or nozzles that eject hydraulic fluid under high
oil at normal operating temperature.
pressure. Do not use hands to search for
leaks; use paper or cardboard. Hydraulic fluid 11. Before returning machine to use, make sure that hy-
escaping under pressure can have sufficient draulic reservoir has correct fluid level.
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. Gan-
grene may result from such an injury.

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
Return or Suction
Flow

Procedure for Traction Circuit Charge Pressure Test
1. Make sure hydraulic oil is at normal operating tem-

perature 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
Prevent personal injury and/or damage to equip-
ment. Read all WARNINGS, CAUTIONS, and Pre-
cautions for Hydraulic Testing at the beginning Figure 24
of this section. 1. Right side frame rail 2. Filter manifold
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). 1
2
Hydraulic
System
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 Figure 25
internal damage or worn parts in gear pump. 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 trac-
tion pedal forward, then reverse.
7. If pressure is good under no load, but drops below

specification when under traction load, the piston (trac-
tion) 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.

Rev. D
TEST NO. 2: Traction Circuit Relief Pressure (Using Pressure Gauge)
CHARGE
CIRCUIT
NOTE: FORWARD DIRECTION TEST SHOWN
TO TRACTION CONTROL
MANIFOLD
TO STEERING CIRCUIT
FROM PTO (MOW) CIRCUIT Working Pressure

Low Pressure
FROM STEERING CONTROL Return or Suction
FROM PTO (MOW) CIRCUIT Flow

Procedure for Traction Circuit Relief Pressure Test
1
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, 1. Forward traction port (faces forward)
turn the engine off and engage the parking brake. 2. Reverse traction port (faces rearward)
CAUTION
cautions for Hydraulic Testing at the beginning
Hydraulic
System
of this section. 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.
1 3
4. Start the engine and move throttle to full speed (2800
+ 50 RPM). Release parking brake. Figure 27
1. Forward relief valve 3. Traction pump
5. Sit on seat, apply brakes fully, and slowly depress the 2. Reverse relief valve
traction pedal in the appropriate direction. While pu-
shing traction pedal, look at pressure reading on gauge:
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 sus-
pected 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.

TEST NO. 3: Cutting Deck Circuit Pressure (Using Pressure Gauge)
FROM LIFT/LOWER CIRCUIT
TO STEERING CIRCUIT
GM 4500--D
Working Pressure
Low Pressure
Return or Suction
Flow
TO STEERING CIRCUIT
GM 4700--D

Procedure for Cutting Deck Circuit Pressure Test
1
1. Make sure hydraulic oil is at normal operating tem- 2

brake is engaged.
CAUTION
Prevent personal injury and/or damage to equip- GM 4500--D DECK CONTROL MANIFOLDS
of this section. 1. Test port (decks 2, 3, & 5) 2. Test port (decks 1 & 4)
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).
Hydraulic
System
CAUTION
1
Keep away from decks during test to prevent per- 2
sonal injury from the cutting blades.
4. Start engine and move throttle to full speed (2800 +

GM 4700--D DECK CONTROL MANIFOLDS
50 RPM). Engage the cutting units.
Figure 29
5. Watch pressure gauge carefully while mowing with
1. Test port (decks 2,3,5,7) 2. Test port (decks 1,4,6)
the machine.
6. Cutting deck circuit pressure should be from 1000 to

3500 PSI and will vary depending on mowing condi-
#4 Deck #1 Deck #5 Deck
tions.
7. Disengage cutting units. Shut off engine.
8. Disconnect test gauge with hose from manifold test

port.
#2 #3 #7 Deck
#6 Deck
Deck Deck (GM4700)
(GM4700)

Figure 30

TEST NO. 4: Cutting Deck Gear Pump Flow (Using Tester with Pressure Gauges and
Flow Meter)
TO STEERING CIRCUIT
NOTE: PUMP SECTION P1 TEST SHOWN
FROM DECK MOTORS
FROM DECK CONTROL
MANIFOLDS
Working Pressure
Low Pressure
Return or Suction
Flow

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 9. Shut off engine.
in the pump can wear. A worn pump will by pass oil and
make the pump less efficient. Eventually, enough oil loss 10.Disconnect flow tester from hydraulic hose and fit-
will occur to cause the cutting unit motors to stall under ting. Reconnect hose to the fitting.
heavy cutting conditions. Continued operation with a
worn, inefficient pump can generate excessive heat and 11. If flow was less than 11.5 GPM or a pressure of 2000
cause damage to the seals and other components in the PSI cannot be obtained, check for restriction in the pump
hydraulic system. intake line (including oil filter and oil cooler). If line is not
restricted, remove gear pump and repair or replace as
1. Make sure hydraulic oil is at normal operating tem- necessary.
3
2. Park machine on a level surface with the cutting units 4
lowered and off. Make sure engine is off and the parking 2
brake is engaged.
CAUTION
Hydraulic
System
of this section.
3. Locate gear pump section to be tested (P1 or P2). 1

Disconnect appropriate hydraulic hose from 90o hy-
draulic fitting in gear pump (Fig. 31).
4. Install hydraulic flow meter in series with the discon- Figure 31

nected hose and fitting in gear pump section. 1. Gear pump 3. Pump section P1 hose
2. 90o hydraulic fitting 4. Pump section P2 hose
5. Make sure the flow control valve on the tester is fully
open.

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 be-
fore 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.

TEST NO. 5: Cutting Deck Manifold Relief Pressure (Using Tester with Pressure Gauges
and Flow Meter)
TO STEERING CIRCUIT
GM 4500--D
TESTER
LOCATION FOR
PUMP SECTION P1
TESTER
LOCATION FOR
PUMP SECTION P2
Working Pressure
Low Pressure
Return or Suction
Flow
TO STEERING CIRCUIT
GM 4700--D
TESTER
LOCATION FOR
PUMP SECTION P1
TESTER
LOCATION FOR
PUMP SECTION P2

Procedure for Cutting Deck Manifold Relief
Pressure Test
Rotation Direction
2. Park machine on a level surface with the cutting units 1 2

brake is engaged.
CAUTION 3
Figure 32
Prevent personal injury and/or damage to equip- 1. Pressure IN 3. Case drain
ment. Read all WARNINGS, CAUTIONS, and Pre- 2. Pressure OUT
of this section.
1
3. Determine deck manifold relief to be tested. Discon- 2
nect the inlet hydraulic hose to the appropriate deck mo-
Hydraulic
tor (Fig. 32):
System
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 dis- GM 4500--D DECK CONTROL MANIFOLDS
connected hose and deck motor inlet.
Figure 33
5. Make sure the flow control valve on the tester is fully 1. Deck 2, 3, & 5 relief valve (pump section P2)
open. 2. Deck 1 & 4 relief valve (pump section P1)
1
CAUTION 2
Keep away from decks during test to prevent per-

sonal injury from the cutting blades.

50 RPM). Engage the cutting units.
7. Watch pressure gauge carefully while slowly closing

GM 4700--D DECK CONTROL MANIFOLDS
the flow control valve to fully closed.
Figure 34
8. As the relief valve lifts, system pressure should be
1. Deck 2, 3, 5, & 7 relief valve (pump section P2)
3400 to 3750 PSI. 2. Deck 1, 4, & 6 relief valve (pump section P1)
9. Disengage cutting units. Shut off engine. If specifica-

tion 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.

TEST NO. 6: Cutting Deck Motor Case Drain Leakage (Using Tester with Pressure
Gauges and Flow Meter)
GM 4500--D DECK #2 TEST SHOWN

TESTER
LOCATION FOR
DECK 2
TO STEERING CIRCUIT
FROM STEERING CONTROL VALVE
MEASURING
CONTAINER
Working Pressure
Low Pressure
Return or Suction
Flow

Procedure for Cutting Deck Motor Case Drain 5. Sit on seat and start the engine. Move throttle to full
Leakage Test speed (2800 + 50 RPM). Move PTO switch to ON.
NOTE: Over a period of time, a deck motor can wear in- 6. While watching pressure gauge, slowly close flow
ternally. A worn motor may by--pass oil to its case drain control valve on tester until a pressure of 1200 PSI is ob-
causing the motor to be less efficient. Eventually, tained.
enough oil loss will cause the deck motor to stall under
heavy cutting conditions. Continued operation with a NOTE: Use a graduated container, special tool
worn, inefficient motor can generate excessive heat, TOR4077, to measure case drain leakage (Fig. 36).
cause damage to seals and other components in the hy-
draulic system, and affect quality of cut. 7. Have another person measure flow from the case
drain line for 15 seconds, then move the PTO switch to
NOTE: One method to find a failing or malfunctioning OFF and stop the engine.
deck motor is to have another person observe the ma-
chine while mowing in dense turf. A bad motor will run TEST RESULTS: Flow less than 0.7 GPM (less than
slower, produce fewer clippings, and may cause a differ- 22.4 ounces (662 ml) of hydraulic fluid in 15 sec-
ent appearance on the turf. onds).
1. Make sure hydraulic oil is at normal operating tem- 8. Disconnect tester from motor and hose. Reconnect
perature by operating the machine for approximately 10 hose to the deck motor. Remove cap from bulkhead fit-
minutes. Make sure the hydraulic tank is full. ting and reconnect case drain hose.
2. Park machine on a level surface with the cutting units 9. If flow is more than 0.7 GPM, the motor is worn or
Hydraulic
System
lowered and off. Make sure engine is off and the parking damaged and should be repaired or replaced.
brake is engaged.
CAUTION 2

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 1
(see Hydraulic Schematic).
3. Disconnect pressure return hose from the motor to Figure 35

be tested (Fig. 35). Install flow tester in series with the 1. Pressure return hose 2. Case drain hose
motor and the disconnected return hose. Make sure the
flow control valve on tester is fully open. (Fig. 36).
4. Disconnect the motor case drain hose (small diame-

ter hose) where it connects to bulkhead fitting at the
frame rail (not at the motor). Put a steel cap on the bulk-
head 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 cut- Figure 36
ting units during test to prevent personal injury
from rotating blades. Do not stand in front of the
machine.

TEST NO. 7: Steering Circuit Relief Pressure (Using Pressure Gauge)
STEERING CYLINDER
NOTE: LEFT TURN SHOWN

R L
1180
PSI
STEERING CONTROL T PB P
VALVE
CHARGE CIRCUIT
TO
TO PTO (MOW) CIRCUIT RESERVOIR
G
50 / 50
PROPORTIONAL
FLOW DIVIDER
TRACTION
P3 P2 P1 P4 CIRCUIT
FROM
RESERVOIR
FROM OIL
FILTER
Working Pressure
Low Pressure
Return or Suction
Flow

Procedure for Steering Circuit Relief Pressure Test

perature by operating the machine for approximately 10 2

brake is engaged.
1
CAUTION
Prevent personal injury and/or damage to equip- Figure 37
ment. Read all WARNINGS, CAUTIONS, and Pre- 1. Steering circuit test port 2. Gear pump
of this section.
3. Raise seat to gain access to steering circuit test port

located on the front end of the gear pump (Fig. 37). Con-
nect a 5000 PSI gauge onto steering circuit test port.
Hydraulic
Route gauge hose to allow seat to be safely lowered.
System
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.
5. Turn steering all the way in one direction and mo- 2

mentarily hold the steering wheel against resistance. 3
GAUGE READING TO BE 1150 TO 1500 PSI. 1
Figure 38
6. Stop the engine. 1. Steering control valve 3. Steering relief valve
2. Steering column
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 ineffi-
ciency. If steering wheel continues to turn at end of cylin-
der travel (with lower than normal effort), steering
cylinder or steering control valve should be suspected
of wear or damage.

TEST NO. 8: Lift/Lower Circuit Relief Pressure (Using Pressure Gauge)
GM 4500--D SHOWN
2200
PSI
FROM STEERING CIRCUIT
TO PTO (MOW)
CIRCUIT
TO STEERING CIRCUIT
FROM PTO (MOW)
CIRCUIT
Working Pressure
Low Pressure
Return or Suction
Flow

Procedure for Lift/Lower Circuit Relief Pressure
Test


lowered and off. Make sure engine is off and the parking 1
brake is engaged.
CAUTION
Figure 39
Prevent personal injury and/or damage to equip- 1. Lift circuit test port 2. Gear pump
of this section. 2
1
3. Raise seat to gain access to lift circuit test port lo-

cated on the front end of the gear pump (Fig. 39). Con-
nect a 5000 PSI gauge onto lift circuit test port. Route
Hydraulic
System
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 3 3

the cutting units. Momentarily hold the lever with the lift
cylinder at full extension while looking at the gauge. Figure 40
1. GM 4500--D control manifold
2. GM 4700--D control manifold
GAUGE READING TO BE 2000 to 2600 PSI. 3. Lift/lower relief valve
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 pres- 1
sure).
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 adjust-
ment socket clockwise (increasing relief pressure). 2
C. If pressure is still too low after relief valve adjust-

ment, pump or lift cylinder(s) should be suspected of
wear, damage or inefficiency.
Figure 41
1. Relief valve cap 2. Adjustment socket

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 LIFT/LOWER CIRCUIT
FORWARD
50 / 50
PROPORTIONAL
FLOW DIVIDER
TRACTION
P3 P2 P1 P4 CIRCUIT
TOW
FROM VALVE
RESERVOIR
FROM OIL CHARGE

FILTER CIRCUIT
Working Pressure
Low Pressure
Return or Suction
Flow

Procedure for Steering and Lift/Lower Gear Pump 7. If the total of the two flows is lower than 6.4 GPM or
Flow Test a pressure of 1000 PSI could not be obtained, check for
restriction in pump intake line. If intake line is not re-
Output from the steering and lift/lower gear pump sec- stricted, remove gear pump and repair or replace as
tion is equally divided by a proportional valve to provide necessary.
flow to the steering circuit and the lift circuit. To test gear
pump flow, testing of both circuits is required. Total gear If the total of the two flows is 6.4 GPM but individual cir-
pump flow is the combined flow from the two circuits. cuit flow is less than 3.2 GPM (e.g. steering circuit has
2 GPM and lift circuit has 4.4 GPM), suspect a problem
1. Make sure hydraulic oil is at normal operating tem- with the proportional valve in the gear pump.

brake is engaged.
2
CAUTION 3
Prevent personal injury and/or damage to equip- 1

Hydraulic
System
of this section.
Figure 42
1. Gear pump 3. Steering circuit hose
IMPORTANT: Make sure that the oil flow indicator 2. Lift circuit hose
arrow on the flow gauge is showing that the oil will
flow from the pump, through the tester, and into the
hydraulic hose.
3. With the engine off and cutting units lowered, install 1

2
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.
IMPORTANT: The pump is a positive displacement 3

type. If pump flow is completely restricted or
stopped, damage to the pump, tester, or other com-
ponents could occur.
4
4. Start the engine and move throttle to full speed (2800
+ 50 RPM). DO NOT engage the cutting units.
Figure 43
5. While watching pressure gauges, slowly close flow 1. Gear pump backplate 3. Steering circuit
control valve until 1000 PSI is obtained on gauge. Verify 2. Lift circuit 4. Proportional valve
engine speed continues to be correct (2800 + 50 RPM).
FLOW GAUGE READING TO BE: Flow approxi-

mately 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.

TEST NO. 10: Counterbalance (RV1) Pressure (Using Pressure Gauge)
GM 4500--D SHOWN
2200
PSI
TO STEERING CIRCUIT
Working Pressure
Low Pressure
Return or Suction
Flow

Procedure for Counterbalance (RV1) Pressure Test


brake is engaged. 2
CAUTION
of this section. 1. Traction assist manifold (GM 4500--D shown)
2. Counterbalance test port
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
Hydraulic
System
(2800 + 50 RPM) with no load on the system. Do not en-
gage the cutting units.
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. 2
1
5. Adjustment of the counterbalance valve can be per-
formed as follows: Figure 45
1. GM 4500--D traction assist manifold
NOTE: Do not remove the valve from the hydraulic 2. GM 4700--D traction assist manifold
3. Counterbalance valve (RV1)
manifold for adjustment.
A. To increase pressure setting, turn the adjusting

dial on the counterbalance valve in a clockwise di-
rection. 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 counterclock-
wise direction. A 1/8 turn on the dial will make a mea-
surable change in counterbalance pressure (Fig.
45).
C. Recheck counterbalance pressure and readjust

as needed.

TEST NO. 11: Rear Traction Circuit (RV5) Relief Pressure (Using Pressure Gauge)
CHARGE
CIRCUIT
TO TRACTION CONTROL
MANIFOLD
TO STEERING CIRCUIT

Low Pressure

Procedure for Rear Traction Circuit (RV5) Relief
Pressure Test

minutes. Make sure the hydraulic tank is full. 1

brake is engaged.
CAUTION
Figure 46
Prevent personal injury and/or damage to equip- 1. 2WD/4WD control manifold (GM 4500--D shown)
ment. Read all WARNINGS, CAUTIONS, and Pre- 2. Relief valve test port
of this section.
2
3. Connect a 1000 PSI gauge to test port on 2WD/4WD
control manifold under operator’s seat (Fig. 46).
Hydraulic
System
(2800 + 50 RPM).
5. Operate the machine in 4WD with the cutting units

lowered. Drive down a slope in a forward direction, de-
crease pressure on the traction pedal, and monitor the 1
pressure gauge. Pressure should increase until the re-
lief valve lifts. Figure 47
1. Manifold: lower side 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

A. To increase relief pressure setting, remove cap 1

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 pres-
sure (Fig. 48).
B. To decrease pressure setting, remove cap on re-

lief valve and turn the adjustment socket on the relief
valve in a counterclockwise direction. A 1/8 turn on 2
the socket will make a measurable change in relief
pressure (Fig. 48).
C. Recheck relief pressure and readjust as needed.
Figure 48
1. Relief valve cap 2. Adjustment socket

TEST NO. 12: Traction Circuit Reducing Valve (PR1) Pressure (Using Pressure Gauge)
CHARGE
CIRCUIT
TO TRACTION CONTROL
MANIFOLD
TO STEERING CIRCUIT

Low Pressure

Procedure for Traction Circuit Reducing Valve (PR1)
Pressure Test

minutes. Make sure the hydraulic tank is full. 1

brake is engaged.
CAUTION
Figure 49
Prevent personal injury and/or damage to equip- 1. 2WD/4WD control manifold (GM 4500--D shown)
ment. Read all WARNINGS, CAUTIONS, and Pre- 2. Relief valve test port
of this section.
3. Connect a 1000 PSI gauge to test port on 2WD/4WD

control manifold under operator’s seat (Fig. 49).
Hydraulic
System
(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

Figure 50
1. Manifold: lower side 2. Reducing valve (PR1)
6. Pressure reducing valve (PR1) is located on the low-
er, rear side of the 2WD/4WD control manifold (Fig. 50).
Adjustment of this valve can be performed as follows:

A. To increase pressure setting, remove cap on re-

ducing valve and turn the adjustment socket on the
valve in a clockwise direction. A 1/8 turn on the sock-
et will make a measurable change in pressure set-
ting.
B. To decrease pressure setting, remove cap on re-

ducing 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 pres-
sure setting.
C. Recheck pressure setting and readjust as need-

ed.

TEST NO. 13: Traction Assist (RV2) Pressure (Using Pressure Gauges)
GM 4500--D SHOWN
2200
PSI
TO STEERING CIRCUIT
Working Pressure
Low Pressure
Return or Suction
Flow

Procedure for Traction Assist (RV2) Pressure Test


brake is engaged. 2
CAUTION
Figure 51
Prevent personal injury and/or damage to equip- 1. Traction assist manifold (GM 4500--D shown)
ment. Read all WARNINGS, CAUTIONS, and Pre- 2. Counterbalance test port
of this section.
1
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
Hydraulic
gauge to forward traction port on traction circuit hydrau-
System
lic tube (Fig. 52).

(2800 + 50 RPM) with no load on the system. Do not en-
gage 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 trac-
tion circuit pressure, look at pressure reading on gauge
connected to the counterbalance test port:
7. Adjustment of the traction assist valve (RV2) can be

performed as follows: 2
1
Figure 53
1. GM 4500--D traction assist manifold
A. To increase pressure setting, loosen the locknut 2. GM 4700--D traction assist manifold
and turn the adjusting screw on the relief valve in a 3. Traction assist valve (RV2)
clockwise direction. A 1/8 turn on the dial will make a
measurable change in pressure (Fig. 45).
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.

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 sys- 1. Check oil level in the hydraulic reservoir and add cor-
tem, park machine on a level surface, engage parking rect oil if necessary. Drain and refill hydraulic system
brake, lower cutting units or attachments, and stop en- reservoir, and change oil filter if component failure was
gine. Remove key from the ignition switch. severe or system is contaminated (see Flush Hydraulic
System).
2. Clean machine before disconnecting, removing, or
disassembling any hydraulic components. Make sure 2. Lubricate O--rings and seals with clean hydraulic oil
hydraulic components, hoses connections, and fittings before installing hydraulic components.
are cleaned thoroughly. Always keep in mind the need
for cleanliness when working on hydraulic equipment. 3. Make sure caps or plugs are removed from the hy-
draulic tubes, hydraulic fittings, and components before
reconnecting.
CAUTION 4. Use proper tightening methods when installing hy-
draulic hoses and fittings (see Hydraulic Fitting Installa-
Operate all hydraulic controls to relieve system tion).
pressure and avoid injury from pressurized hy-
draulic oil. Controls must be operated with the 5. After repairs, check control linkages or cables for
ignition switch in RUN and the engine OFF. Make proper adjustment, binding, or broken parts.
sure all electrically operated control valves are
actuated. Return ignition switch to OFF when 6. After disconnecting or replacing any hydraulic com-
pressure has been relieved. Remove key from ponents, operate machine functions slowly until air is
the ignition switch. out of system (see Charge Hydraulic System).
3. Put caps or plugs on any hydraulic lines, hydraulic fit- 7. Check for hydraulic oil leaks. Shut off engine and cor-
tings, and components left open or exposed to prevent rect leaks if necessary. Check oil level in hydraulic reser-
contamination. voir 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 el-

bow 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

IMPORTANT: Check hydraulic lines and hoses daily
WARNING for leaks, kinked lines, loose mounting supports,
wear, loose fittings, weather deterioration and
Keep body and hands away from pin hole leaks chemical deterioration. Make all necessary repairs
or nozzles that eject hydraulic fluid under high before operating.
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 in-
jected into the skin, it must be surgically re-
moved within a few hours by a doctor familiar
with this type of injury. Gangrene may result from
such an injury.

Flush Hydraulic System
IMPORTANT: Flush the hydraulic system any time 6. Reconnect all hydraulic hoses, lines, and compo-
there is a severe component failure or the system is nents that were disconnected while draining system.
contaminated (oil appears milky, black, or contains
metal particles). NOTE: Use only hydraulic fluids specified in the Trac-
tion Unit Operator’s Manual. Other fluids may cause
IMPORTANT: Flush hydraulic system when chang- system damage.
Ing from petroleum base hydraulic fluid to a biode-
gradable fluid such as Mobil EAL 224H. Operate 7. Fill hydraulic reservoir with new hydraulic fluid (see
machine under normal operating conditions for at Traction Unit Operator’s Manual).
least four (4) hours before draining.
8. Disconnect electrical connector from engine run so-
1. Park machine on a level surface. Lower cutting units, lenoid.
stop engine, and engage parking brake. Remove key
from the ignition switch. 9. Turn ignition key switch; engage starter for 10 se-
conds to prime pump. Repeat this step again.
10.Connect electrical connector to engine run solenoid.

CAUTION
11. Start engine and let it idle at low speed (1300 RPM)
for a minimum of 2 minutes. Increase engine speed to
Hydraulic
Operate all hydraulic controls to relieve system
System
pressure and avoid injury from pressurized hy- high idle (2800 + 50 RPM) for minimum of 1 minute un-
draulic oil. Controls must be operated with the der no load.
ignition switch in OFF. Remove key from the igni-
tion switch. 12.Raise and lower cutting units several times. Turn
steering wheel fully left and right several times.
IMPORTANT: Make sure to clean around any hy- 13.Shut off engine and check for hydraulic oil leaks.
draulic connections that will be disconnected for Check oil level in hydraulic reservoir and add correct
draining. amount of oil if necessary.
2. Drain hydraulic reservoir (see Traction Unit Opera- 14.Operate machine for 2 hours under normal operating
tor’s Manual). conditions.
3. Drain hydraulic system. Drain all hoses, tubes, and 15.Check condition of hydraulic oil. If the new fluid
components while the system is warm. shows any signs of contamination, repeat steps 1
through 14 again until oil is clean. If changing to biode-
4. Change and replace both hydraulic oil filters (see
gradable fluid, repeat steps 1 through 14 again at least
once and until the oil is clean.
5. Inspect and clean hydraulic reservoir (see Hydraulic
16.Assume normal operation and follow recommended
Reservoir Inspection).
maintenance intervals.

Charge Hydraulic System
NOTE: When initially starting the hydraulic system with 11. After the hydraulic system starts to show signs of fill,
new or rebuilt components such as motors, pumps, or actuate lift control lever until the lift cylinder rod moves
lift cylinders, it is important that the hydraulic system be in and out several times. If the cylinder rod does not
charged properly. Air must be purged from the system move after 10 to 15 seconds, or the pump emits abnor-
and its components to reduce the chance of damage. mal sounds, shut the engine off immediately and deter-
mine cause or problem. Inspect for the following:
IMPORTANT: Change hydraulic oil filter whenever
hydraulic components are repaired or replaced. A. Loose filter or suction lines.
1. Park machine on a level surface. Lower cutting units, B. Blocked suction line.
stop engine, and engage parking brake. Remove key
from the ignition switch. C. Faulty charge relief valve.
2. Make sure all hydraulic connections, lines, and com- D. Faulty gear pump.
ponents are secured tightly.
12.If cylinder does move in 10 to 15 seconds, proceed
3. If component failure was severe or the system is con- to step 13.
taminated, flush and refill hydraulic system and tank
(see Flush Hydraulic System). 13.Operate the traction pedal in the forward and reverse
directions. The wheels off the ground should rotate in
4. Make sure hydraulic reservoir is full. Add correct hy- the proper direction.
draulic oil if necessary (see Traction Unit Operator’s
Manual). A. If the wheels rotate in the wrong direction, stop
engine, remove lines from bottom of piston (traction)
5. Disconnect engine run solenoid lead to prevent the pump, and reverse the connections.
engine from starting.
B. If the wheels rotate in the proper direction, stop
6. Check control rod to the piston (traction) pump for engine.
proper adjustment, binding, or broken parts.
14.Adjust traction pedal to the neutral position (see
7. Make sure traction pedal and lift control lever are in Traction Unit Operator’s Manual).
the neutral position. Turn ignition key switch; engage
starter for fifteen (15) seconds to prime the traction and 15.Check operation of the traction interlock switch (see
gear pumps. Traction Unit Operator’s Manual).
8. Reconnect engine run solenoid lead. 16.Remove blocks from frame and lower machine. Re-
move chocks from remaining wheels.
17.If the piston (traction) pump or a traction motor was

WARNING replaced or rebuilt, run the machine so all wheels turn
slowly for 10 minutes.
Before jacking up the machine, review and follow
Jacking Instructions in Chapter 1 -- Safety. 18.Operate machine by gradually increasing its work
load to full over a 10 minute period.
9. Raise one front and one rear wheel off the ground,
19.Stop the machine. Check hydraulic reservoir and fill
and place support blocks under the frame. Chock re-
if necessary. Check hydraulic components for leaks and
maining wheels to prevent movement of the machine.
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

Gear Pump
85 to 95 ft--lb
27 (115 to 128 N--m)
1
32 18 2
17
30 28 25
29 3
24
19 23 4
31 13
5
21
26 23
20
22
24
16
14 11
RIGHT 7 12
8
15
FRONT
10
9
Figure 54
1. Flat washer 12. O--ring 23. O--ring
2. Cap screw 13. 90o hydraulic fitting 24. O--ring
3. 90o hydraulic fitting 14. Suction hose 25. O--ring
4. Hydraulic tee fitting 15. Suction hose 26. Gear pump assembly
5. O--ring 16. O--ring 27. Piston pump assembly
6. Quick fitting 17. Hydraulic hose 28. Coupler
7. Dust cap 18. Hydraulic hose 29. Cap screw
8. 90o hydraulic fitting 19. Hydraulic hose 30. Washer
9. Clamp 20. Hydraulic hose 31. O--ring
10. 90o hydraulic fitting 21. O--ring 32. Spacer
11. O--ring 22. Hydraulic fitting

Removal Installation
1. Park machine on a level surface, lower cutting units, 1. Lubricate new o--rings with clean hydraulic oil and
stop engine, engage parking brake, and remove key position on gear pump.
2. Slide coupler onto the piston pump output shaft.
2. Raise seat and secure it with prop rod to gain access
to gear pump. 3. Position o--rings and spacer to gear pump. Align
gear teeth and slide gear pump input shaft into coupler.
3. Drain the hydraulic reservoir (see Traction Unit Op- Secure gear pump to piston pump with two (2) cap
erator’s Manual). screws and washers.
4. To prevent contamination of hydraulic system during 4. Remove caps and plugs from hydraulic lines and fit-
removal, thoroughly clean exterior of pump and fittings. tings. Install lines to gear pump.
5. Read the General Precautions for Removing and 5. Replace hydraulic filter and fill hydraulic reservoir
Installing Hydraulic System Components at the begin- with new hydraulic oil.
ning of the Service and Repairs section of this chapter.
6. Disconnect engine run solenoid electrical connector
6. Disconnect hydraulic lines from gear pump and put to prevent engine from starting. Prime the hydraulic
caps or plugs on open hydraulic lines and fittings. Label pump by turning the ignition key switch to start and crank
disconnected hydraulic lines for proper reassembly. the engine for 10 seconds. Repeat cranking procedure
again.
Hydraulic
7. Support gear pump assembly to prevent it from fal-
System
ling. 7. Connect engine run solenoid electrical connector,
start the engine, and check for proper operation.
8. Remove two (2) cap screws and washers securing
gear pump to piston pump. Remove gear pump, cou- 8. Properly fill hydraulic system (see Charge Hydraulic
pler, spacer, and o--rings from machine. System).
9. Stop engine and check for hydraulic oil leaks. Check

hydraulic reservoir oil level.

Gear Pump Service
5
15
14 8 3
12 1
25 to 28 ft--lb
2
(34 to 38 N--m)
11
10 4
4 23
13
16
18 17
19
24
21 to 24 ft--lb
(29 to 33 N--m) 14
9
12
20 21 7
28
4
29 4
13
27 22
25
21 to 24 ft--lb
(29 to 33 N--m) 26
12
Figure 55
1. Shaft seal 11. Drive gear assembly 21. Idler gear
2. Washer 12. Wear plate 22. Key
3. Cap screw 13. Pressure seal 23. Front adapter plate
4. O--ring 14. Backup gasket 24. Rear adapter plate
5. Washer 15. Front plate assembly 25. Idler gear
6. Proportional valve 16. Idler gear 26. Rear body
7. Plug 17. Key 27. Backplate assembly
8. Plug 18. Gear 28. Plug
9. O--ring 19. Middle body 29. O--ring
10. Front body 20. Gear
Disassembly NOTE: To maintain maximum pump efficiency, keep

body, gears and wear plates for each section together.
Work in a clean area as cleanliness is extremely impor- do not mix parts between different pump sections.
tant when repairing hydraulic pumps. Thoroughly clean
the outside of pump. After cleaning, remove port plugs IMPORTANT: Avoid using excessive clamping
and drain oil from pump. pressure on the pump housing to prevent distorting
the housing.
1. Scribe a line, at an angle, across front plate (15), bo-
dies (10, 19, 26), adapter plates (23, 24) and backplate 2. Clamp pump in vise, shaft end up and remove the
(27). This will assure proper reassembly. eight cap screws (3).

3. Remove pump from vise, hold pump in hands and Inspection
bump shaft against wooden block to separate front
pump sections. Front body (10) will remain with either 1. Clean and dry all pump components. Remove nicks
front plate (15) or front adapter plate (23). and burrs from all parts with emery cloth.
4. Place front idler gear (16) into gear pocket and tap 2. Check spline drive shaft for twisted or broken teeth.
with soft face hammer until the front body separates. Also check for damaged keyway, on drive shaft, that
Remove idler gear from front plate or adapter plate. 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 ex-
6. Remove front adapter plate (23) from front body (10) cessive wear.
by tapping on the adapter plate with a soft face hammer.
4. Replace gear assembly if shaft measures less than
7. Remove idler gear (21), slip fit gear (18), and key .873” (22.17mm) in bushing area. (One gear assembly
(17). may be replaced separately; shafts and gears are avail-
able as assemblies only. The slip fit gear is available
8. Remove backplate (27) from rear body (26) by tap- separately).
ping on backplate with soft face hammer.
5. Inspect gear faces for scoring or excessive wear.
9. Remove rear idler gear (25), slip fit gear (20) and key
(22). 6. Replace gear assembly if gear width is below 1.181”
(30.00 mm).
Hydraulic
10.Remove drive gear assembly (11) from rear adapter
System
plate (24). 7. Assure that snap rings are in grooves on either side
of drive and idler gears.
11. Place rear idler gear assembly (25) back into gear
pocket and tap protruding end with soft face hammer to 8. If any edge of gear teeth is sharp, break edge with
remove rear body (26) from the backplate assembly (27) emery cloth.
or the rear adapter plate (24).
9. Oil groove in bushings in front plate, backplate and
IMPORTANT: Note position of the open and closed adapter plates should be in line with dowel pin holes and
side of the wear plates before removing. 180 degrees apart. This positions the oil grooves closest
to respective dowel pin holes.
12.Remove the wear plates (12) and o--rings (4) from
front plate (15), front adapter plate (23), and rear adapt- 10.Replace the backplate, front plate or adapter plates
er plate (24). if l.D. of bushings exceed .879” (22.33mm) (Bushings
are not available as separate items).
13.Remove backup gaskets (14) and pressure seals
(13) from wear plates (15) by carefully prying out with a 11. Bushings in front plate and backup gasket side of
sharp tool. adapter plates should be flush with face of plate.
IMPORTANT: Do not damage the seal bore in the 12.Check for scoring on face of backplate and adapter
front plate during seal removal. plates. Replace if wear exceeds .0015” (.038mm).
14.Remove shaft seal (1) and washer (2) from front 13.Check bodies inside gear pockets for excessive
plate (15). scoring or wear.
15.Remove plug (7) and o--ring (9) from rear adapter 14.Replace bodies if l.D. of gear pockets exceeds
plate (24). 2.100” (53.34mm).
16.Remove proportional valve (6) from backplate as-

sembly (27).

Reassembly 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
It is important that the relationship of the backplate, gear pocket of middle body (19). Check key for proper
adapter plates, bodies, wear plates and front plate is alignment.
correct. The two half moon cavities in the bodies must
face away from the front plate or adapter plate. The 11. Dip idler gear (21) in clean hydraulic oil and install in
smaller half moon port cavity must be on the pressure gear pocket of middle body.
side of the pump. The side of the wear plate with mid
section cut out must be on suction side of pump. Suction 12.Install rear adapter plate (24) in place on middle body
side of backplate or adapter plate is always the side with (19). Check positioning mark on all sections of pump.
larger port boss.
13.Position rear body (26) onto rear adapter plate (24).
1. Replace the wear plates, pressure seals, backup Place wear plate (12) into the gear pocket with the pres-
gaskets, shaft seal and o--rings as new parts. During re- sure seal and backup gasket against the rear adapter
assembly, check the scribe mark on each part to make plate.
sure the parts are properly aligned.
14.Install key (22) in slot of drive gear shaft. Dip slip fit
2. Install o--rings (4) in groove of front plate (15), adapt- gear (20) in clean hydraulic oil and slide on shaft and into
er plates (23 and 24), and backplate (27) using a small gear pocket of rear body (26). Check key for proper
amount of petroleum jelly to hold in place. alignment.
3. Install new pressure seals (13) and backup gaskets 15.Dip rear idler gear (25) in clean hydraulic oil and
(14) into new wear plates (12). The flat section in the install in gear pocket of rear body.
middle of the backup gasket must face away from the
wear plate inside the seal. 16.Position backplate (27) over shafts until dowel pins
in body are engaged.
4. Place plug (8) into pocket of front plate (15).
17.Secure pump components with cap screws (3).
5. Apply a thin coat of petroleum jelly to both milled gear Torque cap screws evenly in a crisscross pattern from
pockets of front body (10). Position body onto front plate 25 to 28 ft--Ib (34 to 38 N--m).
(15) with half moon port cavities in body facing away
from front plate. 18.Place washer (2) over drive shaft into housing. Liber-
ally oil shaft seal (1) and install over drive shaft carefully
NOTE: The small half moon port cavity must be on the so that rubber sealing lips are not cut.
pressure side of pump.
19.Place 1--3/8” O.D. sleeve over shaft and press in
6. Place wear plate (12) into the gear pocket with the shaft seal .200” (5.08mm) below surface of front plate.
pressure seal and backup gasket against the front plate.
The side with the mid section cut away must be on suc- 20.Install plug (7) and o--ring (9) into rear adapter plate.
tion side of pump.
21.If removed, install plug (28) with o--ring into back-
7. Dip drive gear assembly (11) and idler gear assem- plate and torque from 21 to 24 ft--lb (29 to 33 N--m).
bly (16) into clean hydraulic oil. Slip both gear assem-
22.Install proportional valve (6) into backplate. Torque
blies into gear pocket of front body (10) and into front
plug from 21 to 24 ft--lb (29 to 33 N--m).
plate bushings.
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 pres-
sure seal and backup gasket against the front adapter
plate.

Hydraulic
System

Piston (Traction) Pump
85 to 95 ft--lb
27 (115 to 128 N--m)
1
32 18 2
17
30 28 25
29 3
24
19 23 4
31 13
5
21
26 23
20 16
22
24
33
6 35
36 5
14
RIGHT 7 34 12
8
15 21
FRONT
11
11 37
10
9
Figure 56
1. Flat washer 14. Suction hose 26. Gear pump assembly
2. Cap screw 15. Suction hose 27. Piston pump assembly
3. 90o hydraulic fitting 16. Wire harness 28. Coupler
4. Hydraulic tee fitting 17. Hydraulic hose 29. Cap screw
5. O--ring 18. Hydraulic hose 30. Washer
6. Quick fitting 19. Hydraulic hose 31. O--ring
7. Dust cap 20. Hydraulic hose 32. Spacer
8. 90o hydraulic fitting 21. O--ring 33. O--ring
9. Clamp 22. Hydraulic fitting 34. O--ring
10. 90o hydraulic fitting 23. O--ring 35. O--ring
11. Hydraulic fitting 24. O--ring 36. O--ring
12. Hydraulic tee fitting 25. O--ring 37. O--ring
13. 90o hydraulic fitting

1. Park machine on a level surface, lower cutting units, 1. Carefully lower piston pump into the machine and
stop engine, engage parking brake, and remove key position it to the engine adapter plate. Support pump to
from the ignition switch. prevent it from falling while installing two (2) cap screws
and washers securing piston pump to engine adapter
2. To prevent contamination of hydraulic system during plate. Torque screws from 85 to 95 ft--lb (115 to 128
removal, thoroughly clean exterior of pump assembly. N--m).
3. Remove traction rod from control arm on piston 2. Install gear pump to piston pump (see Gear Pump
pump by removing lock nut, spacer and cap screw. Installation).
4. Disconnect two wires from neutral switch on traction 3. Position traction rod to control arm on piston pump
pump. by installing cap screw, spacer and lock nut.
5. Read the General Precautions for Removing and 4. Connect two wires to neutral switch on traction
Installing Hydraulic System Components at the begin- pump.
5. Remove plugs and caps from disconnected hydrau-
6. Put a drain pan below the pump assembly. Remove lic hoses and open ports of the pump assembly. Install
hydraulic hoses and fittings connected to piston and fittings and hoses to correct location on gear and piston
gear pumps. Put plugs or caps on disconnected hydrau- pumps.
lic hoses to prevent contamination of the system. Put
Hydraulic
System
plugs in open ports of pumps. 6. Install new filter and fill hydraulic reservoir with cor-
rect oil.
7. Remove gear pump from machine (see Gear Pump
Removal). 7. Disconnect engine run solenoid electrical connector
to prevent engine from starting. Prime pumps by turning
8. Support the piston pump to prevent it from falling ignition key switch to crank engine for 10 seconds. Re-
while removing two (2) cap screws and washers retain- peat cranking procedure again.
ing pump assembly to engine adapter plate. Carefully
pull pump assembly from adapter plate and raise it out 8. Connect engine run solenoid electrical connector,
of the machine. 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.

Piston (Traction) Pump Service
100 to 110 ft--lb 27 to 31 ft--lb

(136 to 149 N--m) 16 (37 to 42 N--m)
20
100 to 110 ft--lb
(136 to 149 N--m)
150 to 160 in--lb 38 15
18
(17 to 18 N--m)
4 to 6 ft--lb
14 (5 to 8 N--m)
1 29 26 40 to 48 in--lb
4 45 22 (4.5 to 5.4 N--m)
27
10 17
23
33 28 8
7 30
34 43
5 35
31 32
36 44
6
11
40 to 48 in--lb
(4.5 to 5.4 N--m) 25 to 28 ft--lb
37 (34 to 38 N--m)
42
19 40 41
31
39 5
40 to 48 in--lb
(4.5 to 5.4 N--m)
37
21
12 33
3
3 9
13
24
2 25
Figure 57
1. Jam nut 16. Relief valve (Reverse) 31. Flat washer
2. Retaining ring 17. Socket head screw 32. Housing gasket
3. Retaining ring 18. Valve plate 33. Cover plate gasket
4. Seal washer 19. Pump housing 34. Control assembly gasket
5. Socket head screw 20. Backplate assembly 35. Plug
6. Rotating kit assembly 21. Drive shaft 36. O--ring
7. Servo piston assembly 22. Nut 37. Seal sub--assembly
8. Piston follower 23. Lock washer 38. Roll pin
9. Cover plate 24. Washer 39. Bearing
10. Cover plate 25. Shaft seal 40. Dowel bushing
11. Camplate assembly 26. Relief valve (Forward) 41. Cradle sub--assembly
12. Thrust race 27. Control arm 42. Cap screw
13. Thrust bearing 28. Servo control assembly 43. Button head cap screw
14. Bypass valve 29. Washer 44. Bushing
15. Cap screw 30. Orifice plate (3 used) 45. Bearing

Disassembly (3), thrust race (12), thrust bearing (13), second thrust
race (12), and second retaining ring (3) from drive shaft
Work in a clean area as cleanliness is extremely impor- (21).
tant when repairing hydraulic pumps. Thoroughly clean
the outside of pump. After cleaning, remove port plugs 12.Remove the two cap screws (42) that secure cradle
and drain oil from pump. sub--assembly inside housing. Move the cradle sub--as-
sembly back--and--forth to release dowel bushings (40)
1. Position the pump into a protected jaw vise, clamp- and remove cradle sub--assembly from housing.
ing onto the outer portion of the flange, with the cap
screws up. Mark the relationship of the working ports 13.Remove button head cap screw (43) to remove
(for reassembly identification) to the servo control as- bushing (44) from cradle.
sembly with a scribe. Remove the four cap screws (15)
retaining backplate (20). 14.Remove remaining plugs from housing.
2. Lift backplate (20) straight up off drive shaft (21) and 15.Discard the shaft seal (25), gaskets (32, 33, 34), and
housing (19). Remove valve plate (18) from backplate o--rings from all assemblies. Replace with new seals
(20) or from rotating kit assembly (6), still in housing upon reassembly.
(19).
Inspection
3. From backplate (20), remove bypass valve (14), for-
ward relief valve (26) and reverse relief valve (16). Note: 1. Inspect backplate assembly:
Mark the valves in relationship to the cavity it was re-
A. Check the bearing (45) (press fit) in backplate
moved, for reassembly purposes.
Hydraulic
(20). If needles remain in cage, move freely, and set-
System
4. Remove housing gasket (32) from housing (19) or ting is at the dimension shown in Figure 58, bearing
backplate (20). removal is not required.
5. With pump still in vise, remove the six socket head B. Check roll pin (38) in backplate (20). If tight and
screws (17) retaining the servo control assembly (28). set to the dimension shown in Figure 58, removal not
Remove the control assembly and control housing gas- required.
ket (34) from the housing. Remove orifice plates (30),
noting location for reassembly. Remove nut (22), lock Numbered end
washer (23), and control arm (27) from servo control in-
put shaft. Note position of control arm for reassembly.
.090 inch .173 inch
6. To remove rotating kit assembly (6) from housing,
(2.29 mm) (4.39 mm)
first remove pump from vise holding the rotating kit as-
sembly 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 Figure 58
remove the housing (19) and drive shaft (21) from rotat-
ing kit assembly (6) and camplate assembly(11). 2. Check the bearing (39) (press fit) in pump housing
(19). If needles remain in cage, move freely, and setting
7. Remove camplate (11) from rotating kit assembly (6) at the dimension shown in Figure 59, bearing removal
and servo piston follower (8) from camplate (11). is not required.
8. Remove the four socket head screws (5) and wash-
Flange end of housing
ers (31) retaining each cover plate (9 & 10). Numbered end
9. Remove jam nut (1), washer (29), and seal washer

(4). Hold the servo piston bolt with hex key and unscrew
.070 inch
cover plate (10) from bolt. (1.78 mm)
10.Remove servo piston assembly (7) and seal sub--as-

semblies (two sets) (37) from housing. Note: Disassem-
bly 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),
Figure 59
and washer (24) from housing. Remove retaining ring
3. Inspect camplate assembly:
3
A. The finish on the piston shoe surfaces of the cam- 2
plate (11) should show no signs of scoring.
1
B. Inspect camplate (11) bushing surface for wear.
Also inspect surface for coating transfer from bush-
ing.
4
4. Inspect bushing (44) for contamination embedment 5
within coating of bushing surface coming in contact with
camplate (11).
5. Inspect rotating kit (Fig. 60): Figure 60

1. Piston assemblies 4. Piston block
2. Spider 5. Retainer
A. The pistons should move freely in the rotating kit 3. Spider pivot
piston block bore. If they are sticky in the bore, ex-
amine the bore for scoring or contamination.
.500 inch
B. Examine the O.D. of the pistons for finish condi- (12.7 mm)
tion. 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 con- Right Side Left Side
tact with the camplate. Do not lap piston shoes.
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 Install servo piston

Reassembly in this direction
1. All parts should be cleaned and internal pump parts Figure 61

lubricated with clean hydraulic oil before reassembly.
5. Install new seal washer (4), washer (29), and jam nut
2. If necessary, press new bearing into pump housing (1) to servo piston bolt. Holding servo piston bolt with
to dimension shown in Figure 59 with the numbered end hex key wrench, torque jam nut from 150 to 160 in--lb (17
of bearing outward. to 18 N--m). Check the centering of servo piston assem-
bly (7). Install new cover plate gasket (33) and cover
3. Install the two new seal sub--assemblies (37) into the
plate (9) to open side of servo piston and retain with four
servo piston cavity of pump housing (19).
washers (31) and socket head screws (5). Torque
4. Screw the cover plate (10) onto the servo piston as- screws from 40 to 48 in--lb (4.5 to 5.4 N--m).
sembly (7). Install new cover plate gasket (33) in place
6. Press dowel bushings (40) into cradle and secure
on pump housing. Install servo piston assembly (7) and
bushing (44) onto cradle with button head cap screw
cover plate (10) into servo piston bore in right side of
(43). Torque button head cap screw from 14 to 16 in--lb
housing (Fig. 61). Retain cover plate with four washers
(1.6 to 1.8 N--m).
(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 7. Place cradle sub--assembly (41) into housing (19)
the servo piston assembly is required. Measure in from making sure dowel bushings (40) and cradle (41) are
the left side and set servo piston .500” (12.7 mm) from completely seated into housing. Retain cradle sub--as-
surface of housing servo bore as shown in Figure 61. sembly with two cap screws (42) after applying Loctite
#277 (or equivalent) to the end of threads. Torque cap
NOTE: Re--adjustment may be required for neutral at
screws from 25 to 28 ft--lb (34 to 38 N--m).
unit start--up.

8. Place exterior retaining ring (3), thrust race (12), 16.Apply a small amount of petroleum jelly to the steel
thrust bearing (13), second thrust race (12), and second side of valve plate (18) to hold in place for installation.
retaining ring (3) onto drive shaft (21). Position washer Aligning the index pin, place the valve plate (18) in posi-
(24) and shaft seal (25) onto shaft. tion onto the backplate (20), with steel side against
backplate.
9. Install shaft assembly into front of housing. Seat seal
(25) into position with seal driver and retain with interior 17.Install backplate assembly (20) onto housing assem-
retaining ring (2). bly (19). Make sure ports are positioned correctly, and
that valve plate (18) and gasket (32) stay in place.
10.Install servo piston follower (8) onto camplate dowel
pin. Install camplate (11) carefully onto bushing (44) 18.Retain backplate (20) with four cap screws (15).
(coat bushing surface with hydraulic oil), aligning servo Torque cap screws from 27 to 31 ft--lb (37 to 42 N--m).
piston follower (8) with slot in servo piston assembly (7).
19.Install control housing gasket (34) onto housing.
11. Position housing in a horizontal position. Holding Install orifices (30) into servo control assembly (28) and
camplate (11) in position with screw driver through con- retain in position with petroleum jelly. Position the feed-
troller linkage passageway at the top of housing, place back link at 90 degrees from control housing. Install
rotating kit assembly (6) over shaft and into housing until manual servo control assembly (28) onto housing mak-
pistons are against camplate (11). Make sure all parts ing sure feedback link entered small groove in servo pis-
are in housing completely and are properly positioned. ton assembly (7).
Return the pump to the vise with open end of housing up,
clamping housing on the outer portion of the flange. 20.Secure control assembly with six socket head
screws (17). Torque screws from 40 to 48 in--lb (4.5 to
Hydraulic
System
12.Install gasket (32) onto housing. 5.4 N--m).
13.If necessary, press new bearing (45) and roll pin (38) 21.Install control arm (27) onto control assembly input
in backplate (20) to dimension shown in Figure 58. Note: shaft. Retain with lock washer (23) and nut (22). Torque
Bearing should be installed with the numbered end out- nut from 4 to 6 ft--lb (5 to 8 N--m).
ward. Roll pin should be installed with split oriented
away from bearing. 22.Install remaining plugs that were removed from
pump. Torque 3/4 in. plug from 21 to 24 ft--lb (28 to 32
NOTE: Forward and reverse relief valves are identical. N--m). Torque 1--1/4 in. plug from 40 to 45 ft--lb (54 to 61
N--m).
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).
15.Install new o--ring on bypass valve (14). Install by-

pass 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.

Piston Pump Manual Servo Control Assembly
44 to 52 ft--lb
(60 to 70 N--m)
15
10
1 14
2 9 13
3
4 7 12
5
4 8
6
16
24
17 to 26 in--lb 17
(2 to 3 N--m) 23
11
22
28 to 34 in--lb
21 (3.2 to 3.8 N--m)
18
20 19
Figure 62
1. Plug 9. O--ring 17. Set screw
2. O--ring 10. Wiper seal 18. Set screw
3. Retaining ring 11. O--ring 19. Pin
4. Spring retainer 12. Adaptor 20. Retaining ring
5. Spring 13. Ball 21. Feedback link
6. Spool valve 14. Pin 22. Dowel pin
7. Control housing 15. Neutral switch 23. Bell crank
8. Input shaft 16. O--ring 24. Set screw
Disassembly Reassembly
1. Remove wiper seal with screw driver. Remove set 1. Install spring retainer, spring, and second spring re-
screw (18) that retains input shaft and remove input tainer onto spool valve. Compress spring to allow retain-
shaft from control housing. Remove o--ring from shaft. ing ring (3) to be installed onto spool valve.
2. Remove set screw (24) from plug that retains valve 2. Install spool valve into control housing making sure
spool. Remove plug from control housing and o--ring that metering notches on spool valve can be seen in the
from plug. metering ports.
3. Remove retaining ring (20) from pin that retains feed- 3. Position bell crank in housing. Slide feedback link
back link and spool valve. Remove pin, feedback link, into position between clevis on valve spool, aligning
spool valve, and bell crank from control housing. holes, and install dowel pin and retaining ring (20).
4. Compress spring and remove retaining ring (3). Re- 4. Install new o--ring (9) onto input shaft. Hold bell crank
move spring retainer, spring, and second spring retainer in position with feedback link slot and align splined hole
from spool valve. 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.

5. Apply Loctite #242 or equivalent to set screw (18) 5. Test the switch by moving the control arm to the det-
and install into control housing. Adjust set screw until it ent position, the light should be on. Move the control arm
bottoms out on input shaft and back out one--quarter out of detent, the light should go off.
turn.
6. Remove test light and put servo control assembly
6. Install wiper seal on input shaft. into operation.
7. Install new o--ring (2) onto plug and install plug. Ad-
just plug until there is no end play in the valve spool with
Reassembly
input shaft held stationary. Secure plug in place with set “A”
Step 4--C
screw (24). Torque set screw from 17 to 26 in--lb (2 to 3
N--m).
Disassembly -- Neutral Switch
1. Loosen set screw (17) in adapter and remove neutral

switch from adapter.
2. Remove adapter from control housing.

Reassembly “B”
3. Remove pin, ball, and o--rings (11 & 16) from adapt- Step 4--D
er.
Hydraulic
Reassembly -- Neutral Switch
System
1. Install new o--ring (11) onto adapter and new o--ring
(16) onto pin.
2. Install ball and pin into adapter. Lubricate with petro-

leum jelly to hold in place during installation.
Reassembly “B”
3. Install adapter into control housing. Torque from 44 Step 4--E
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 “A”
until the “detent” action is very slight.
Figure 63
B. Attach the leads from a test light to the switch ter-
minals. Note: A multimeter could be used instead of
a test light.
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 be-

tween “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).

Hydraulic Control Manifolds: 2 Wheel/4 Wheel Drive, Filtration and Charge, Power Down
and Traction Assist
2 3
RIGHT
6
FRONT
5
Figure 64
1. Power down/traction assist manifold 4. Flange head screw (4 used) 6. Cap screw (2 used)
2. Flange head screw (3 used) 5. 2WD/4WD manifold 7. Flange nut (2 used)
3. Filtration/charge manifold

NOTE: The ports on the manifolds are marked for easy 1. Install hydraulic manifold to the frame using Figure
identification of components. Refer to the Hydraulic 64 as guide.
Schematics to identify the function of the hydraulic lines
and cartridge valves at each port. 2. Remove caps and plugs from fittings and hoses.
Properly connect hydraulic lines to manifold.
1. Read the General Precautions for Removing and
Installing Hydraulic System Components at the begin- 3. If 2WD/4WD control manifold was removed, connect
ning of the Service and Repairs section of this chapter. electrical connector to the solenoid valve.
2. If 2WD/4WD control manifold is being removed, dis- 4. Fill hydraulic reservoir with hydraulic fluid as re-
connect electrical connector from the solenoid valve. quired (see Traction Unit Operator’s Manual).
3. Disconnect hydraulic lines from manifold being re-

moved and put caps or plugs on open hydraulic lines
and fittings. Label disconnected hydraulic lines for prop-
er reassembly.
4. Remove hydraulic manifold from the frame using

Figure 64 as guide.
Hydraulic
System

Hydraulic Control Manifold Service: 2 Wheel/4 Wheel Drive Control
80 to 90 ft--lb 25
18 (108 to 122 N--m)
19 12
18 13 7
16 17
19 18
1 19
80 to 90 ft--lb 17 20 7
(108 to 122 N--m) 21
16
18
16 17 17 19 17
16 16
5
4
12
24
6 13
17
11 15
9 16
14
13
12
3
10 21
60 to 70 ft--lb
(81 to 95 N--m)
8 20
35 to 40 ft--lb PLUG TORQUE
(47 to 54 N--m) 2 SAE #2: 41 TO 49 in--lb (4.6 to 5.6 N--m)

25 to 30 ft--lb SAE #4: 6 to 10 ft--lb (8 to 13 N--m)
23 (34 to 41 N--m) SAE #5: 10 to 15 ft--lb (13 to 20 N--m)
4 to 6 ft--lb SAE #6: 15 to 20 ft--lb (20 to 27 N--m)
(5 to 8 N--m) 22 SAE #10: 35 to 40 ft--lb (48 to 54 N--m)
Figure 65
1. Manifold body 10. Reducing valve (PR1: port 8) 19. O--ring
2. Solenoid valve (SV: port 2) 11. Seal kit 20. Plug (SAE #10)
3. Seal kit 12. Plug (SAE #2) 21. O--ring
4. Check valve (CV: port 3) 13. O--ring 22. Solenoid coil
5. Seal kit 14. Plug (SAE #4) 23. Nut
6. Expander plug (not serviced) 15. O--ring 24. Expander plug (not serviced)
7. Seal kit 16. Plug (SAE #5) 25. Control valve (PD1 & PD2: ports 5A &
8. Relief valve (RV5: port 7) 17. O--ring 5B)
9. Seal kit 18. Plug (SAE #6)
NOTE: The ports on the manifold are marked for easy IMPORTANT: Use care when handling the cartridge
identification of components. Example: P1 is a piston valve. Slight bending or distortion of the stem tube
pump connection port and 2 is the location for the sole- can cause binding and malfunction.
noid valve (See Hydraulic Schematics to identify the
function of the hydraulic lines and cartridge valves at 3. Remove cartridge valve with a deep socket wrench.
each port). Note correct location for o--rings, sealing rings, and
backup rings. Remove and discard seal kit.
Cartridge Valve Service
4. Visually inspect the port in the manifold for damage
1. Make sure the manifold is clean before removing the to the sealing surfaces, damaged threads, and contami-
valve. nation.
2. If cartridge is solenoid operated, remove nut secur-

ing solenoid to the cartridge valve. Carefully slide sole-
noid off the valve.

5. Visually inspect cartridge valve for damaged sealing 7. Reinstall the cartridge valve:
surfaces and contamination.
A. Lubricate new seal kit components with clean hy-
A. Contamination may cause valves to stick or hang draulic oil and install on valve. The o--rings, sealing
up. Contamination can become lodged in small valve rings, and backup rings must be arranged properly
orifices or seal areas causing malfunction. on the cartridge valve for proper operation and seal-
ing.
B. If valve sealing surfaces appear pitted or dam-
aged, the hydraulic system may be overheating or IMPORTANT: Use care when handling the valve car-
there may be water in the system. tridge. Slight bending or distortion of the stem tube
can cause binding and malfunction.
CAUTION B. Thread cartridge valve carefully into manifold

port. The valve should go in easily without binding.
Use eye protection such as goggles when using C. Torque cartridge valve using a deep socket to val-
compressed air. ue identified in manifold illustration.
D. If cartridge is solenoid operated, carefully install

6. Clean cartridge valve using clean mineral spirits.
solenoid coil to the cartridge valve. Apply Loctite
Submerge valve in clean mineral spirits to flush out con-
#242 or equivalent to the threads of the valve. Torque
tamination. Particles as fine as talcum powder can affect
nut to value identified in manifold illustration.
the operation of high pressure hydraulic valves. If car-
Hydraulic
tridge design allows, use a wood or plastic probe to push
System
8. If problems still exist, remove valve and clean again
the internal spool in and out 20 to 30 times to flush out or replace valve.
contamination. Be extremely careful not to damage car-
tridge. Use compressed air for cleaning.

Hydraulic Control Manifold Service: Filtration and Charge Control
35 to 40 ft--lb
(47 to 54 N--m)
7
60 to 70 ft--lb 4 6
(81 to 95 N--m)
2
10
5
12 11
13 10
9
3 8
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. Filter manifold assembly 7. Seal kit 12. Plug (SAE #5)
2. Check valve (Reservoir return) 8. Plug (SAE #4) 13. O--ring
3. Seal kit 9. O--ring 14. Plug (SAE #10)
4. Check valve (Filter bypass) 10. Plug (SAE #6) 15. O--ring
5. Seal kit 11. O--ring 16. Oil filter element
6. Check valve (Charge pressure)
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 Con-
trol in this section. Refer to Figure 66 for cartridge valve
installation torque.

Hydraulic Control Manifold Service: Power Down and Traction Assist (GM 4500--D)
25 ft--lb
3 (33.9 N--m)
2
25 ft--lb
(33.9 N--m)
20 ft--lb
(27.1 N--m)
6 5
20 ft--lb
(27.1 N--m)
Hydraulic
System
1
Figure 67
1. Manifold body 4. Expanding plug (not serviced) 6. Traction pressure sensing valve
2. Traction assist valve (RV2: port 2) 5. Lift relief valve (RV7: port 7) (PD3: port 5)
3. Counterbalance valve (RV1: port 4)

identification of components. Example: CB is the con-
nection port from the lift/lower control valve and CHG is
the charge circuit connection (See Hydraulic Schemat-
ics to identify the function of the hydraulic lines and car-
tridge valves at each port).


Hydraulic Control Manifold Service: Power Down and Traction Assist (GM 4700--D)
25 ft--lb
2 3
(33.9 N--m) 20 ft--lb
(27.1 N--m)
25 ft--lb
(33.9 N--m)
3
20 ft--lb 4 20 ft--lb
(27.1 N--m) (27.1 N--m)
6
7
20 ft--lb
(27.1 N--m) 7
Figure 68
1. Manifold body 4. Counterbalance valve (RV1: port 4) 6. Lift relief valve (RV7: port 7)
2. Traction assist valve (RV2: port 2) 5. Traction pressure sensing valve 7. Expanding plug (not serviced)
3. Power down valve (deck 6) (PD3: port 5) 8. Power down valve (deck 7)

identification of components. Example: C1 is the con-
nection 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).


Hydraulic
System

Hydraulic Control Manifold: Deck Drive (GM 4500--D)
8
16
15
1
10
2
17 11
11
3 2
13
18
11 4
RIGHT 2 5
FRONT 11
12 4 10 12 6 13
7 14
Figure 69
1. Hydraulic manifold: decks 2, 3, & 5 7. 90o hydraulic fitting 13. O--ring
2. Hydraulic adapter 8. Quick fitting 14. O--ring
3. 90o hydraulic fitting 9. Dust cap 15. O--ring
4. 90o hydraulic fitting 10. O--ring 16. Flange nut
5. Hydraulic manifold: decks 1 & 4 11. O--ring 17. Cap screw
6. Straight hydraulic fitting 12. O--ring 18. Plug
Removal 3. Disconnect hydraulic lines from manifold and put

caps or plugs on open hydraulic lines and fittings. Label
NOTE: The ports on the manifold are marked for easy disconnected hydraulic lines for proper reassembly.
pump connection port. (See Hydraulic Schematics to 4. Remove hydraulic manifold from the frame using
identify the function of the hydraulic lines and cartridge Figure 69 as guide.
Installation
Installing Hydraulic System Components at the begin- 1. Install hydraulic manifold to the frame using Figure
ning of the Service and Repairs section of this chapter. 69 as guide.
2. Disconnect electrical connector from the solenoid 2. Remove caps and plugs from fittings and hoses.
valve. Properly connect hydraulic lines to manifold.
3. Connect electrical connector to the solenoid valve.

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
4 (33.9 N--m)
25 ft--lb
(33.9 N--m) 2
6 8
198 in--lb
(22.4 N--m)
Hydraulic
System
1
120 in--lb 10
(13.6 N--m)
11
11
Figure 70
1. Manifold body 5. Relief valve (RV8) 9. Plug (SAE #4)
2. Solenoid valve (PRV2) 6. Pilot piston 10. Zero leak plug (#4)
3. Solenoid coil 7. Nut 11. Expanding plug (not serviced)
4. Logic cartridge (LC1) 8. Zero leak plug (#6)
NOTE: The ports on the manifold are marked for easy NOTE: The Groundsmaster 4500--D deck drive man-
identification of components. Example: P1 is the gear ifold uses several zero leak plugs. These plugs have a
pump connection port. (See Hydraulic Schematics to tapered sealing surface on the plug head that is de-
identify the function of the hydraulic lines and cartridge signed to resist vibration induced plug loosening. The
valves at each port location). zero leak plugs also have an o--ring as a secondary seal.
If zero leak plug removal is necessary, lightly rap the
For solenoid and control valve service procedures, see plug head using a pin punch and hammer before using
Hydraulic Control Manifold Service: 2 Wheel/4 Wheel an allen wrench to remove the plug: the impact will allow
Drive Control in this section. Refer to Figure 70 for car- plug removal with less chance of damage to the socket
tridge valve installation torque. head of the plug.

Hydraulic Control Manifold: Deck Drive (GM 4700--D)
15
17
1
11
2
10
16 2
11 2
3 4 13
12 11
4 2
5
RIGHT 18
10
13
FRONT
11 14
6
7
12
Figure 71
1. Hydraulic manifold: decks 2, 3, 5, & 7 7. 90o hydraulic fitting 13. O--ring
2. Hydraulic adapter 8. Quick fitting 14. O--ring
3. 90o hydraulic fitting 9. Dust cap 15. O--ring
4. 90o hydraulic fitting 10. O--ring 16. Cap screw
5. Hydraulic manifold: decks 1, 4, & 6 11. O--ring 17. Flange nut
6. Straight hydraulic fitting 12. O--ring 18. Plug
Removal 3. Disconnect hydraulic lines from manifold and put

caps or plugs on open hydraulic lines and fittings. Label
NOTE: The ports on the manifold are marked for easy disconnected hydraulic lines for proper reassembly.
pump connection port. (See Hydraulic Schematics to 4. Remove hydraulic manifold from the frame using
identify the function of the hydraulic lines and cartridge Figure 71 as guide.
Installation
Installing Hydraulic System Components at the begin- 1. Install hydraulic manifold to the frame using Figure
ning of the Service and Repairs section of this chapter. 71 as guide.
2. Disconnect electrical connector from the solenoid 2. Remove caps and plugs from fittings and hoses.
valve. Properly connect hydraulic lines to manifold.
3. Connect electrical connector to the solenoid valve.

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
7 20 ft--lb
(27.1 N--m)
8 (27.1 N--m)
5
5
25 ft--lb
(33.9 N--m)
3
7
25 ft--lb
4
(33.9 N--m)
198 in--lb
(22.4 N--m) 9
9
25 ft--lb 2
(33.9 N--m) 198 in--lb
9 (22.4 N--m)
Hydraulic
System
10 75 ft--lb
1 (101.7 N--m)
120 in--lb
(13.6 N--m)
12
9 198 in--lb
(22.4 N--m)
11
165 in--lb
(18.6 N--m)
Figure 72
1. Manifold body 5. Relief valve (RV8 and RV9) 9. Zero leak plug (#6)
2. Proportional relief solenoid (PRV2) 6. Pilot piston 10. Zero leak plug (#12)
3. Solenoid valve (SV2) 7. Solenoid coil 11. Plug (SAE #4)
4. Logic valve (LC1 and LC2) 8. Nut 12. Zero leak plug (#4)
NOTE: The ports on the manifold are marked for easy NOTE: The Groundsmaster 4700--D deck drive man-
identification of components. Example: P1 is the gear ifold uses several zero leak plugs. These plugs have a
pump connection port. (See Hydraulic Schematics to tapered sealing surface on the plug head that is de-
identify the function of the hydraulic lines and cartridge signed to resist vibration induced plug loosening. The
valves at each port location). zero leak plugs also have an o--ring as a secondary seal.
If zero leak plug removal is necessary, lightly rap the
For solenoid and control valve service procedures, see plug head using a punch and hammer before using an
Hydraulic Control Manifold Service: 2 Wheel/4 Wheel allen wrench to remove the plug: the impact will allow
Drive Control in this section. Refer to Figure 72 for car- plug removal with less chance of damage to the socket
tridge valve installation torque. head of the plug.

Rear Axle Motor
Arrows on side of
motor case point up
5
6
7
7
8
4
5
9
1 10
2
3
59 to 73 ft--lb
(80 to 99 N--m)
RIGHT
FRONT
Figure 73
1. Axle motor 5. O--ring 8. 90o hydraulic fitting
2. O--ring 6. Hydraulic fitting 9. Cap screw
3. Pinion gear 7. O--ring 10. Flat washer
4. External snap ring

1. Park machine on a level surface, lower cutting units, 1. If removed, install pinion gear to axle motor.
from the ignition switch. 2. Install o--ring onto motor. Position motor to rear axle
assembly making sure that arrows on the side of motor
2. Read the General Precautions for Removing and case point upward. Align gear teeth and slide motor into
Installing Hydraulic System Components at the begin- place.
3. Secure motor to axle with cap screws and flat wash-
NOTE: To ease reassembly, tag the hydraulic hoses to ers. Torque screws from 59 to 73 ft--lb (80 to 99 N--m).
show their correct position on the axle motor. Also, clean
the port areas of the motor before disconnecting hydrau- 4. Remove plugs from ports. Attach hydraulic hoses to
lic lines. axle motor.
3. Disconnect hydraulic hoses from motor. Put caps or 5. Fill hydraulic reservoir with hydraulic fluid as re-
plugs on ports to prevent contamination. quired (see Traction Unit Operator’s Manual).
IMPORTANT: Support axle motor to prevent motor 6. After assembly is completed, verify that hydraulic
from falling during removal. hoses and fittings do not contact anything.
4. Remove motor using Figure 73 as a guide.
Hydraulic
System

Front Wheel Motors
1
2
20 3
21
14 22
18
10 16
14
23 24 15
6
19 18 25 10
19
17
16
10
15
14 10
13
12
11
75 to 85 ft--lb 9
(101 to 115 N--m) 8 5
7
4
Arrows on side of
RIGHT motor case point up
FRONT
Figure 74
1. Flange head screw 10. O--ring 18. O--ring
2. Splined brake shaft 11. Piston wheel motor 19. O--ring
3. Planetary assembly 12. Flat washer 20. RH brake assembly
4. Wheel assembly 13. Cap screw 21. Hydraulic tee fitting
5. Lug nut 14. O--ring 22. 45o hydraulic fitting
6. Retaining ring 15. 90o hydraulic fitting 23. O--ring
7. LH brake assembly 16. O--ring 24. Hydraulic fitting
8. Flange head screw 17. 90o hydraulic elbow 25. O--ring
9. Plug

1. Park machine on a level surface, lower cutting units, 1. Position wheel motor to brake assembly making sure
stop engine, engage parking brake, and remove key that arrows on the side of motor case point upward.
2. Align splines on motor shaft and splined brake shaft.
2. Read the General Precautions for Removing and Slide motor into brake assembly.
Installing Hydraulic System Components at the begin-
ning of the Service and Repairs section of this chapter. 3. Secure motor to brake assembly with cap screws
and flat washers. Tighten cap screws from 75 to 85 ft--lb
NOTE: To ease reassembly, tag the hydraulic hoses to (101 to 115 N--m).
show their correct position on the wheel motor. Also,
clean the port area of the motor before disconnecting 4. Remove plugs from motor ports. Attach hydraulic
the hydraulic lines. hoses and tubes to wheel motor.
3. Disconnect hydraulic hoses and tubes from wheel 5. Fill reservoir with hydraulic fluid as required (see
motor. Put caps or plugs on motor ports to prevent con- Traction Unit Operator’s Manual).
tamination.
IMPORTANT: Support wheel motor to prevent mo-

tor from falling during removal.
4. Remove wheel motor using Figure 74 as a guide.
Hydraulic
System

Rear Axle/Front Wheel Motor Service
15 to 18 ft--lb
FRONT WHEEL MOTOR SHOWN (20 to 24 N--m)
1
7
9 2
10
13
10
9
11
18
8
6
19
20
14
15
16
12
3
17
Figure 75
1. Drive shaft 8. Shaft seal (front motor only) 15. Roll pin
2. Backplate 9. Retaining ring 16. Bearing
3. Housing assembly 10. Thrust race 17. Bearing
4. Rotating assembly 11. O--ring 18. Washer
5. Cam plate insert 12. Valve plate 19. Plug
6. Retaining ring 13. Thrust bearing 20. O--ring
7. Cap screw 14. Roll pin
NOTE: The front wheel motors (shown in Figure 75) are Disassembly
identical. The rear axle motor is similar to the front wheel
motors. Service of the front and rear motors requires the 1. Clamp the drive shaft end of the piston motor in a pro-
same procedure. tected jaw vise with the cap screws up. Remove the six
cap screws (7) from the motor assembly.
NOTE: The rear axle motor does not have a shaft seal.
The case drain from the rear axle motor provides lu- 2. Use a soft face hammer and tap the backplate (2) to
brication for the input gear case of the rear axle. loosen and remove from housing.
Cleanliness is extremely important when repairing hy- 3. Remove valve plate (12) and O--ring (11) from back-
draulic motors. Work in a clean area. Before disconnect- plate. It is not necessary to remove roll pins (14 and 15)
ing the lines, clean port area of motor. Thoroughly clean in backplate.
the outside of the motor. After cleaning, remove port
plugs and drain oil from motor.

4. Remove motor from vise and remove rotating as- 2. If necessary, install new needle bearing (17) in hous-
sembly (4) from motor housing. ing (3) with numbered end of the bearing outward.
5. Remove the camplate insert (5) from housing. Use 3. Install retaining ring (9) on shaft. Install thrust race
caution not to mar the finish that makes contact with pis- (10), thrust bearing (13), and second thrust race (10).
tons. Secure with second retaining ring (9).
6. Remove retaining ring (6) from housing. Press shaft 4. Install shaft in housing. Install washer (18), new shaft
from housing and remove shaft seal (8) and washer seal (8), and retaining ring (6).
(18).
5. Install camplate insert (5) with the lettering side of in-
7. Remove retaining rings (9) from shaft and remove sert to the front of the housing. Use petroleum jelly to
thrust races (10) and thrust bearing (13). hold in place during assembly.
8. Discard the shaft seal and o--ring, and replace with 6. Install rotating assembly (4) into housing. Make sure
new items upon reassembly. 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. 8. If roll pins were removed, install to dimension shown
in Figure 76 and with opening of roll pin oriented away
2. Inspect valve plate (12) on the bronze side next to the from bearing within 5o of bearing center line.
Hydraulic
piston block for wear. A smooth surface is required. Do
System
not lap valve plate bronze surface. Replace valve 9. To replace bearing (16) in backplate (2). Press bear-
plate if any wear exists. ing down to the dimension shown (Fig. 76) protruding
from backplate with numbered end of bearing facing up
3. Inspect the piston block surface that makes contact next to valve plate.
with valve plate. This surface should be smooth and free
of deep scratches. Do not lap piston block.
.173 in (4.39 mm) .090 in (2.3 mm)
4. The pistons should move freely in the piston block Roll Pin (15) Bearing
bore. If they are sticky in the bore, examine the bore for
scoring or contamination.
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 cam-
plate. 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. Figure 76
8. The polished finish on the shoe surface of the cam- 10.Apply small amount of petroleum jelly to the steel
plate insert (5) should show no signs of scoring. side of valve plate (12) to hold in place for installation.
Place the valve plate in position onto the backplate (2),
9. Inspect the shaft for wear in the seal, bearing and with steel side against backplate, bronze colored side
spline areas. against piston block.
10.Inspect thrust bearing (13) and races (10) for wear. 11. Placing new o--ring (11) onto backplate, install back-
plate assembly (2) onto housing assembly. Make sure
11. Check the condition of the needle bearing (17) in valve plate stays in position.
housing and replace if necessary.
12.Insert cap screws and torque from 15 to 18 ft--Ib (20
Reassembly to 24 N--m) in a criss--cross pattern.
1. Clean all parts in suitable solvent and lubricate all in- 13.Fill case half full of new hydraulic oil.
ternal parts with clean hydraulic oil before reassembly.


Cutting Deck Motor
The hydraulic motors used on all cutting decks are the
same.
2
Removal

from the ignition switch. 1
2. Read the General Precautions for Removing and 1
NOTE: Before disconnecting the hydraulic lines, clean Figure 77

the port area of the deck motor. 1. Socket head screw 2. Hydraulic motor
3. Disconnect hydraulic lines from deck motor. Put

caps or plugs on fittings and hoses to prevent contami-
nation. Tag hydraulic lines for proper reassembly.
Hydraulic
System
4. Remove two socket head screws that secure hy-
draulic motor to cutting deck (Fig. 77).
5. Lift hydraulic motor from cutting deck.
Installation
1. Align splines on motor shaft and spindle shaft. Posi-

tion 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 compo-
nents.

Cutting Deck Motor Service
1
2
8
4
7
5
6
7
8
12
5 13
9
10
38 to 43 ft--lb
11
(51 to 58 N--m)
30 to 35 ft--lb 15
(41 to 47 N--m) 14
Figure 78
1. Outer shaft seal 6. Front bearing block 11. Idler gear
2. Inner shaft seal 7. O--ring 12. Rear bearing block
3. Retaining ring 8. Dowel pin 13. Rear cover
4. Front flange 9. Housing 14. Cap screw
5. Pressure seal 10. Drive gear 15. Relief valve assembly
Disassembly (Fig. 78)

SCRIBE MARK
1. Plug motor ports and clean the outside of the motor
thoroughly. After cleaning, remove plugs and drain any
oil out of the motor.
2. Use a marker or scribe to make a diagonal mark

across the front flange, housing, and rear cover for reas-
sembly 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 Figure 79

end down.
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.

7. Carefully remove housing by lifting housing straight 4. Inspect bearing blocks for the following:
up. Make sure the rear bearing block remains on the
drive and idler gear shafts. Remove and discard o--rings A. Bearing areas should not have excessive wear or
from the housing. scoring.
Safety
IMPORTANT: Note position of the open and closed B. Face of bearing blocks that are in contact with
side of the bearing blocks before removing. Also, gears should be free of wear, roughness or scoring.
identify bearing blocks (front and rear) for proper re-
assembly. C. Thickness of bearing blocks should be equal.
Product Records
and Manuals
8. Carefully remove rear bearing block, idler gear, drive 5. Inspect front flange and rear cover for damage or
gear, and front bearing block from the front flange. wear.
9. Remove and discard pressure seals from bearing

blocks. 3
10.Turn front flange over, with seal side up.
Diesel Engine
2
Kubota
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
Hydraulic
System
Inspection 4
1. Remove any nicks and burrs from all parts with Figure 80
emery cloth. 1. Gear shaft spline 3. Gear teeth
2. Gear shaft 4. Gear face edge
Reassembly (Fig. 78)

CAUTION
Electrical
System
NOTE: When reassembling the motor, check the mark-
Use eye protection such as goggles when using er or scribe marks on each part to make sure the parts
compressed air. are properly aligned during reassembly.
1. Lubricate o--rings, pressure seals, and bearing block
Wheels, Brakes,
2. Clean all parts with solvent. Dry all parts with com- grooves with a thin coat of petroleum jelly. Lubricate all
and Chassis
pressed air. other internal parts freely with clean hydraulic oil.
3. Inspect drive gears and idler gears for the following 2. Install inner shaft seal into front flange with seal lip
(Fig. 80): facing in (Fig. 81). Seal should be pressed into place un-
til it reaches the bottom of the bore.
A. Drive gear shaft spline should be free of twisted or
broken teeth. 3. Install retaining ring into the groove of the front
flange.
B. Gear shafts should be free of rough surfaces and
excessive wear at bushing points and sealing areas. 4. Install outer shaft seal in front flange with seal lip fac-
Scoring, rough surfaces, or wear on gear shafts indi- ing out (Fig. 81). Seal should be pressed into place until
cates need for replacement. it reaches the bottom of the bore.
C. Gear teeth should be free of excessive scoring 5. Place front flange, shaft seal side down, on a flat sur-
and wear. Any broken or nicked gear teeth must be face.
replaced.
6. Install the pressure seals into the grooves in the
D. Inspect gear face edge for sharpness. Sharp bearing blocks.
edges of gears will mill into bearing blocks and, thus,
must be replaced. 7. Apply a light coating of petroleum jelly to the exposed
side of the front flange.

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 2
bearing block with the pressure seal side down. Careful-
ly install shaft into front flange.
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 1
up. 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

Figure 81
marks on the housing and front flange.
1. Inner shaft seal 3. Outer shaft seal
2. Retaining ring
IMPORTANT: Do not dislodge pressure seals from
bearing blocks when installing housing to assem-
bly.
Rotation Direction
13.Gently slide the housing onto the assembly. Firm
hand pressure should be sufficient to engage the dowel
pins.
14.Check to make sure that the surface of the rear bear-

ing 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. Cor- 1 2
rect before proceeding.
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 1. Pressure IN 3. Case drain
2. Pressure OUT
pressure on the motor housing to prevent distorting
the housing.
18.Place front flange of the motor into a vise and alter-

nately 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.

Relief Valve Service
IMPORTANT: Do not remove the relief valve as-

sembly unless testing shows it to be faulty.
1. When removing or installing the relief valve, motor

should be removed from deck and positioned horizon-
tally with the relief valve pointed down (Fig. 83). This
process will prevent the relief valve from falling into mo-
tor passages. 5
NOTE: The relief valve seat is difficult to remove be- 4

cause it has a thin, hex head and has sealant applied to
3
the threads. Inspect the seat carefully and remove it only
if damage or wear is identified. RELIEF VALVE KIT 2
2. Remove plug with o--ring, spring, and relief valve 1
from the rear cover.
3. Clean and inspect removed parts. Visually inspect

Figure 83
relief valve seat and plug threads in the rear cover.
1. Plug 4. Relief valve
2. O--ring 5. Relief valve seat
4. If relief valve seat was removed, apply medium 3. Spring
Hydraulic
System
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).
5. Apply hydraulic oil to relief valve components. Re-

place 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.

Lift/Lower Control Valve (GM 4500--D)
11 10
9 25
9
12 5
6
13 8 7
4
24 3
14
2
15
1
16
17 23
22
21
18
20
RIGHT 19
FRONT
Figure 84
1. Control valve assembly (1 spool) 10. Lift lever 18. Insert nut
2. O--ring 11. Control knob 19. Flange nut
3. Hydraulic adapter 12. Curved washer 20. Extension spring
4. O--ring 13. Cotter pin 21. Cap screw
5. Hydraulic fitting 14. Thread forming screw 22. Valve support
6. Orifice (port B) 15. Proximity switch 23. Link
7. Cap screw 16. Flange head screw 24. Lock nut
8. Spacer 17. Switch plate 25. O--ring
9. Spacer tube

1. Park machine on a level surface, lower cutting units, 1. Install control valve using Figure 86 as a guide.
from the ignition switch. 2. Make sure hydraulic tank is full. Add correct oil if nec-
essary 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.
4. Remove lift/lower control valve using Figure 86 as a

guide.
Hydraulic
System

Lift/Lower Control Valve Service (GM 4500--D)
10 to 12 ft--lb
4 to 5 ft--lb 19 (13 to 16 N--m)
(5 to 7 N--m) 13
24
25 23
30 to 35 ft--lb
(41 to 48 N--m) 18
9 17
26 6
22
27 11
7
15 30 to 35 ft--lb
(41 to 48 N--m)
12
4
2
28
5
1
21
20 to 25 ft--lb
(27 to 33 N--m)
15
8
10
20
14
3
16
Figure 85
1. Poppet 11. Detent plunger 20. Washer
2. Plunger 12. Control valve body 21. Wiper seal
3. Spacer 13. Detent plug 22. Backup washer
4. Spool 14. Spool spring 23. O--ring
5. Seat 15. O--ring 24. O--ring
6. Plug 16. Retaining ring 25. O--ring
7. Seat retaining plug 17. Detent spring 26. O--ring
8. Bushing 18. Disc 27. Backup washer
9. Lockout spring 19. Plug 28. O--ring
10. Spool cap

NOTE: Cleanliness is extremely important when Assembly
repairing hydraulic components. Work in a clean area.
Before disassembly, drain the oil, then plug the ports 1. Thoroughly clean and dry all parts. Apply a light coat-
and thoroughly clean the exterior. During repairs, ing of clean hydraulic oil to parts prior to assembly.
always protect machined surfaces.
NOTE: All O--rings, back--up washers, wiper seals and
Disassembly nylon poppet should be replaced as new items.
1. Plug all ports and clean outside of valve thoroughly. 2. Install new O--ring (15) in proper groove in spool
bore.
2. Remove spool cap (10). Do not remove retaining ring
(16) from spool (4) unless spool spring (14) is broken. 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).
3. Remove spool (4) from control valve body (12).
4. Lubricate plunger (2) with clean hydraulic oil and
4. Remove bushing (8) and O--rings (15) from spool install it into control valve body.
and O--ring from spool bore.
IMPORTANT: Check location and positioning of
5. Remove plug (6). plunger during installation.
IMPORTANT: Check location and positioning of 5. Install new O--ring (28) on seat (5). Install new back--
plunger when removing from body to assure proper up washer (27) and O--ring (26) on seat retaining plug
assembly. (7).
Hydraulic
System
6. Remove seat retaining plug (7), lockout spring (9), 6. Lubricate seat (5) with clean hydraulic oil. Install seat
poppet (1), seat (5) and plunger (2). (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).
7. Install plug (19) with new O--ring (24).
8. Remove detent plug (13), disc (18), spring (17) and
detent plunger (11). 8. Lubricate detent plunger (11) with clean hydraulic oil.
Install plunger, detent spring (17), disc (18), and detent
9. Remove all O--rings and back--up rings from all plugs plug (13) with new O--ring (25).
and seats.
9. If retaining ring (16) was removed to replace spool
Inspection spring (14), install washer (20), spring (14), spacer (3),
and secure with retaining ring (16).
1. Remove all nicks and burns from parts and inspect
for excessive wear. 10.Slide bushing (8) over spool. Slide new O--ring (21)
over spool and position next to bushing. Dip spool in
2. Inspect plunger and seats for burrs or roughness. clean hydraulic oil and install spool assembly into proper
location of control valve body.
3. Inspect spool spring (14), lockout spring (9), and det-
ent spring (17) for breakage. 11. Install spool cap (10) and tighten from 20 to 25 ft--lb
(27 to 33 N--m).
4. If spool (4) has excessive wear, the control valve be-
comes non--serviceable as the spool and spool bore are 12.Install new wiper seal (21).
matched. Damaged spools cannot be replaced.

Lift/Lower Control Valve (GM 4700--D)
13
14 12
4 8
11 4
6 5
16 15 10 7
9
17
6
4
18
3
19
20 2
27 1
21
26
25
22
24
RIGHT 23
FRONT
Figure 86
1. Control valve assembly (3 spool) 10. Spacer 19. Lock nut
2. O--ring 11. Left lift lever 20. Flange head screw
3. Hydraulic adapter 12. Control knob (3 used) 21. Switch plate
4. O--ring 13. Center lift lever 22. Nut insert
5. Hydraulic fitting 14. Right lift lever 23. Flange nut
6. O--ring 15. Curved washer (if equipped) 24. Extension spring (3 used)
7. Orifice (port D) 16. Cotter pin 25. Cap screw
8. Cap screw 17. Thread forming screw 26. Valve support
9. 90o hydraulic fitting 18. Proximity switch (3 used) 27. Link (3 used)

1. Park machine on a level surface, lower cutting units, 1. Install control valve using Figure 86 as a guide.

the port area of the lift/lower control valve assembly.
4. Remove lift/lower control valve using Figure 86 as a

guide.
Hydraulic
System

Lift/Lower Control Valve Service (G 4700--D)
30 to 35 ft--lb 6
(41 to 48 N--m)
4
29
28
10 to 12 ft--lb 12 22
(13 to 16 N--m)
4 to 5 ft--lb
(5 to 7 N--m) 27
21
26
17
20
19
18
11
12
25 16 8
5 14
24 15
3
1
23 13
20 to 25 ft--lb
10 (27 to 33 N--m)
9
30 to 35 ft--lb
(41 to 48 N--m) 7
Figure 87
1. Poppet 11. Control valve body 21. Plug
2. Plunger 12. O--ring 22. Wiper seals
3. Spacer 13. Retaining ring 23. Backup washer
4. Spool 14. Washer 24. O--ring
5. Seat 15. Spool spring 25. O--ring
6. Plug 16. Plunger 26. O--ring
7. Seat retaining plug 17. Detent plunger 27. O--ring
8. Bushing 18. Detent plug 28. O--ring
9. Lockout spring 19. Disc 29. Backup washer
10. Spool cap 20. Detent spring

NOTE: Cleanliness is extremely important when Assembly
repairing hydraulic components. Work in a clean area.
Before disassembly, drain the oil, then plug the ports 1. Thoroughly clean and dry all parts. Apply a light coat-
and thoroughly clean the exterior. During repairs, ing of clean hydraulic oil to parts prior to assembly.
NOTE: All O--rings, back--up washers, wiper seals and
Disassembly nylon poppets should be replaced as new items.
1. Plug all ports and clean outside of valve thoroughly. 2. Install new O--rings (12) in proper grooves in spool
bores.
2. Remove spool caps (10). Do not remove retaining
rings (13) from spools unless spool spring (15) is bro- 3. Install plugs (6) with new back--up washers (29) and
ken. O--rings (28). Torque plugs from 30 to 35 ft--lb (41 to 48
N--m).
NOTE: Spools and spool bores are matched sets. Be
sure each spool is identified with the correct control 4. Lubricate plungers (2 and 16) with clean hydraulic oil
valve body spool bore. and install them into their correct position in valve body.
3. Remove spools (4) from control valve body (11). IMPORTANT: Check location and positioning of
plungers during installation.
4. Remove bushings (8) and O--rings (12) from spools
and O--rings from spool bores. 5. Install new O--rings (25) on seats (5). Install new
back--up washers (23) and O--rings (24) on plugs (7).
Hydraulic
5. Remove plugs (6).
System
6. Lubricate seats (5) with clean hydraulic oil. Install
IMPORTANT: Check location and positioning of seats (5), new poppets (1), and seat retaining plugs (7).
plungers when removing from body to assure prop- Torque plugs from 30 to 35 ft--lb (41 to 48 N--m).
er assembly.
7. Install plug (21) with new O--ring (27). Torque plug
6. Remove seat retaining plugs (7), lockout springs (9), from 10 to 12 ft--lb (13 to 16 N--m).
poppets (1), seats (5) and plungers (2 and 16).
8. Lubricate detent plunger with clean hydraulic oil.
7. Remove plug (21). Install detent plunger (17), detent spring (20), disc (19),
and detent plug (18) with new O--ring (26). Torque plug
8. Remove detent plugs (18), discs (19), detent springs from 4 to 5 ft--lb (5 to 7 N--m).
(20) and detent plungers (17).
9. If retaining ring (13) has been removed to replace
9. Remove all O--rings and back--up rings from all plugs spool spring (15), install washer (14), spring (15),
and seats. spacer (3), and secure with retaining ring (13).
Inspection 10.Slide bushings (8) over spools. Slide new O--rings

(12) over spools and position next to bushings. Dip
1. Remove all nicks and burns from parts and inspect spools in clean hydraulic oil and install spool assemblies
for excessive wear. into proper location of body.
2. Inspect all plungers and poppet seats for burrs or 11. Install spool caps (10) and tighten from 20 to 25 ft--lb
roughness. (27 to 33 N--m).
3. Inspect spool springs (15), lockout springs (9), and 12.Install new wiper seals (22).
detent springs (20) for breakage.
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 re-
placed.

Steering Valve
20 to 26 ft--lb
6 (28 to 35 N--m)
5
8 4
9
10
3
11
12
21
13 20
9
19
RIGHT 18
2 17
FRONT
14 15 1
16
Figure 88
1. Steering valve 8. Steering column bracket 15. Hydraulic adapter
2. Steering column 9. Flange head screw 16. O--ring
3. Flange head screw (3 used) 10. Flange head screw (1 used) 17. In port (P)
4. Dust cover 11. Lock washer 18. Right turn port (R)
5. Steering wheel 12. Flat washer 19. Load sensing port (PB)
6. Hex nut 13. Steering tower cover 20. Left turn port (L)
7. Steering wheel cover 14. O--ring 21. Out port (T)

Rev. D
1. Park machine on a level surface, lower cutting units, 1. Install steering valve using Figure 88 as a guide.

the port area of the steering valve assembly.
4. Remove steering valve from machine using Figure

88 as a guide.
Hydraulic
System

Steering Valve Service
8
1
3
24
2
7 6
4
5
19
19 20
23
22
150 in--lb 21
(17 N--m)
9
10
11
12
13
14 140 to 160 in--lb
15 (16 to 18 N--m)
16
18 17
Figure 89
1. Steering valve housing 9. Cap screw 17. Geroter drive
2. Dust seal 10. End cap 18. Wear plate
3. O--ring 11. O--ring 19. Bearing race
4. Spool 12. Seal ring 20. Thrust bearing
5. Spring retaining ring 13. O--ring 21. Plug
6. Pin 14. Geroter 22. O--ring
7. Sleeve 15. O--ring 23. Relief valve
8. Centering springs/spacers 16. Spacer 24. Quad seal
Disassembly 4. Slide the spool and sleeve assembly from the hous-
ing.
NOTE: Cleanliness is extremely important when
repairing hydraulic components. Work in a clean area. 5. Remove the thrust bearing and bearing races (2).
Before disassembly, drain the oil, then plug the ports
and thoroughly clean the exterior. During repairs, 6. Remove the quad seal.
7. Use a small blade screwdriver to carefully pry the
1. Remove the seven cap screws from the steering dust seal from the housing. Be careful to not damage the
valve assembly. dust seal seat in the housing.
2. Remove end cap, geroter, spacer, geroter drive, 8. Remove the pin that holds the spool and sleeve to-
wear plate, seal ring, and o--rings from housing (Fig. 89). gether.
3. Remove the plug and relief valve. 9. Carefully slide the spool out of the sleeve. The cen-
tering springs and spring retaining ring will stay with the
spool as it is removed.

8. Put the thrust bearing and races into the housing.
CAUTION The thrust bearing goes between the two races
(Fig. 90).
The centering springs are under tension. Re- IMPORTANT: Do not damage the dust or quad seals
move the retaining ring carefully. when installing the spool and sleeve assembly.
9. Apply a light coating of clean hydraulic fluid to the

10.Remove the spring retaining ring and centering
spool and sleeve assembly and slide carefully the as-
springs from the spool.
sembly into the housing.
Reassembly
10.Clamp the housing in a vise. Use only enough clamp-
Check all mating surfaces. Replace any parts with ing force to hold the housing securely.
scratches or burrs that could cause leakage. Wash all
11. Lubricate and install a new o-ring seal in the groove
metal parts in clean solvent. Blow them dry with pressur-
in the housing.
ized air. Do not wipe parts dry with paper towels or cloth.
Lint in a hydraulic system will cause damage. 12.Install the wear plate and align screw holes in the
wear plate with threaded holes in the housing.
NOTE: Always use new seals and o--rings when
reassembling the steering control unit. NOTE: The holes in the wear plate are symmetrical.
IMPORTANT: During reassembly, lubricate the new 13.Install the geroter drive, making sure the slot in the
seals with petroleum jelly. Also, lubricate machined
Hydraulic
drive engages the pin.
System
surfaces and bearings with clean hydraulic fluid.
14.Lubricate and install new o-ring in wear plate groove.
1. Install the quad seal:
15.Install the gerotor and align the screw holes.
A. Put one of the bearing races and sleeve into the
housing. 16.Lubricate and install new o-ring in gerotor ring
groove.
B. Together, the housing and bearing race create a
groove into which the quad seal will be installed. 17.Lubricate and install new o-ring and seal ring in gero-
tor star groove.
C. Hold the bearing race tightly against the input end
of the housing by pushing on the gerotor end of the 18.Install the spacer.
sleeve.
19.Install the end cap and seven cap screws. Tighten
D. Fit the quad seal into its seat through the input end the cap screws, in a crossing pattern, from 140 to 160
of the housing. Be sure the seal is not twisted. 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. 21.Install the relief valve and plug. Tighten the plug to
150 in-lb (17 N--m).
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. Thrust Bearing
Dust Seal and Race (2)
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.
Figure 90
7. Apply a light coating of petroleum jelly to the inner
edge of the dust and quad seals.

Lift Cylinders: Decks #1, #4, and #5
2
3
4
5
6
9 7
8
10
12 11
13
13
1
5
RIGHT
FRONT
Figure 91
1. Lift arm (deck #4) 6. O--ring 10. Lift cylinder (deck #4)
2. Flange nut 7. 90o hydraulic fitting 11. Lift cylinder (deck #1)
3. Lift arm (deck #1) 8. O--ring 12. Lift cylinder (deck #5)
4. Cylinder pin (3 used) 9. Lift arm (deck #5) 13. Cylinder pin (3 used)
5. Flange head screw

Removal (Fig. 91)
1. Park machine on a level surface, lower cutting units, #4 Deck #1 Deck #5 Deck

NOTE: To ease reassembly, tag the hydraulic hoses to #2 #3

#6 Deck #7 Deck
show their correct position on the lift cylinder. Also, clean (GM4700)
Deck Deck (GM4700)
hydraulic fittings and hose ends prior to disconnecting
the hoses.
3. Disconnect hydraulic hoses from lift cylinder.
4. Remove flange nut and flange head screw that se-

cure the cylinder pin (4) to the lift arm. Remove pin from CUTTING DECK LOCATIONS
lift arm and cylinder shaft clevis which will free lift cylin-
Figure 92
der from lift arm.
5. Remove flange nut and flange head screw that se-
Hydraulic
System
cure 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 cyl-

inder 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

5. After assembly is completed, operate lift cylinder to

verify that hydraulic hoses and fittings are not contacted
by anything.

Lift Cylinders: Decks #2 and #3
8
9
4
10
11
7 7
6
12
6
5
4
3
2
14
RIGHT
13
1
FRONT
Figure 93
1. Lift arm (deck #2 shown) 6. O--ring 11. Lift cylinder
2. Cylinder pin 7. Retaining ring 12. Flange nut
3. Flange head screw 8. Cylinder pin 13. Rotation stop
4. O--ring 9. Hydraulic fitting 14. Set screw
5. 90o hydraulic fitting 10. Grease fitting

Removal (Fig. 93)

NOTE: Before disconnecting the hydraulic lines, clean #2 #3

#6 Deck #7 Deck
the port area of the steering valve assembly. (GM4700)
Deck Deck (GM4700)
NOTE: To ease reassembly, tag the hydraulic hoses to

show their correct position on the lift cylinder. Also, clean
the hoses.
3. Disconnect hydraulic hoses from lift cylinder. CUTTING DECK LOCATIONS
4. Remove flange head screw and flange nut that se- Figure 94
cure the cylinder pin (2) to the lift arm. Remove pin from
lift arm and cylinder shaft clevis.
Hydraulic
System
5. Remove one retaining ring from the cylinder pin (8).
Remove cylinder pin from the frame and cylinder barrel
clevis.
1. Position cylinder barrel clevis to frame and insert cyl-

inder pin (8) with one retaining ring installed through the
frame and cylinder clevis. Secure pin with second re-
taining 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.


by anything.

Lift Cylinders: Decks #6 and #7 (GM 4700--D)
1
13
14 10
12
11
10
7 9
8
2 4
1
15
7
6
1
5 3
16
RIGHT
2
FRONT
4
1
3
Figure 95
1. Retaining ring 7. Plastic roller 12. O--ring
2. Cylinder pin 8. Rear link 13. Grease fitting
3. Thrust washer 9. Lock nut 14. O--ring
4. Lift link 10. 90o hydraulic fitting 15. Support frame
5. Link assembly 11. Lift cylinder 16. Lift arm (deck #6 shown)
6. Bushing

Removal (Fig. 95)

NOTE: To ease reassembly, tag the hydraulic hoses to #2 #3

#6 Deck #7 Deck
show their correct position on the lift cylinder. Also, clean (GM4700)
Deck Deck (GM4700)
the hoses.
3. Disconnect hydraulic hoses from lift cylinder.
4. Remove lock nuts (9) that secure link assembly (5).

Remove rear link (8) from link assembly. Pull link assem- CUTTING DECK LOCATIONS
bly from support frame, lift links (4), and cylinder shaft
Figure 96
clevis which will free lift cylinder from lift arm. Locate and
remove plastic rollers (7) positioned on both sides of cyl-
inder clevis.
Hydraulic
System
5. Remove one retaining ring that secures the cylinder
pin (2) to the support frame. Pull pin from frame and cyl-
inder barrel clevis.
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. In-

sert 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.


by anything.

Lift Cylinder Service
12
10
9
5
7
4
1
2
11
Figure 97
1. Barrel with clevis 5. Rod seal 9. O--ring
2. Collar 6. O--ring 10. Uni--ring
3. Shaft with clevis 7. Back--up ring 11. Piston
4. Dust seal 8. Head 12. Locking nut

Disassembly Assembly
1. Remove oil from lift cylinder into a drain pan by slowly 1. Make sure all parts are clean before reassembly.
pumping the cylinder shaft. Plug both ports and clean
the outside of the cylinder. 2. Coat new O--rings, Uni--ring, rod seal, back--up ring,
and dust seal with clean hydraulic oil.
IMPORTANT: Prevent damage when clamping the
cylinder’s barrel into a vise; clamp on the clevis A. Install Uni--ring and O--ring to the piston.
only. Do not close vise enough to distort the barrel.
B. Install dust seal, O--ring, back--up ring, and dust
2. Mount lift cylinder into a vice. Remove collar with a seal to the head.
spanner wrench.
IMPORTANT: Do not clamp vise jaws against the
3. Extract shaft with head and piston by carefully twist- shaft surface. Protect shaft surface before mount-
ing and pulling on the shaft. ing in a vice.
IMPORTANT: Do not clamp vise jaws against the 3. Mount shaft securely in a vise by clamping on the cle-
shaft surface. Protect shaft surface before mount- vis of the shaft.
ing in a vice.
A. Coat shaft with clean hydraulic oil.
4. Mount shaft securely in a vise by clamping on the cle-
vis of the shaft. Remove lock nut and piston from the B. If removed, install collar onto shaft.
shaft. Slide head off the shaft.
C. Slide head and piston onto the shaft. Secure pis-
Hydraulic
System
5. Remove Uni--ring and O--ring from the piston. Re- ton to shaft with locknut.
move O--ring, back--up ring, rod seal, and dust seal from
4. Lubricate head and piston with hydraulic oil. Slide
the head.
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.

Steering Cylinder
6 9
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. Steering cylinder 6. Grease fitting 11. Ball joint spacer
2. Ball joint 7. 90o hydraulic fitting 12. Axle washer
3. Ball joint 8. O--ring 13. Hex slotted nut
4. Retaining ring 9. O--ring 14. Cotter pin
5. Grease fitting 10. Ball joint spacer 15. Drive axle assembly

1. Park machine on a level surface, lower cutting units, 1. Place a washer onto each ball joint. Slide ram end
stop engine, engage parking brake, and remove key ball joint through hole on steering arm. Secure with axle
from the ignition switch. washer and hex slotted nut. Slide fixed end of cylinder
through hole on axle. Install spacer onto ball joint and
2. Read the General Precautions for Removing and secure with hex slotted nut. Torque slotted nuts from 100
Installing Hydraulic System Components at the begin- to 125 ft--lbs (135 to 169 N--m) prior to inserting cotter
ning of the Service and Repairs section of this chapter. pins.
NOTE: To ease reassembly, tag the hydraulic hoses to 2. Install hydraulic hoses to steering cylinder.
show their correct position on the steering cylinder. Also,
clean hydraulic fittings and hose ends prior to discon- 3. Fill reservoir with hydraulic fluid as required (see
necting the hoses. Traction Unit Operator’s Manual).
3. Remove hydraulic hoses from steering cylinder. 4. After assembly is completed, operate steering cylin-
der to verify that hydraulic hoses and fittings are not con-
4. Remove cotter pins, hex slotted nuts, axle washer, tacted by anything.
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.
Hydraulic
System

Steering Cylinder Service
11
4
10
8
7
5 2
Figure 99
1. Butt and tube assembly 5. Lock nut 9. O--ring
2. Shaft 6. O--ring 10. U--cup
3. Piston rod assembly 7. PTFE seal 11. Wiper
4. Gland 8. O--ring
Hydraulic System (Rev. A) Page 4 -- 116 Rev. C Groundsmaster 4500--D/4700--D

IMPORTANT: To prevent damage when clamping 1. Use a complete repair kit when rebuilding the cylin-
cylinder barrel or rod in a vise, clamp only on pivotal der. Put a coating of clean hydraulic oil on all new seals,
ends. and O--rings.
1. Pump oil out of cylinder into a drain pan by SLOWLY 2. Install new O--rings and PTFE seal to the piston rod
moving rod and piston in and out of cylinder bore. Plug and new O--ring, U--cup, and wiper to gland.
ports and clean outside of cylinder.
3. Lubricate shaft with clean hydraulic oil. Slide gland
2. Mount cylinder in a vise so piston rod end of cylinder and piston onto shaft. Install and tighten lock nut.
is tilted up slightly. Do not close vise so firmly that cylin-
der tube could become distorted. Loosen gland with 4. Put a coating of clean hydraulic oil on all cylinder
spanner wrench. parts to ease assembly.
3. Grasp end of piston rod and use a twisting and pull- 5. Slide piston rod assembly into cylinder tube.
ing motion to carefully extract piston, piston rod, and
gland from cylinder tube. 6. Install and tighten gland with spanner wrench.
IMPORTANT: Do not clamp vise jaws against

smooth piston rod surface; the piston rod will be-
come damaged.
Hydraulic
System
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 com-

pressed 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 dam-

age (deep scratches, out--of--round, etc.). Replace en-
tire 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
2
3
4 1
5
6
19
80 to 87 ft--lb
(108 to 118 N--m)
9
8 16
12 7
18
RIGHT 10
11
FRONT 11
13
17
14
15
30 to 60 in--lb
(3.4 to 6.8 N--m)
Figure 100
1. Hydraulic reservoir cap 8. O--ring 14. Flat washer (3 used)
2. O--ring 9. O--ring 15. Flange head screw (3 used)
3. Dipstick 10. Hydraulic tee fitting 16. Tank strainer
4. Air breather 11. O--ring 17. Clamp
5. Breather adapter 12. O--ring 18. O--ring
6. Hydraulic tank 13. Tank mount grommet (3 used) 19. Filter screen
7. Hydraulic fitting
Removal Inspection
1. Park machine on a level surface, lower cutting units, 1. Clean hydraulic reservoir and suction strainer with
stop engine, engage parking brake, and remove key solvent.
2. Inspect for leaks, cracks, or other damage.
Installing Hydraulic System Components at the begin- Installation
1. Install reservoir using Figure 100 as a guide. Torque
3. Drain reservoir into a suitable container (see Trac- mounting cap screws (15) from 30 to 60 in--lb (3.4 to 6.8
tion Unit Operator’s Manual). N--m).
4. Disconnect hydraulic hoses from reservoir. 2. Using a wrench, tighten strainer into port to a torque
from 80 to 87 ft--lb (108 to 118 N--m).
5. Remove hydraulic reservoir using Figure 100 as a
guide. 3. Reconnect hydraulic hoses.

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
stop engine, engage parking brake, and remove key Figure 101
from the ignition switch. 1. Oil cooler latch 3. Hose from oil cooler
2. Hose to oil cooler
1
3. Remove oil cooler using Figures 101, 102, and 103
Hydraulic
System
as guides.
Inspection
1. Back flush oil cooler with cleaning solvent. After cool-

er is clean, make sure all solvent is drained from the
cooler. 2
CAUTION Figure 102

1. Oil cooler latch 2. Oil cooler
Use eye protection such as goggles when using

compressed air. 2
3 3
1
2. Dry inside of oil cooler using compressed air in the
opposite direction of the oil flow.
10
3. Plug both ends of oil cooler. Clean exterior of cooler. 9
Make sure fins are clear of dirt and debris.
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
7
2. Fill reservoir with hydraulic fluid as required (see 6
Traction Unit Operator’s Manual). RIGHT 5
4
FRONT
Figure 103
1. Oil cooler 6. Clamp
2. Washer 7. Flat washer
3. Flange head screw 8. Cap screw
4. Flange nut 9. Wire form latch
5. Mount plate 10. Cap screw


Chapter 5
Electrical System
Table of Contents
ELECTRICAL SCHEMATICS AND ELECTRICAL Hour Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
HARNESS AND CONNECTORS DRAWINGS . . . 2 Glow Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Start, Neutral, Seat, Cutting Deck, Parking Brake,
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . 3 and High Temperature Relays . . . . . . . . . . . . . . 16
Starting Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Hydraulic Valve Solenoids . . . . . . . . . . . . . . . . . . . 17
General Run & Transport Problems . . . . . . . . . . . . 4 Engine Run Solenoid . . . . . . . . . . . . . . . . . . . . . . . 18
Cutting Unit Operating Problems . . . . . . . . . . . . . . 5 Fuel Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
ELECTRICAL SYSTEM QUICK CHECKS . . . . . . . . 6 Glow Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Battery Test (Open Circuit) . . . . . . . . . . . . . . . . . . . 6 Temperature Sender . . . . . . . . . . . . . . . . . . . . . . . . 21
Check Operation of Interlock Switches . . . . . . . . . 6 Temperature Gauge . . . . . . . . . . . . . . . . . . . . . . . . 22
COMPONENT TESTING . . . . . . . . . . . . . . . . . . . . . . . 7 High Temperature Shutdown Switch . . . . . . . . . . 23
Ignition Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Traction Neutral Switch . . . . . . . . . . . . . . . . . . . . . 24
Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Diode Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Indicator Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Diode Circuit Board . . . . . . . . . . . . . . . . . . . . . . . . . 25
PTO and Hi--Lo Speed Control Switches . . . . . . 10 Standard Control Module . . . . . . . . . . . . . . . . . . . . 26
Seat Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 SERVICE AND REPAIRS . . . . . . . . . . . . . . . . . . . . . 27
Parking Brake Switch . . . . . . . . . . . . . . . . . . . . . . . 11 Battery Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Cutting Deck Position Switch . . . . . . . . . . . . . . . . 12 Battery Care . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Electrical
System
Cutting Deck Lift/Lower Switch . . . . . . . . . . . . . . . 13 Battery Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Ramp--up Module . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Groundsmaster 4500--D/4700--D Page 5 -- 1 Electrical System (Rev. A)

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 cir-
cuits 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 me-
ter in the voltage mode will make sure that excess cur-
rent 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 wa-
terproof 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
CAUTION components used on this machine (see Chapter 9 --
Electrical Diagrams).
Remove all jewelry, especially rings and
watches, before doing any electrical trouble- If the machine has any interlock switches by--passed,
shooting or testing. Disconnect the battery reconnect the switches for proper troubleshooting and
cables unless the test requires battery voltage. safety.
Starting Problems
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.
Starter solenoid clicks, but starter will not crank. Low battery charge.
NOTE: If the solenoid clicks, the problem is not in the in- Loose or corroded battery cables.
terlock circuit.
Electrical
System
Loose or corroded ground.
Faulty wiring at the starter.
Faulty starter solenoid.
Faulty starter.
Nothing happens when start attempt is made. Control The traction pedal is not in neutral position or the
panel lights and gauges operate with the ignition neutral switch or circuit wiring is faulty.
switch in ON.
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 The engine run solenoid is out of adjustment or circuit
released from the START position. wiring is faulty.
High temperature shutdown switch or circuit wiring is

faulty.

Starting Problems (continued)
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 The traction neutral switch is out of adjustment.
is depressed.
The traction neutral switch or circuit wiring is faulty.
General Run and Transport Problems
Engine continues to run, but should not, when the The engine fuel stop solenoid is stuck open.
ignition switch is turned off.
Ignition switch or circuit wiring is faulty.
Engine continues to run, but should not, when the The seat switch or circuit wiring is faulty.
traction pedal is engaged with no operator in the seat.
Traction neutral switch or circuit wiring is faulty.
The engine stops during operation, but is able to The operator is lifting off the seat.
restart.
The seat switch or circuit wiring is faulty.
The engine shutdown delay 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 The cutting deck position switch or circuit wiring is
shut off with PTO switch. 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 The PTO switch or circuit wiring is faulty.
PTO switch in the OFF (disengage) position.
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

The PTO relay or circuit wiring to the affected decks is

faulty.
The Ramp--up module or circuit wiring is faulty.
Hydraulic valve solenoid(s) or circuit wiring to the
Electrical
System

section of Chapter 4 -- Hydraulic System).
All cutting decks do not operate. The cutting decks are raised.
Fuse 2 (PTO) is faulty.
The PTO switch or circuit wiring is faulty.
The 2WD/4WD switch or circuit wiring is faulty.

section of Chapter 4 -- Hydraulic System).
Cutting deck(s) operation is intermittent over rough The cutting deck lift/lower switch or circuit wiring for the
terrain. affected decks is faulty.
Diode D1--C on Diode Circuit Board is faulty.

Electrical System Quick Checks
Battery Test (Open Circuit Test)

Use a multimeter to measure the voltage between the Voltage Measured Battery Charge Level
battery terminals.
12.68 V (or higher) Fully charged (100%)
Set multimeter to the DC volts setting. The battery 12.45 V 75% charged
should be at a temperature of 60 to 100oF (16 to 38oC).
12.24 V 50% charged
The ignition key should be off and all accessories turned
off. Connect the positive (+) meter lead to the positive 12.06 V 25% charged
battery post and the negative (--) meter lead to the nega- 11.89 V 0% charged
tive battery post.
NOTE: This test provides a relative condition of the bat-

tery. Load testing of the battery will provide additional
and more accurate information.
Check Operation of Interlock Switches

Interlock switch operation is described in the Traction
Unit Operator’s Manual. Testing of interlock switches
CAUTION and relays is included in the Component Testing section
of this Chapter.
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 op-
erating the machine.
Electrical System (Rev. A) Page 5 -- 6 Rev. D Groundsmaster 4500--D/4700--D

Component Testing
For accurate resistance and/or continuity checks, elec-
trically disconnect the component being tested from the
circuit (e.g. unplug the ignition switch connector before CAUTION
doing a continuity check).
When testing electrical components for continu-
NOTE: For engine component testing information, see ity with a multimeter (ohms setting), make sure
the Kubota Workshop Manual, Diesel Engine, V2003--T that power to the circuit has been disconnected.
Series at the end of Chapter 3 -- Kubota Diesel Engine.
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 A
continuity exists between the various terminals for each B
position. Verify continuity between switch terminals.
Y
POSITION CIRCUIT S
X
OFF NONE
ON / PREHEAT B + I + A, X + Y I
START B+I+S
Electrical
System
2
1
4
3
Figure 3
1. Key 3. Lock washer
2. Hex nut 4. Ignition switch
OFF
45 °
ON / PREHEAT
45 °
START
Figure 4

Fuses
The fuse block is located under the operator’s control
panel. Machines with serial numbers below 220999999 1
have four (4) fuses (Fig. 5). Machines with serial num-
bers above 230000000 have six (6) fuses (Fig. 6).
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
2
connected to it.
Fuse 1 (15 Amp)
A. Supplies power to ignition switch terminal B.
Fuse 2 (10 Amp) Figure 5

1. Control panel 2. Fuse block
A. Supplies power to the PTO circuit.
Fuse 3 (10 Amp)

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 Figure 6

above 230000000) 1. Control panel 2. Fuse block
A. Supplies power from ignition switch terminal S.
Testing 5 6
Remove fuses from the fuse block for testing. Fuse
should have continuity between fuse terminals.
2A
10A
15A
10A
10A
10A
1 2 3 4
Figure 7

Indicator Lights
Testing Indicator Lights
3 2
1. Apply 12 VDC to terminals 1A and 2A.
2. Ground terminals 1B and 2B. 4 1

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 indi-
cating correct operation of the electrical wiring to the oil
pressure switch.
High Temperature Shutdown Light

Figure 8
If the engine coolant temperature rises to 230oF 1. Charge indicator 3. High temp shutdown
2. Engine oil pressure 4. Glow plug indicator
(110oC), the high temperature light should come on as
the high temperature shutdown switch stops the engine.
Electrical
System
To test the high temperature shutdown light and circuit 5
wiring, start the engine and ground the blue/white wire
attached to high temperature shutdown switch on fly- 3 2
wheel end of engine (see High Temperature Shutdown
Switch in this Chapter). Warning light should illuminate
and engine should stop running.
Glow Plug Indicator Light 4 1

The glow plug light should come on when the ignition 6
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.
1B 1A (+)
Charge Indicator Light
The charge indicator light should come on when the igni-

tion switch is in ON with the engine not running, or with 2B 2A (+)
an improperly operating charging circuit while the en-
gine is running.
Figure 9
1. Charge indicator 4. Glow plug indicator
2. Engine oil pressure 5. Warning light front
3. High temp shutdown 6. Warning light back

PTO and Hi--Lo Speed Control Switches
The PTO and Hi--Lo Speed Control Switches are lo-
cated on the control console (Fig. 10). These rocker
switches have common switching logic.
The switch terminals are marked as shown in Figure 11.

1
The circuitry of these switches is shown in the chart be-
low. 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 termi-
nals.
2
SWITCH NORMAL OTHER

POSITION CIRCUITS CIRCUITS
ON 2+3 5+6
Figure 10
OFF 1+2 4+5 1. PTO switch 2. Hi--Lo speed switch
4 5 6
1 2 3
BACK OF SWITCH
Figure 11

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 electri- 1
cal connector are located directly under the seat. Test-
ing of the switch can be done without seat removal by
disconnecting the seat wire from the machine wiring 2
harness.
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

Figure 12
multimeter (ohms setting) across the connector termi-
1. Electrical connector 2. Seat switch
nals.
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.
6. Replace switch as needed. Reconnect switch con-

nector.
Electrical
System
Parking Brake Switch
The switch used for the parking brake is a normally open
proximity switch. The parking brake switch is located un-
der the steering tower cover (Fig. 13) and closes when 3
the parking brake is released. The sensing plate for the
2
switch is an integral component of the parking brake rod.
Switch Testing 1
1. Make sure the engine is off. Locate switch for testing.
2. Disconnect electrical connector from the switch.

multimeter (ohms setting) across the connector termi-
nals. Figure 13
4. With the parking brake released, there should be 1. Parking brake switch 3. Brake rod (brake ON)
2. Sensing plate
continuity across the switch terminals.
5. Apply the parking brake. There should be no continu-

ity 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 be-

tween switch and sensing plate on the brake rod when
the parking brake is released.

Cutting Deck Position Switch
The cutting deck position switch is a normally open prox-
imity switch that is located on the traction unit frame (Fig. 3
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 1
switches on the GM 4700--D: for decks 4, 5, 6, and 7. 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
Figure 14
1. Park machine on a level surface, lower cutting units, 1. Position switch 3. Lift arm (#5 shown)
stop engine, engage parking brake, and remove key 2. Switch connector
2. Disconnect deck position switch that requires testing

from machine wiring harness. #4 Deck #1 Deck #5 Deck

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.
#2 #3 #7 Deck
#6 Deck
5. Raise the cutting unit. There should be no continuity (GM4700)
Deck Deck (GM4700)
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 be- CUTTING DECK LOCATIONS
tween switch and sensing plate on the lift arm.
Figure 15

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 1
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 3
position switch. The cutting deck lift/lower switch is de-
signed to keep the PTO relay energized in this situation
to maintain cutting deck operation.
Figure 16
1. Lift/lower switch location (GM4700 shown)
Switch Testing and Adjustment 2. Switch connector
3. Switch plate screw
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 wir-
5
Electrical
ing harness.
System
4. Check the continuity of the switch by connecting a 4
multimeter (ohms setting) across the switch connector
3
terminals.
2
5. With the lift lever in the neutral position there should 1
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 Figure 17
applies any pressure to the spool in the lift/lower control 1. Lever support 4. Lift/lower switch
valve. 2. Switch plate 5. Thread forming screw
3. Switch plate 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
FROM PTO SWITCH SWITCH
(PTO SWITCH ON)
(IN CENTER POSITION)
FRONT PTO
(DECKS 2, 3, 5)
FRONT DECK FRONT DECK
POSITION POSITION
(DECK LOWERED) (DECK LOWERED)
FRONT PTO
(DECKS 1,4)
TO GROUND
Figure 18

Ramp--up Module
The ramp--up module is located under the console cover
(Fig. 19).
1 2
The ramp--up module is used to prevent hydraulic
spikes that could affect cutting system hydraulic compo-
nents. As the PTO relay for decks #1 to #5 is energized,
the ramp--up module provides a gradual, increasing cur-
rent 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.
The ramp--up module can be monitored by the three

LED’s located on the module below the harness connec-
tion.
1. All module LED’s will be off when the PTO switch is Figure 19
OFF. 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 im-
mediately. The “S1” and “S2” LED’s will gradually illumi-
nate 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).

Hour Meter
The meter is located on the control console next to the
operator seat.
1. Connect the positive (+) terminal of a 12 VDC source

Hobbs
QUARTZ
to the positive (+) terminal of the hour meter. 1
00001 10
2. Connect the negative (--) terminal of the voltage HOURS
source to the other terminal of the hour meter.
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
The glow relay is attached to the battery support brack-
et. When energized, the glow relay allows electrical cur-
rent to the engine glow plugs. 87
86 87
Two styles of glow relays have been used on the
Groundsmaster 4500--D/4700--D. On machines with se-
rial numbers below 260000600, two of the four relay
Electrical
System
connections are secured with screws (Fig. 21). On ma- 85 30 30
85 86
chines with serial numbers above 260000600, the relay
is attached to the wire harness with a four wire connector
(Fig. 22).
Figure 21
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 86 87 30
resistance of the meter and test leads. Subtract this val-
ue from from the measured value of the component you
are testing. 85 86
85 30 87
1. Verify coil resistance between terminals 86 and 85
with a multimeter (ohms setting).
A. On machines with serial numbers below Figure 22

260000600, resistance should be from 41 to 51
ohms.
B. On machines with serial numbers above

260000600, resistance should be approximately 72
ohms.
2. Connect multimeter (ohms setting) leads to relay ter-

minals 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)
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 3
several switches. These machines do not use a start,
neutral, seat, parking brake or high temperature relay. 2 4 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.

7
digital multi meter, short the meter test leads together. 8 9
0.5 ohms or less). This resistance is due to the internal Figure 23
resistance of the meter and test leads. Subtract this val- 1. Control panel 6. K2 relay: decks 1 -- 5
2. K8 relay: seat 7. K6 relay: high temp
ue from from the measured value of the component you 3. K9 relay: neutral (behind) 8. K5 relay: start
are testing. 4. K7 relay: parking brake 9. K1 relay: GM4700 deck 6
5. K3 relay: GM4700 deck 7
1. Verify coil resistance between terminals 85 and 86
with a multimeter (ohms setting):
A. For the Tyco Electronics relay (#VF4--65F11), re- 86 87A 87

87
sistance should be from 71 to 88 ohms.
87A
86 85
B. For the Hella Electronics relay (#66211), resist-
ance should be from 70 to 80 ohms.
30
85 30
minals 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 from terminal 85 and multimeter

lead from terminal 87.

minals 30 and 87A. Apply +12 VDC to terminal 85. The
relay should make and break continuity between termi-
nals 30 and 87A as +12 VDC is applied and removed
from terminal 85.
Figure 24
5. Disconnect voltage and multimeter leads from the
relay terminals.

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
2
has five solenoids: two on each cutting deck manifold
and one on the traction manifold. Testing of these sole-
noids can be done with the solenoid on the hydraulic 2
valve. 1
NOTE: Prior to taking small resistance readings with a 3
digital multimeter, short the meter test leads together. 1
0.5 ohms or less). This resistance is due to the internal Figure 25
resistance of the meter and test leads. Subtract this val- 1. Deck manifold (4500--D) 3. Solenoid connector
ue from from the measured value of the component you 2. Valve solenoid
are testing.
1. Make sure engine is off. Disconnect hydraulic valve 2

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.
3
4. Measure resistance between the two connector ter-
minals. The resistance for the solenoid coil should be
Electrical
System
about 7.2 ohms.
1
5. Install new solenoid if necessary.
Figure 26
1. Deck manifold (4700--D) 3. Solenoid connector
A. Apply “Loctite 242” or equivalent to threads on 2. Valve solenoid
end of valve stem before installing nut.
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 malfunc-
tion.
6. Reconnect electrical connector to the solenoid.

Engine Run Solenoid
The engine run solenoid must be energized for the en-
gine to run. The solenoid is mounted on the engine block
near the injection pump.
2
In Place Testing 1
3
digital multimeter, short the meter test leads together.
0.5 ohms or less). This resistance is due to the internal
resistance of the meter and test leads. Subtract this val-
ue from from the measured value of the component you
are testing.
1. Disconnect the connector from the engine run sole- Figure 27

noid. 1. Engine run solenoid 3. Injection pump
2. Solenoid connector
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 2
ohms.
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 4
10.9 ohms.
4. Connect solenoid to the wiring harness.

1
Live Testing
Figure 28
1. Disconnect connector from the engine run solenoid.
1. Engine run solenoid 3. White wire (pull coil)
2. Red wire (hold coil) 4. Black wire (common)
NOTE: The solenoid may be removed from the engine
or tested in place.
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 sole-

noid.

Fuel Pump
The fuel pump is attached to the frame near the fuel pre--
filter (Fig. 29). 1 2
IMPORTANT: When testing fuel pump, make sure
that pump is not operated without fuel. 3
Fuel Pump Capacity Test

stop engine, and engage parking brake.
2. Disconnect electrical connector from the engine run

solenoid to prevent the engine from firing.
3. Disconnect fuel pump discharge hose from the water Figure 29

separator. 1. Fuel pump 3. Pump discharge hose
2. Fuel pre--filter
4. Make sure fuel hoses attached to the fuel pump are
free of obstructions. Fuel Pump Specifications
5. Place disconnected pump discharge hose into a Pump Capacity 23.5 fl oz/min (695 ml/min)
large, graduated cylinder sufficient enough to collect 1
quart (0.95 liter). Pressure 3.3 psi (22.8 kPa)
Max. Current 0.9 amp
6. Collect fuel in the graduated cylinder by turning igni- Draw
tion switch ON. Allow pump to run for 30 seconds, then
release ignition switch to OFF.
Electrical
System
7. The amount of fuel collected in the graduated cylin-
der 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 so-

lenoid.
10.Bleed the fuel system (see Traction Unit Operator’s

Manual).

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.
3 6
Controller Operation
2 5
1. When the ignition switch is placed in the ON position,
1 4
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 posi-

tion, the glow plugs will energize and the glow lamp will 1
not light.
3. When the ignition switch is released from START to

ON, the glow plugs will deenergize and the glow lamp 3
will remain off.
Figure 30
Controller Checks 1. Glow controller end view 3. Controller side view
2. Controller top view
1. Make sure there is power from the battery.

5. If any of the conditions in step 3 are not met or power
2. Disconnect electrical connector to the run solenoid to terminal 1 exists and any of the other conditions in
to prevent the engine from starting. step 4 are not met:
3. Place ignition switch in the ON position. Verify the fol- A. Verify continuity of the circuitry from the battery to
lowing while in the ON position: the glow relay and glow plugs (see Chapter 9 -- Elec-
trical Schematics and Diagrams).
A. Glow indicator lamp is on.
B. Verify continuity of the circuitry from the battery to
B. Glow relay is energized. ignition switch, glow controller, glow lamp, glow
relay, and ground (see Chapter 9 -- Electrical Sche-
C. Glow plugs are energized. matics and Diagrams).
D. Glow indicator lamp goes out and glow plugs C. Replace parts as necessary.
deenergize after 10 seconds.
6. Connect electrical connector to the run solenoid.
4. Place ignition switch in the START position. Verify
the following while in the START position:
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 con-

troller, verify continuity of the circuitry from the ignition
switch to the controller and perform step 4 again (see
Chapter 9 -- Electrical Schematics and Diagrams).

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
Handle the hot oil with extreme care to prevent Figure 31

personal injury or fire. 1. Temperature sender 2. Alternator
NOTE: Prior to taking resistance readings with a digital

multi meter, short the meter test leads together. The me- VOA
ter will display a small resistance value (usually 0.5
ohms or less). This resistance is due to the internal re-
sistance of the meter and test leads. Subtract this value
from from the measured value of the component you are
Electrical
System
testing.
3. Check resistance of the sender with a multimeter

(ohms setting) as the temperature increases. 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 thor-

oughly. Apply thread sealant to the threads of the
sender.
B. Screw sender into the water flange. Torque send-

er 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 Opera-

tor’s Manual).

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 be-
fore connecting it to the electrical circuit to avoid
electrical shock and prevent damaging the 14 VDC + 0.01 VDC
gauge.
-- +
1. Connect temperature gauge to the variable resis-
tance 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 1
glass cover for the each test point. For each variable re- 2
sistance setting, the needle must be pointed between 4
the two white dots.
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).
B. Set variable resistance to 38 ohms. The needle 3

should point between the green and red area
(105oC).
Figure 34
3. Turn off the voltage source. Disconnect voltage 1. Middle position 3. Edge of glass cover
source, gauge, and variable resistance. 2. High temp position 4. Cold temp position
Temperature Gauge Check
The following procedure can be used to check the tem-

perature 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 tem- 2

perature sender. The gauge needle should move toward
the high temp position. Figure 35
1. Temperature sender 2. Alternator
4. Reconnect wire to temperature sender.

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 sys- 2
tem are encountered, the following procedure can be
used to determine if the problem is related to the switch
or the switch circuit:
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 1. High temperature shutdown switch
circuit is functioning correctly. If the engine continues 2. Glow plug connection
running with the grounded jumper wire, the switch circuit
needs repair.
Shutdown Switch Test VOA
CAUTION
Electrical
System
Make sure engine is cool before removing the
temperature switch.
Figure 37
1. Lower coolant level in the engine and remove the
temperature shutdown switch. 6. Install switch to the water flange.
2. Put switch in a container of oil with a thermometer A. Clean threads of cylinder head and switch thor-
and slowly heat the oil (Fig. 37). oughly. Apply thread sealant to the threads of the
switch.
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
7. Fill engine cooling system (see Traction Unit Opera-
personal injury or fire.
tor’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.

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 2 1

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. Figure 38
1. Piston (traction) pump 2. Neutral switch
See Piston Pump Control Assembly in Chapter 4 -- Hy-
draulic Systems for disassembly and reassembly proce-
dures 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 2
when relays and hydraulic valve solenoids are de--ener-
gized. The diodes plug into the wiring harness at various
locations (see Wire Harness Drawings in Chapter 9 --
Electrical Diagrams).
3
Diode Test
1
The diodes (Fig. 39) can be individually tested using a
digital multimeter (diode test or ohms setting) and the Figure 39
table to the right. 1. Diode 3. Female terminal
2. Male terminal
Multimeter Multimeter
Red Lead (+) Black Lead (--) Continuity
on Terminal on Terminal
Female Male YES
Male Female NO

Diode Circuit Board
The diode circuit board contains four diodes (Fig. 40)

and is located under the console housing. Diode D1--A H
provide logic for the interlock switches. Diodes D1--C, G
D1--B (GM 4700--D right deck), and D1--D (GM 4700--D D1--D
left deck) are used for circuit protection from voltage F

D1--A
spikes when PTO relays are de--energized. D1--C E
D1--B
Diode Circuit Board Test D
D1--D
D1--C
D1--A
D1--B
C
The diodes can be individually tested using a digital
multimeter (ohms setting) and the table to the right. If B
any of the diodes are damaged, the diode circuit board CIRCUIT BOARD A
must be replaced. DIODE DIAGRAM
Figure 40
Red Lead (+) Black Lead (--)

on on Continuity
Terminal Terminal
H A YES
A H NO
G B YES
B G NO
Electrical
System
F C YES
C F NO
E D YES
D E NO

Standard Control Module
Groundsmaster 4500--D and 4700--D machines with

Serial Numbers above 230000000 are equipped with a 1
Standard Control Module to monitor and control electri-
cal components required for safe operation. This Mod-
ule is located under the console cover.
Inputs from the neutral, parking brake, PTO, start (igni-

tion), 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 Figure 41
data. 1. Control panel
2. Standard control module
The Standard Control Module can be used to check op-
eration 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 occu- 1 6
pied and the ignition switch in the run position), testing
of the switch and circuit wiring would be required. 7
2 8
Refer to the Operator’s Manual for operation and trou-
bleshooting of the Standard Control Module. 3 9
4 10
5 11
Figure 42
1. Power input LED 6. Neutral input LED
2. Start input LED 7. Park brake off input LED
3. Engine run output LED 8. PTO switch input LED
4. Start output LED 9. In seat input LED
5. PTO output LED 10. High temp input LED
11. Backlap input (not used)

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: 4. Store battery in a cool atmosphere to avoid quick de-
terioration of the battery charge.
1. Remove the battery and charge it fully (see Battery
Service). 5. To help prevent the battery from freezing, make sure
it is fully charged (see Battery Service).
2. Either store battery on a shelf or on the machine.
3. Leave cables disconnected if the battery is stored on

the machine.
Battery Care
1. Battery electrolyte level must be properly main- 3. Battery cables must be tight on terminals to provide
tained. The top of the battery must be kept clean. lf the good electrical contact.
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 temper-
atures are cool.
WARNING
Connecting cables to the wrong post could re-
sult in personal injury and/or damage to the
WARNING
Electrical
System
electrical system.
Wear safety goggles and rubber gloves when

4. If corrosion occurs at terminals, disconnect cables.
working with electrolyte. Charge battery in a
Always disconnect negative (--) cable first. Clean
well ventilated place so gasses produced
clamps and terminals separately. Reconnect cables
while charging can dissipate. Since the gases
with positive (+) cable first. Coat battery posts and cable
are explosive, keep open flames and electrical
connectors with skin--over grease (Toro Part No.
sparks away from the battery; do not smoke.
505-165) or petroleum jelly to prevent corrosion.
Nausea may result if the gases are inhaled. Un-
plug charger from electrical outlet before con- 5. Check electrolyte level every 25 operating hours,
necting or disconnecting charger leads to or and every 30 days if machine is in storage.
from battery posts.
6. Maintain cell level with distilled or demineralized wa-
IMPORTANT: Do not remove fill caps while clean- ter. Do not fill cells above the fill line.
ing.
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 solu-

tion 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 petro-
leum jelly to prevent corrosion.

Battery Service
The battery is the heart of the electrical system. With
regular and proper service, battery life can be extended. 3
Additionally, battery and electrical component failure
can be prevented.
CAUTION
When working with batteries, use extreme cau-

tion to avoid splashing or spilling electrolyte.
Electrolyte can destroy clothing and burn skin or 2
eyes. Always wear safety goggles and a face 1
shield when working with batteries.
Electrolyte Specific Gravity

Fully charged: 1.265 corrected to 80oF (26.7oC)
Figure 43
Discharged: less than 1.240 1. Negative cable 3. Battery strap
2. Positive cable
Battery Specifications
BCI Group Size 24 D. Check that the cover seal is not broken away. Re-
650 CCA at 0o F (--17.8o C)
Reserve Capacity of 105 minutes at 80oF (26.7oC) place the battery if the seal is broken or leaking.
Dimensions (including terminal posts and caps) E. Check the electrolyte level in each cell. If the level
Length 11 inches (27.9 cm) is below the tops of the plates in any cell, fill all cells
Width 6.76 inches (17.2 cm)
Height 9.2 inches (23.4 cm) with distilled water between the minimum and max-
imum fill lines. Charge at 15 to 25 amps for 15 min-
Removal and Installation (Fig. 43) utes to allow sufficient mixing of the electrolyte.
See Traction Unit Operator’s Manual for battery removal 2. Conduct a hydrometer test of the battery electrolyte.
and installation information.
IMPORTANT: Make sure the area around the cells is
NOTE: Before connecting the negative (ground) cable, clean before opening the battery caps.
connect a digital multimeter (set to amps) between the
negative battery post and the negative (ground) cable A. Measure the specific gravity of each cell with a
connector. The reading should be 0 amps. If the reading hydrometer. Draw electrolyte in and out of the
is 0.1 amp or more, this indicates a parasitic draw and hydrometer barrel prior to taking a reading to warm--
the unit’s electrical system should be tested and re- up the hydrometer. At the same time take the tem-
paired. perature of the cell.
Inspection, Maintenance, and Testing B. Temperature correct each cell reading. For each
10oF (5.5oC) above 80oF (26.7oC) add 0.004 to the
1. Perform following inspections and maintenance: specific gravity reading. For each 10oF (5.5oC) be-
low 80oF (26.7oC) subtract 0.004 from the specific
A. Replace battery if case is cracked or leaking. gravity reading.
B. Check battery terminal posts for corrosion. Use Example: Cell Temperature 100oF
wire brush to clean corrosion from posts. Cell Gravity 1.245
100oF minus 80oF equals 20oF
IMPORTANT: Before cleaning the battery, tape or (37.7oC minus 26.7oC equals 11.0oC)
block vent holes to the filler caps and make sure the 20oF multiply by 0.004/10oF equals 0.008
caps are on tightly. (11oC multiply by 0.004/5.5oC equals 0.008)
ADD (conversion above) 0.008
C. Check for signs of wetness or leakage on the top Correction to 80oF (26.7oC) 1.253
of the battery which might indicate a loose or missing
filler cap, overcharging, loose terminal post, or over-
filling. 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.
C. If the difference between the highest and lowest H. Using the table below, determine the minimum
cell specific gravity is 0.050 or greater or the lowest voltage for the cell temperature reading:
cell specific gravity is less than 1.225, charge the bat-
tery. Charge at the recommended rate and time giv-
Minimum Battery Electrolyte
en in Charging or until all cells specific gravity is
Voltage Temperature
1.225 or greater with the difference in specific gravity
between the highest and lowest cell less than 0.050. 9.6 70oF (and up) 21.1oC (and up)
If these charging conditions can not be met, replace 9.5 60oF 15.6oC
the battery.
9.4 50oF 10.0oC
3. Perform a high--discharge test with an adjustable 9.3 40oF 4.4oC
load tester.
9.1 30oF --1.1oC
This is one of the most reliable means of testing a battery 8.9 20oF --6.7oC
as it simulates the cold--cranking test. A commercial bat- 8.7 10oF --12.2oC
tery load tester is required to perform this test.
8.5 0 oF --17.8oC
CAUTION I. If the test voltage is below the minimum, replace

the battery. If the test voltage is at or above the mini-
mum, return the battery to service.
Follow the manufacturer’s instructions when us-
ing a battery tester. Charging
A. Check the voltage across the battery terminals To minimize possible damage to the battery and allow
prior to testing the battery. If the voltage is less than the battery to be fully charged, the slow charging meth-
12.4 VDC, recharge the battery. od is presented here. This charging method can be ac-
complished with a constant current battery charger
B. If the battery has been charged, apply a 150 amp which is available in most shops.
Electrical
load for 15 seconds to remove the surface charge.
System
Use a battery load tester following the manufactur-
er’s instructions. CAUTION
C. Make sure battery terminals are free of corrosion.
Follow the manufacturer’s instructions when us-
D. Measure the temperature of the center cell. ing a battery charger.
E. Connect a battery load tester to the battery termi-

NOTE: Using specific gravity of the battery cells is the
nals following the manufacturer’s instructions.
most accurate method of determining battery condition.
Connect a digital multimeter to the battery terminals.
1. Determine the battery charge level from either its
F. Apply a test load of one half the Cranking Perfor-
specific gravity or open circuit voltage.
mance (see Battery Specifications) rating of the bat-
tery for 15 seconds.
Battery Charge Specific Open Circuit
G. Take a voltage reading at 15 seconds, then re- Level Gravity Voltage
move the load.
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

2. Determine the charging time and rate using the 3. Following the manufacturer’s instructions, con-
manufacturer’s battery charger instructions or the nect the charger cables to the battery. Make sure a good
following table. connection is made.
4. Charge the battery following the manufacturer’s

Battery Battery Charge Level instructions.
Reserve (Percent of Fully Charged)
Capacity 5. Occasionally check the temperature of the battery
(Minutes) 75% 50% 25% 0%
electrolyte. If the temperature exceeds 125oF (51.6oC)
80 or less 3.8 hrs 7.5 hrs 11.3 hrs 15 hrs or the electrolyte is violently gassing or spewing, the
@ @ @ @ charging rate must be lowered or temporarily stopped.
3 amps 3 amps 3 amps 3 amps
6. Three hours prior to the end of the charging, mea-
81 to 125 5.3 hrs 10.5 hrs 15.8 hrs 21 hrs
@ @ @ @ sure the specific gravity of a battery cell once per hour.
4 amps 4 amps 4 amps 4 amps The battery is fully charged when the cells are gassing
freely at a low charging rate and there is less than a
126 to 5.5 hrs 11 hrs 16.5 hrs 22 hrs 0.003 change in specific gravity for three consecutive
170 @ @ @ @
readings.
171 to 5.8 hrs 11.5 hrs 17.3 hrs 23 hrs
250 @ @ @ @
above 6 hrs 12 hrs 18 hrs 24 hrs
250 @ @ @ @
CAUTION
Do not charge a frozen battery because it can ex-

plode 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 elec-
trical spark away from the battery. Do not smoke.
Nausea may result if the gases are inhaled. Un-
plug the charger from the electrical outlet before
connecting or disconnecting the charger leads
from the battery posts.

Chapter 6
Axles, Planetaries, and Brakes

Table of Contents
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Rear Axle Assembly . . . . . . . . . . . . . . . . . . . . . . . . 12
ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Bevel Gear Case and Axle Case . . . . . . . . . . . . . 14
SERVICE AND REPAIRS . . . . . . . . . . . . . . . . . . . . . . 4 Differential Shafts . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Brake Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Axle Shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Brake Inspection and Repair . . . . . . . . . . . . . . . . . . 6 Input Shaft/Pinion Gear . . . . . . . . . . . . . . . . . . . . . 20
Planetary Wheel Drive Assembly . . . . . . . . . . . . . . 8 Differential Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Planetary Wheel Drive Service . . . . . . . . . . . . . . . 10 Pinion Gear to Ring Gear Engagement . . . . . . . . 25
Axles, Planetaries,
and Brakes
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 75 to 85 ft--lb (101 to 115 N--m)
mounting screw torque
Rear wheel toe--in .125 in (3.2 mm)
Tire pressure (front and rear) 20 psi (1.4 bar)
Planetary gear drive lubricant SAE 85W--140 wt. gear lube

Planetary gear lube capacity (each wheel) 16 fl oz (.47 l)
Rear axle lubricant SAE 85W--140 wt. gear lube

Rear axle gear lube capacity 80 fl oz (2.37 l)
Axles, Planetaries, and Brakes (Rev. B) Page 6 -- 2 Groundsmaster 4500--D/4700--D

Adjustments
See Traction Unit Operator’s Manual for adjustment
procedures for Groundsmaster 4500--D and Ground-
smaster 4700--D axles, planetaries, and brakes.
Axles, Planetaries,
and Brakes

Service and Repairs
Brake Assembly
1
2
18 3
6
17
17
19
7
8
9
15 16
14
13
12
RIGHT 11 5
10
FRONT 75 to 85 ft--lb
(101 to 115 N--m)
4
85 to 100 ft--lb
(115 to 135 N--m)
Figure 1
1. Flange head screw 8. Compression spring 14. Flat washer
2. Splined brake shaft 9. Jam nut 15. Cap screw
3. Planetary assembly 10. LH Brake assembly 16. O--ring
4. Tire and wheel assembly 11. Flange head screw 17. O--ring
5. Lug nut 12. Hex plug 18. RH brake assembly
6. Retaining ring 13. Piston motor 19. Brake cable
7. Spring plate

Remove Brake Assembly (Fig. 1) 3. Install flange head screws (11) to secure brake as-
sembly to frame. Tighten screws in a crossing pattern to
1. Park machine on a level surface and raise cutting a torque from 75 to 85 ft--lb (101 to 115 N--m).
units to allow easier access to front brake assembly.
Stop engine, engage parking brake, and remove key 4. Install brake cable to pull rod on brake assembly.
from the ignition switch. Brake cable end should be completely threaded onto
pull rod.
2. Drain oil from planetary wheel drive/brake assembly
(see Traction Unit Operator’s Manual). 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).
CAUTION
When changing attachments, tires, or perform- WARNING
ing other service, use correct blocks, hoists,
and jacks. Make sure machine is parked on a Failure to maintain proper torque could result
solid, level surface such as a concrete floor. in failure or loss of wheel and may result in
Prior to raising machine, remove any attach- personal injury.
ments that may interfere with the safe and
proper raising of the machine. Always chock or 6. Install wheel assembly. Torque lug nuts from 85 to
block wheels. Use jack stands or solid wood 100 ft--lb (115 to 135 N--m).
blocks to support the raised machine. If the ma-
chine is not properly supported by blocks or 7. Lower machine to ground.
jack stands, the machine may move or fall,
which may result in personal injury. 8. Make sure drain plug is installed in bottom of brake
assembly (Fig. 3). Fill planetary wheel drive/brake as-
3. Chock rear wheels and jack up front of machine (see sembly with SAE 85W--140 gear lube (see Traction Unit
Jacking Instructions in Chapter 1 -- Safety). Support ma- Operator’s Manual).
chine with jack stands or solid wood blocks.
9. Check and adjust brake cables for proper brake op-
4. Remove wheel assembly. eration (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).
Axles, Planetaries,
3 2
and Brakes
6. Disconnect brake cable from pull rod on brake.
NOTE: Be careful not to drop splined brake shaft as 1

brake assembly is removed.
Figure 2
7. Support brake assembly and remove flange head 1. Splined brake shaft step 3. Planetary assembly end
2. Hydraulic motor end
capscrews (11) securing brake assembly to frame. Re-
move brake assembly.
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

2
must be aligned toward the hydraulic wheel motor (Fig.
2).
1. Install splined brake shaft into brake assembly. 3
2. Install brake assembly onto frame, aligning splined Figure 3

brake shaft with input shaft on planetary wheel drive. 1. Brake housing 3. Drain plug
2. Check plug

Brake Inspection and Repair
3
2
4
5
6
7
8
9
15
10
14
13
12
11
Figure 4
1. Brake housing (LH shown) 6. Hitch pin 11. Rotating actuator
2. Seal 7. Stationary disc 12. Extension spring
3. Pull rod 8. Rotating disc 13. Ball
4. Clevis pin 9. Retaining ring 14. Plug
5. Link 10. Gasket 15. O--ring
Brake Inspection and Repair (Fig. 4) 6. Remove seal (2) from brake housing.
1. Scrape gasket material (10) from brake housing and 7. Wash parts in cleaning solvent. Inspect components
planetary wheel drive mounting surfaces. 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).
9. Use a new gasket (10) when installing brake assem-
4. Remove extension springs (12). bly to machine.
5. Remove actuator assembly (3, 4, 5, 6, and 11) and

balls (13).

Axles, Planetaries,
and Brakes

Planetary Wheel Drive Assembly
75 to 85 ft--lb
(101 to 115 N--m)
1
2
18 3
6
17
17
7
8
9
15 16
14
13
12
RIGHT 11 5
10
FRONT 75 to 85 ft--lb
(101 to 115 N--m)
4
85 to 100 ft--lb
(115 to 135 N--m)
Figure 5
1. Flange head screw 7. Spring plate 13. Piston motor
2. Splined brake shaft 8. Compression spring 14. Flat washer
3. Planetary assembly 9. Jam nut 15. Cap screw
4. Tire and wheel assembly 10. LH Brake assembly 16. O--ring
5. Lug nut 11. Flange head screw 17. O--ring
6. Retaining ring 12. Hex plug 18. RH brake assembly
Planetary Wheel Drive Removal

CAUTION
stop engine, engage parking brake, and remove key When changing attachments, tires, or perform-
from the ignition switch. ing other service, use correct blocks, hoists,
and jacks. Make sure machine is parked on a
2. Drain oil from planetary wheel drive/brake assembly
solid, level surface such as a concrete floor.
(see Traction Unit Operator’s Manual).
Prior to raising machine, remove any attach-
ments 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 ma-
chine 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 ma-
chine with jack stands or solid wood blocks.
1
4. Remove front wheel assembly.
5. Remove flange head screws that secure brake as-

sembly to planetary assembly (see Brake Assembly).
2
6. Support planetary assembly to prevent it from falling.
Loosen and remove flange head screws that secure 3
planetary assembly to frame. Remove planetary as-
sembly from machine.
Planetary Wheel Drive Installation Figure 6

1. Brake housing 3. Drain plug
1. Position planetary assembly to machine. Install 2. Check plug
flange head screws that secure planetary assembly.
Torque screws from 75 to 85 ft--lb (101 to 115 N--m).
2. Install brake assembly to planetary (see Brake As-

sembly).
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).
4. Lower machine from jack stands.
Axles, Planetaries,
5. Make sure drain plug is installed in bottom of brake
and Brakes
assembly (Fig. 6). Fill planetary wheel drive/brake as-
sembly 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 op-

eration (see Traction Unit Operator’s Manual).

Planetary Wheel Drive Service
3 118 to 144 in--lb

4 (13.3 to 16.3 N--m)
7
8
9
11
12
1
13
2 14
15
5 16
6
10
28
20
27 19
26 18
17
25
24
23
22
21
29
Figure 7
1. Spindle 11. Bearing cup 21. Thrust plug
2. Boot seal 12. Bearing cone 22. Thrust washer
3. Oil seal 13. O--ring 23. Retaining ring
4. Bearing cone 14. Bearing shim 24. Primary gear
5. Bearing cup 15. Snap ring 25. Drive shaft
6. Wheel stud 16. Ring gear 26. Primary carrier
7. Socket head screw 17. Retaining ring 27. Secondary gear
8. Lock washer 18. Plug 28. Secondary carrier
9. Housing 19. End cap 29. O--ring
10. Dowel pin 20. O--ring
Planetary Wheel Drive Disassembly (Figure 7) 6. Remove socket head screws (7) and remove ring
gear (16).
1. Remove retaining ring (17).
7. Remove snap ring (15) and bearing shim (14).
2. Remove end cap (19) and o--ring (20).
8. Use a puller to remove spindle (1) from housing (9).
3. Remove thrust plug (21) and thrust washer (22). Remove bearing cone (12).
4. Remove retaining ring (23), primary gear (24), and 9. Remove and discard all seals.
drive shaft (25).
10.If bearings will be replaced, use a puller to remove
5. Remove primary carrier (26), secondary gear (27), bearing cone (4) from spindle. Remove bearing cups (5
and secondary carrier (28). and 11) from housing (9).
NOTE: Steps 6 -- 10 are necessary only if inspecting or

replacing bearings and/or seals.

Planetary Wheel Drive Assembly (Figure 7) 8. Install secondary carrier (28), secondary gear (27),
and primary carrier (26).
NOTE: Use new seal kit when assembling planetary
wheel drive. 9. Install drive shaft (25) and primary gear (24). Secure
gear with retaining ring (23).
1. Clean parts in solvent. Inspect parts for damage or
excessive wear and replace as necessary. 10.Install thrust washer (22) and thrust plug (21).
2. Install oil seal (3) to spindle (1). 11. Install o--ring (20) and end cap (19). Secure end cap
with retaining ring (17).
3. Press bearing cups (5 and 11) into housing (9).
12.Check operation of planetary wheel drive before
4. Press bearing cone (4) onto spindle (1). installing assembly on the machine. With a constant
turning force applied, rotation of the planetary should be
5. Install boot seal (2) to housing (9). Assemble hous- consistent. If there is more drag at certain points, gears
ing (9) to spindle (1). are not rolling freely and the planetary should be ex-
amined for improper assembly or damaged compo-
6. Press bearing cone (12) onto spindle and secure
nents.
with bearing shim (14) and snap ring (15).
7. Install o--ring (13), then secure ring gear (16) to

housing (9) with socket head screws (7) and lock wash-
ers (8). Torque screws from 118 to 144 in--lb (13.3 to
16.3 N--m).
Axles, Planetaries,
and Brakes

Rear Axle Assembly
7
6 70 ft--lb (94 N--m) maximum
1 8
4 5
3
2
9
10
11
13 12
14
15
16
24
22
23 17
21 85 to 100 ft--lb
RIGHT 20 (115 to 135 N--m)
19
FRONT
18
Figure 8
1. Steering cylinder 9. Cap screw 17. Tire and wheel assembly
2. Needle bearing 10. Flat washer 18. Lug nut
3. External snap ring 11. Piston motor 19. Hex plug
4. External snap ring 12. O--ring 20. O--ring
5. Thrust washer 13. Pinion gear 21. Drive axle assembly
6. Flat washer 14. Gear 22. Axle pivot pin
7. Lock nut 15. Cap screw 23. Stop pin
8. Grease fitting 16. Lock washer 24. Hydraulic fitting
Remove Rear Axle 3. Chock front wheels and jack up rear of machine (see
Jacking Instructions in Chapter 1 -- Safety). Support ma-
1. Park machine on a level surface, lower cutting units, chine with jack stands or solid wood blocks.
from the ignition switch. 4. Remove wheels from rear axle.
2. Drain oil from rear axle and axle gearbox (see Trac- 5. Remove hydraulic motor from axle assembly (see
tion Unit Operator’s Manual). Rear Axle Motor in Service and Repairs section of Chap-
ter 4 -- Hydraulic System).
CAUTION 6. Remove hydraulic hoses from steering cylinder.
When servicing rear axle, use correct blocks, 7. Remove hydraulic hose from hydraulic fitting on side
hoists, and jacks. Make sure machine is parked of input gear case.
on a solid, level surface such as a concrete
8. Remove lock nut and flat washer from pivot pin.
floor. Always chock or block wheels. Use jack
stands or solid wood blocks to support the 9. Support rear axle to prevent it from falling. Remove
raised machine. If the machine is not properly pivot pin. Lower rear axle from machine. Note location
supported by blocks or jack stands, the ma- of thrust washer on both ends of axle mounting boss.
chine may move or fall, which may result in per-
sonal injury.

10.If needed for further axle disassembly, remove steer- 9. Fill axle with SAE 85W--140 weight gear lube (see
ing cylinder from axle (see Steering Cylinder in Service Traction Unit Operator’s Manual).
and Repairs section of Chapter 4 -- Hydraulic System).
10.Check rear wheel toe--in and adjust if necessary (see
11. If required, remove tie rod ends from steering arms Traction Unit Operator’s Manual).
on rear axle (Fig. 9). Remove the cotter pins and castle
nuts from the tie rod ball joints. Use a ball joint fork and 11. Check steering stop bolt adjustment. When the
remove the tie rod ends from the axle steering arms. steering cylinder is fully extended (right turn), a gap of
1/16” (1.6 mm) should exist between bevel gear case
12.Clean the rear axle pivot pin and pivot bushings. In- casting and stop bolt on left axle case. Figure 10 shows
spect the pin and bushings for wear or damage. Replace stop bolt location.
components as necessary.
Install Rear Axle 4 3

2
1. If removed, install steering cylinder to axle assembly 5
(see Steering Cylinder in Service and Repairs section of 1
Chapter 4 -- Hydraulic System).
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, Figure 9
1. Tie rod 4. Castle nut
there should be from .002 to .020 inch (.05 to .51 mm) 2. Dust cover 5. Tie rod end
clearance between rear frame mount and axle mounting 3. Cotter pin 6. Steering arm (LH)
boss. Add thrust washers if needed to adjust clearance.
5. Install flat washer and lock nut onto pivot pin. Lock
nut should be tightened enough to allow pivot pin to ro-
tate (70 ft--lb (94 N--m) maximum).
Axles, Planetaries,
6. Install hydraulic motor to axle assembly (see Rear
1
and Brakes
Axle Motor in Service and Repairs section of Chapter 4
-- Hydraulic System).
7. Install hydraulic hoses to steering cylinder and input 2

gear case.
WARNING
Failure to maintain proper wheel lug nut
Figure 10
torque could result in failure or loss of wheel
and may result in personal injury. 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.

Bevel Gear Case and Axle Case
The following procedures assume the rear axle assem-
35 to 41 ft--lb
bly has been removed from the machine. (47 to 56 N--m)
Removal
1
6 5
1. Remove the mounting screws, nuts, and lock wash-
ers. Remove the bevel gear case/axle case assembly
and O-ring from the axle support (Fig. 11).
4
2
2. Mark both right and left bevel gear case/axle case
assemblies. 3
35 to 41 ft--lb
IMPORTANT: Do not interchange right and left (47 to 56 N--m)
bevel gear case/axle case assemblies.
Figure 11
1. Cap screw 5. Bevel gear case/axle
2. Lock nut case assembly
3. Lock washer 6. O-ring
4. Axle support
3. Remove the axle cover mounting screws. Remove

the axle cover from the axle case as an assembly 17 to 20 ft--lb
(Fig. 12). (23 to 27 N--m)
1
4
Figure 12
1. Axle case 3. Mounting screw
2. Axle cover assembly 4. O-ring
4. Remove the axle case support mounting screws, the

axle case support, and the support shims (Fig. 13). Thread--locking
Compound 3
2
57 to 67 ft--lb
(77 to 91 N--m)
Figure 13
1. Axle case 3. Mounting screw
2. Axle case support 4. Support shim

5. Remove the knuckle pin mounting screws and the
knuckle pin. Remove the gasket and any remaining gas-
2
ket material from either mating surface (Fig. 14). 1
6. While holding the bevel gear case, tap the upper end 17 to 20 ft--lb
(23 to 27 N--m) 3
of the bevel gear shaft out of the upper bearing and up-
per bevel gear.
Thread--locking 4
7. Pull the bevel gear case from the axle case and re- Compound
move the upper bevel gear, and collar from the gear
case. 5
14
8. Remove the axle case cover screws, cover, and the 7
O-ring from the axle case. 15 11
8
9. Remove the plug and sealing washer from the center
of the axle case cover. While holding the axle case cov-
er, lightly tap the lower end of the bevel gear shaft out of
6
the lower bearing and lower bevel gear.
10.Remove and discard bevel gear shaft seal from axle

case (Fig. 14).
9 13
12
10
17 to 20 ft--lb
(23 to 27 N--m)
Figure 14
1. Knuckle pin 9. Lower bevel gear
2. Mounting screw 10. Lower bearing
3. O--ring 11. Axle case
4. Bevel gear case 12. Axle case cover
5. Upper bearing 13. O-ring
6. Bevel gear shaft 14. Shaft seal
7. Collar 15. Bushing
8. Upper bevel gear
Axles, Planetaries,
and Brakes
Inspection
1. Measure the knuckle pin O.D. and the axle case sup-
1
port bushing I.D. to determine the bushing to pin clear-
ance (Fig. 15). Replace components as necessary.
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)
Figure 15
1. Knuckle pin 2. Axle case support
2. Inspect all gears, shafts, bearings, cases, and cov-
ers for damage and wear. Replace components as nec-
essary.

Installation
1. Coat new shaft seal with grease and install in axle

case as shown (Fig. 16).
3
Figure 16
1. Axle case 3. Shaft seal
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 7
install the axle case cover (Fig. 17). Tighten cover 8
screws from 17 to 20 ft-lb (23 to 27 N--m).
3. Slide the bevel gear case over the bevel gear shaft
and install the bevel gear and collar. Make sure the bevel 6
gear shaft is completely seated in the upper and lower
bearings (Fig. 17).
4. Install the knuckle pin. Use medium strength thread-- 5

locking compound and tighten the knuckle pin mounting
screws from 17 to 20 ft-lb (23 to 27 N--m).
2
1
Figure 17
1. Axle case cover 5. Upper bevel gear
2. Lower bevel gear 6. Collar
3. Bevel gear shaft 7. Upper bearing
4. Lower bearing 8. Knuckle pin

5. Determine necessary quantity of support shims.
4 57 to 67 ft--lb
A. Lubricate the axle case support bushing with a (77 to 91 N--m)
thin coat of grease and slide axle case support onto
knuckle pin. 1
B. Position support shims that were removed during VERTICAL

disassembly between axle case support and axle ENDPLAY 6
case. Install mounting screws into axle case. Slowly
tighten screws while frequently checking for clear- 5 2
ance (vertical endplay) between axle case support
and knuckle pin. If binding of components is noted
before screws are fully tightened, add additional sup- 3
port shims. Torque screws from 57 to 67 ft--lb (77 to
91 N--m).
C. Use dial indicator to measure vertical endplay of Figure 18

1. Axle case support 4. Dial indicator
axle case (Fig. 18). 2. Axle case 5. Knuckle pin
3. Bevel gearcase 6. Support shim location
AXLE CASE ASSEMBLY ENDPLAY:
0.001 to 0.008 in. (0.02 to 0.20 mm)
3 2
D. Adjust endplay by increasing or reducing number 1
of axle case support shims.
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 4
mm) thickness.
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).
5
IMPORTANT: Correct engagement between bevel
gears is critical to axle performance and durability.
Axles, Planetaries,
and Brakes
7. Temporarily install the bevel gear case/axle case as- Figure 19
sembly on the axle support. Position a dial indicator at 1. Axle support 4. Dial indicator
2. Upper bevel gear 5. Axle bearing shims
the tooths center. Prevent the axle from turning and 3. Differential shaft gear
measure the upper bevel gear to differential shaft gear
backlash (Fig. 19).
UPPER BEVEL GEAR BACKLASH: 4

5
0.004 to 0.016 in. (0.10 to 0.40 mm)
1
8. Adjust backlash by increasing or reducing axle bear-
ing 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 4. Dial indicator
2. Lower bevel gear 5. Axle bearing shims
3. Axle gear

9. Remove the bevel gear case/axle case assembly NOTE: Axle bearing shims are available in 0.008 in.
from the axle support. Coat a new O-ring with grease (0.2 mm), 0.012 in. (0.3 mm), and 0.020 in. (0.5 mm)
and temporarily install the axle cover assembly. Position thickness.
a dial indicator at the tooths center. Prevent the axle
from turning and measure the lower bevel gear to axle 11. Tighten axle cover screws from 17 to 20 ft-lb (23 to
gear backlash (Fig. 20). 27 N--m).
LOWER BEVEL GEAR BACKLASH: 12.Coat a new O-ring with grease and install the bevel
0.004 to 0.016 in. (0.10 to 0.40 mm) gear case/axle case assembly on the axle support.
Tighten mounting screws and nuts from 35 to 41 ft-lb (47
10.Adjust backlash by increasing or reducing axle bear- to 56 N--m) (Fig. 11).
ing shim thickness (see Axle Shafts in this section of this
manual).
Differential Shafts
35 to 41 ft--lb
Removal
1
6 5
IMPORTANT: Do not interchange right and left dif-
ferential shaft assemblies.
1. Remove the mounting screws, nuts, and lock wash- 4

2
ers. Remove the bevel gear case/axle case assembly
and O-ring from the axle support (Fig. 21). 3 7
35 to 41 ft--lb
2. Mark and pull the differential shaft assembly from the (47 to 56 N--m)
axle support.
3. Remove the retaining ring and bevel gear (Fig 22). Figure 21
1. Cap screw 5. Bevel gear/axle case
2. Lock nut assembly
4. Drive the differential shaft out of the bearings. Re- 3. Lock washer 6. O-ring
move the bearings and bearing shims. 4. Axle support 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 6

combination of bearing shims in axle support and drive 3
differential shaft and bearing assembly into axle sup- 5
port. 4
2
1
2. Install bevel gear and retaining ring.
3. Coat new O-ring with grease. Align differential shaft

splines with differential gear assembly and slide differ-
ential shaft assembly onto axle support.
4. Install bevel gear case/axle case assembly (see

Bevel Gear Case/Axle Case Assembly in this section of Figure 22
1. Retaining ring 4. Bearing
this manual). 2. Bevel gear 5. Bearing shims
3. Differential shaft 6. O-ring

Axle Shafts
17 to 20 ft--lb
1
Removal 4
1. Remove the axle cover mounting screws. Remove 3

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).
2
3. Remove the shims, spacer, and retaining ring. Drive
the axle out of the bearing and cover. Remove and dis-
Figure 23
card the axle shaft seal. 1. Axle case 3. Mounting screw
2. Axle cover assembly 4. O-ring
4. Inspect all gears, shafts, bearings, spacers, and
cases for damage and wear. Replace components as
necessary.
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 4

axle shaft. Press only on the inner race of the cover 3
5
bearing (Fig. 25).
3. Install retaining ring, spacer, and correct combina-

tion of bearing shims. Install bevel gear and bearing.
4. Coat a new O-ring with grease and install the axle
Axles, Planetaries,
cover assembly. Tighten axle cover screws from 17 to 20
Figure 24
and Brakes
ft-lb (23 to 27 N--m). 1. Bearing 4. Spacer
2. Bevel gear 5. Retaining ring
3. Shims
2 3
Figure 25
1. Axle shaft seal 3. Bearing
2. Axle cover 4. Axle shaft

Input Shaft/Pinion Gear
35 to 41 ft--lb 1
(47 to 56 N--m) 18
2
3
17
4
5
6
7 16
8
9 18
10 15
14
10
9
13
35 to 41 ft--lb
11 (47 to 56 N--m)
12
Figure 26
1. Nut 7. O-ring 13. Shim
2. Lockwasher 8. Seal collar 14. Screw
3. Stud 9. Bearing 15. Gear case
4. Locknut 10. O-ring 16. Gasket
5. Stake washer 11. Input shaft/Pinion gear 17. Cover plate
6. Oil seal 12. Bearing case 18. Dowel pin
The following procedures assume the rear axle assem- NOTE: Replacement input shaft/pinion gear (11) is only
bly has been removed from the machine. available in matched set with differential ring gear.
1. Remove the cover plate, gasket, and gear case as- NOTE: When installing bearing cones onto the input
sembly from the axle assembly. Remove the gasket and shaft/pinion gear, press only on the inner race of the
any remaining gasket material. bearing cone.
2. Remove the retaining rings and the driven gear from 1. If the inner bearing cone was removed, press a new
the input shaft/pinion gear. bearing cone all the way onto the input shaft/pinion gear.
3. Remove input shaft/pinion gear assembly from the 2. Place the shaft and bearing assembly in the bearing
gear case. Remove the shims and bearing case O- case and install the outer bearing cone.
rings.
NOTE: The bearings must be completely seated.
4. Release the stake washer and remove the locknut. There should be no input shaft/pinion gear end play.
Remove and discard the stake washer.
3. Coat a new oil seal with grease and install as shown
5. Drive the input shaft/pinion gear out from the outer (Fig. 27). The seal should be installed with the garter
bearing cone and bearing case. Remove and discard spring towards the hydraulic motor.
the oil seal and O-ring.
4. Coat new O-ring with grease. Install O-ring in the oil
6. Inspect all gears, shafts, bearings, spacers, and seal collar, and install the collar.
cases for damage and wear. Replace components as
necessary. 5. Install a new stake washer. Install the lock nut finger
tight.

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 sur-
face of the bearing case. Subtract the “Design Cone
Center Distance” from this distance to determine initial
shim thickness (Fig. 28). 3
DESIGN CONE CENTER DISTANCE

(distance from mating surface of axle support to end Figure 27
face of pinion gear): 1. Oil seal 3. Seal garter spring
2. Bearing case
1.870 + 0.002 in. (47.5 + 0.05 mm)
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

Design
case in the gear case. Place shims on the gear case and 1 Cone Center
temporarily install gear case assembly into axle case. Distance
Tighten mounting nuts and screws from 35 to 41 ft-lb (47
to 56 N--m).
10.Insert a screwdriver through the drain plug hole to

hold ring gear and measure the pinion gear to ring gear 2
backlash (Fig. 29).
PINION GEAR TO RING GEAR BACKLASH:

0.004 to 0.016 in. (0.10 to 0.40 mm)
Axles, Planetaries,
11. Adjust backlash by increasing or reducing gear case Figure 28
1. Input shaft/pinion gear 2. Bearing case
and Brakes
shim thickness.
12.Check pinion gear to ring gear engagement (see Pin-

ion 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).
3 2
14.Install retaining rings and driven gear on input shaft/
pinion gear.
15.If the drive gear (on drive motor shaft) was removed, 4
install the retaining rings and drive gear on the motor
shaft.
16.Use a new gasket and install the cover plate. Use a

Figure 29
new O-ring and install the drive motor. 1. Axle case 3. Dial indicator
2. Screwdriver 4. Input shaft/pinion gear

Differential Gear
35 to 41 ft--lb
bly has been removed from the machine. 5 (47 to 56 N--m)
1
Removal 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 dif-

ferential shafts assemblies. 7
4
2. Mark and pull the differential shaft assemblies from
the axle support. 3
35 to 41 ft--lb
3. Remove input shaft/pinion gear assembly, shims, (47 to 56 N--m)
and O-ring from the axle support (Fig. 30). Figure 30
1. Gear Case 5. Case screw
4. Remove the axle support case screws. Separate the 2. Pinion Gear 6. Differential gear
3. Axle support (left) 7. O-ring
axle support halves and remove the O-ring. 4. Axle support (right)
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 1

punch and hammer. Discard the spring pin (Fig. 31).
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
4
5 5
4
22 to 25 ft--lb 2
(30 to 34 N--m) 3
Thread--locking
Compound
7
6
Figure 32
1. Differential pinion shaft 5. Side gear shims
2. Pinion gear 6. Ring gear
3. Pinion washer 7. Differential case
4. Side gear

Inspection
1. Measure the differential side gear O.D. and the dif-

ferential 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)
SIDE GEAR O.D. (Factory Spec.): 1

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 nec-
essary.
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) Figure 33
1. Side gear 2. Differential case
PINION GEAR I.D. (Factory Spec.):
0.551 to 0.552 in. (13.10 to 14.02 mm)
3. Inspect all gears, shafts, bearings, cases, and cov-

ers for damage and wear. Replace components as nec-
essary.
Axles, Planetaries,
and Brakes
1
Figure 34
1. Pinion shaft 2. Pinion gear

Installation
3
1. If the ring gear was removed from the differential
2
case, use medium strength Loctite thread locker and
tighten the mounting screws from 22 to 25 ft-lb (30 to
34 N--m). 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. Figure 35
1. Vise 3. Dial indicator
4. Place the differential pinion gears and pinion wash- 2. Differential gear case
ers in their original location in the differential case. Tem-
porarily install the differential pinion shaft.
More than 35% total tooth contact
5. Secure the differential case in a soft jawed vise. Posi-
tion a dial indicator on a tooth of the differential pinion
gear. Press the pinion and side gear against the differen-
tial case and measure the pinion gear to side gear back-
lash (Fig. 35).
PINION GEAR TO SIDE GEAR BACKLASH: 1/3 to 1/2 of entire width

0.004 to 0.016 in. (0.10 to 0.40 mm) from small end of tooth
6. Adjust backlash by increasing or reducing side gear Figure 36

shim thickness.
12.Install differential gear assembly in right side axle
NOTE: Side gear shims are available in 0.043 in. (1.10 support half.
mm), 0.047 in. (1.20 mm) and 0.051 in. (1.30 mm) thick-
ness. 13.Coat a new o-ring with grease and install left side
axle support half. Tighten axle support case screws from
7. Apply gear marking compound, such as DyKemR 35 to 41 ft-lb (47 to 56 N--m).
Steel Blue lightly over several gear teeth.
14.Install input shaft/pinion gear assembly (see Input
8. While applying a light load to either side gear, rotate Shaft/Pinion Gear in this section of this manual).
either pinion gear until the side gears have made one
complete revolution. 15.Coat new o-rings with grease, align differential shaft
splines with differential gear assembly and slide differ-
9. Ideal tooth contact should cover more than 35% of ential shaft assemblies onto axle support.
each tooth surface. The contact area should be in the
center of each tooth and extend 1/3 to 1/2 way across 16.Install bevel gear case/axle case assemblies (see
each tooth from the toe (small) end (Fig. 36). Bevel Gear Case/Axle Case Assembly in this section of
this manual).
10.Adjust side gear shims if necessary to correct tooth
contact. Recheck differential pinion gear to side gear
backlash if any changes are made.
11. After backlash and tooth contact have been ad-

justed, align the hole in the differential pinion shaft with
the hole in the differential case and install a new spring
pin.

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 fol- PROFILE
TOP LAND
lowing procedure.
GEAR TOOTH DEFINITIONS (Fig. 37):
Toe -- the portion of the tooth surface at the end to- TOE
LENGTHWISE
wards the center. BEARING
ARC
Heel -- the portion of the gear tooth at the outer end. HEEL
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 ROOT
Steel Blue.
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 1/3 to 1/2 of entire width
from small end of tooth
to 1/2 way across each tooth from the toe end (Fig. 38).
Adjustments to the gear contact position are made by Figure 38

moving the input shaft/pinion gear (bearing case shims)
or by moving the differential gear case (differential bear-
ing shims) (Fig. 39). 4
Axles, Planetaries,
3
and Brakes
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
1
this section of this manual).
Example: If the pinion gear to ring gear backlash is set

Figure 39
correctly to specifications and the bearing case shim is 1. Input shaft/pinion gear 4. Differential bearing
changed to adjust tooth contact, it may be necessary to 2. Bearing case shims shims
readjust backlash to the correct specification before 3. Differential gear case
checking the contact pattern.

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.
Toe Contact Tip Contact
C. Repeat until proper tooth contact and pinion gear
to ring gear backlash are correct.
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.

Chapter 7
Chassis
Table of Contents
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . 1 Lift Arms For Cutting Decks #2 and #3 . . . . . . . . . 6
Cutting Deck Identification . . . . . . . . . . . . . . . . . . . . 1 Lift Arms For Cutting Decks #6 and #7
SERVICE AND REPAIRS . . . . . . . . . . . . . . . . . . . . . . 2 (Groundsmaster 4700--D only) . . . . . . . . . . . . . . 8
Steering Tower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Hood . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Lift Arms For Cutting Decks #1, #4, and #5 . . . . . 4
General Information
Cutting Deck Identification

Cutting decks on the Groundsmaster 4500--D and
4700--D are identified as shown in Figure 1.
#2 #3 #7 Deck
#6 Deck
Deck Deck (GM4700)
(GM4700)
Chassis
Figure 1
Groundsmaster 4500--D/4700--D Page 7 -- 1 Chassis

Service and Repairs
Steering Tower
20 to 26 ft--lb
1 (28 to 35 N--m)
20
21
22 19 18 45 44
2
3
23 5
24 4
25
26 47 48
11 6 46
7
31 8
29 27 9
10
28 11
30
13
15
42 14
32 41 13
39 12
24 43 40
33
RIGHT
34 16
35
FRONT 34 17
38 36 37
Figure 2
1. Steering wheel cover 17. Steering valve 33. Cotter pin
2. Hex nut 18. Warning lamp (temp/glow plug) 34. Flat washer
3. Steering wheel 19. Warning lamp (oil pressure/charge) 35. Parking brake rack
4. Parking brake knob 20. Speed control knob 36. Hydraulic fitting
5. Dust cover 21. Speed control lever 37. O--ring
6. Flange head screw 22. Instrument plate 38. O--ring
7. Friction disc 23. Steering column bracket 39. Switch plate
8. Spring pin 24. Flange head screw 40. Carriage bolt
9. Cotter pin 25. Compression spring 41. Flat washer
10. Cable 26. Flange head screw 42. Lock nut
11. Flat washer 27. Lock washer 43. Parking brake proximity switch
12. Lock nut 28. Flat washer 44. Screw
13. Spring washer 29. Cotter pin 45. Flat washer
14. Tube 30. Parking brake rod 46. Lock washer
15. Lever bracket 31. Ignition switch 47. Nut
16. Steering column 32. Tower cover 48. Ignition key
Chassis Page 7 -- 2 Groundsmaster 4500--D/4700--D

Rev. D
1. Park machine on a level surface, lower cutting units, 1. Assemble steering tower using Figure 2 as a guide.
2. Disassemble steering tower as needed using Figure

2 as a guide.
Chassis

Lift Arms for Cutting Decks #1, #4, and #5
2 1
3
4
5
37
30 6 7
38
8
9
36
10
32
2
11
12
13
15 14
4
10
32
34
33
14
5
16
35
RIGHT 17
31 32
19 18
FRONT 29
27
26
28
19
25
24 20
23
16 22 21
Figure 3
1. Lock nut 14. Lift cylinder pin 27. Lock nut
2. Flange nut 15. Flange nut 28. Bumper support bracket
3. Lift arm (#1 deck) 16. Washer head screw 29. Bumper
4. Lift cylinder pin 17. Skid plate 30. Lift arm (#5 deck)
5. Flange head screw 18. Lift arm (#4 deck) 31. Lock nut
6. Hydraulic fitting 19. Cap screw 32. Flange bushing
7. Cap screw 20. Carrier frame shaft 33. Front carrier frame
8. Lift cylinder (#4 and #5 decks) 21. Lynch pin 34. Grease fitting
9. Lift cylinder (#1 deck) 22. Thrust washer 35. Deck carrier frame
10. Thrust washer 23. Carriage bolt 36. Grease fitting
11. Lock nut 24. Switch bracket 37. O--ring
12. Pivot pin 25. Proximity switch 38. O--ring
13. Slotted roll pin 26. Proximity switch plate
Removal 3. If lift arm for either deck #4 or #5 (Fig. 4) is to be re-

moved, tag and remove hydraulic hoses from the deck
1. Park machine on a level surface, lower cutting units, motor (Fig. 5). Slide hoses out of the hose retaining loop
stop engine, engage parking brake, and remove key on the lift arm.
4. Remove lift cylinder pin that secures lift cylinder to lift
2. Remove cutting deck from lift arm (see Cutting Unit arm.
Operator’s Manual).
5. Loosen and remove lock nut from lift arm pivot pin.

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
#2 #3 #7 Deck
#6 Deck
1. Position lift arm to frame (Fig. 3). Fit thrust washer (GM4700)
Deck Deck (GM4700)
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 CUTTING DECK LOCATIONS
cylinder pin to lift arm with flange head screw and flange
nut. Figure 4
NOTE: Install thrust washer on deck pivot shaft before

installing cutting deck on pivot shaft.
1 4
4. Position and install cutting deck to lift arm (see Cut-
ting Unit Operator’s Manual).
5. If lift arm for either deck #4 or #5 was removed, slide

3
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.
2
6. Lubricate lift arm and lift cylinder grease fittings after
assembly is complete (see Traction Unit Operator’s
Manual).
7. After assembly, raise and lower the cutting deck to Figure 5

verify that hydraulic hoses and fittings do not contact 1. Pressure “in” hose 3. Case drain hose
anything. 2. Pressure “out” hose 4. Hose retaining loop
Chassis

Lift Arms for Cutting Decks #2 and #3
29 2 1
3
4
5
20
19
30
17 18
16
15 15
29
14
21
RIGHT
31 13
29
FRONT 25
30
22
23
24
7 8 13
6 28
Thread--locking 27
Compound 11
12
10
26
9
Figure 6
1. Flange nut 12. Lift arm (#2 deck shown) 22. Flange head screw
2. Bulkhead bracket 13. Flange bushing 23. Lift cylinder pin
3. Hydraulic t--fitting 14. Flange nut 24. Cap screw
4. Flange head screw 15. Retaining ring 25. Hydraulic fitting
5. Lock nut 16. Lift cylinder 26. Cap screw
6. Slotted roll pin 17. Grease fitting 27. Lift arm rotation stop
7. Pivot pin 18. Lock nut 28. Set screw
8. Bumper 19. Hydraulic fitting 29. O--ring
9. Thrust washer 20. Lift cylinder pin 30. O--ring
10. Rebound washer 21. Thrust washer 31. Grease fitting
11. Deck pivot shaft

Removal
2. Remove cutting deck from lift arm (see Cutting Unit

3. Remove lift cylinder pin that secures lift cylinder to lift

arm. #2 #3
#6 Deck #7 Deck
Deck Deck (GM4700)
(GM4700)
4. Loosen and remove lock nut from pivot pin.
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 Figure 7
bushings and pivot pin for damage or wear.
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.
3. Install lift cylinder to lift arm with cylinder pin. Secure

nut.
NOTE: Install thrust washer on deck pivot shaft before

installing cutting deck on pivot shaft.

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
Chassis
position the stop. Apply medium strength thread--lock-
ing compound (e.g. Loctite blue) to set screws and re-
tighten set screws to secure stop. The rotation stop
should contact the lift arm across the full width of the
stop.

Manual).
6. After assembly, raise and lower the cutting deck to

verify that hydraulic hoses and fittings do not contact
anything.

Lift Arms for Cutting Decks #6 and #7 (Groundsmaster 4700--D only)
1
2
3
41 34
4
40
5 6
7
4 8
9
27 30 10
1 31 37
6 36
32 34
33 1
11
12 15
13
14 17
18
19
20
39
16
39
RIGHT 27 38
28
10 23 22 35 21
1 15 29
24
FRONT 25
26
42
Figure 8
1. Retaining ring 15. Thrust washer 29. Slotted roll pin
2. Flat washer 16. Cap screw 30. Support arm (deck #6 shown)
3. Cap screw 17. Lock nut 31. Flange nut
4. Hydraulic fitting 18. Proximity switch 32. Bushing
5. Lift cylinder 19. Lock nut 33. Link
6. Plastic roller 20. Thrust washer 34. Grease fitting
7. Lock nut 21. Lift arm (deck #6 shown) 35. Self tapping screw
8. Grease fitting 22. Carrier pivot pin 36. R--clamp
9. Rear link 23. Compression spring 37. Wire harness
10. Lift link 24. Thrust washer 38. Switch actuator
11. Carriage screw 25. Flat washer 39. Flange bushing
12. Neutral switch plate 26. Lock nut 40. O--ring
13. Switch bracket 27. Pin 41. O--ring
14. Carriage bolt 28. Pivot pin 42. Deck carrier frame

Removal
2. Remove cutting deck from lift arm (see Cutting Unit

3. Remove pin that secures lift links (10) to lift arm.

#2 #3 #7 Deck
#6 Deck
4. Loosen and remove lock nut from pivot pin. (GM4700)
Deck Deck (GM4700)
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. 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 piv-
ot pin with slot in support arm flange.
3. Install lift cylinder to lift arm with cylinder pin. Secure

nut.
NOTE: Install compression spring and thrust washer

on carrier pivot pin before installing cutting deck on pivot
pin.


Manual).
Chassis
6. After assembly, raise and lower the cutting deck to
verify that hydraulic hoses and fittings do not contact
anything.

Hood
8 6
32
31 48
1 49
2 14
9
7
9
10
10 44
13 46
15
12
11
21
3 20 50 23 25
24 26
4 19 22 27
5 51 18 28
46 29
17 30
47
16 45 17
13
37
36
RIGHT 35
38 34
22
39 33
FRONT 40
43 41
42
Figure 10
1. RH hood frame tube 18. Cap screw 35. Hood receiver retainer
2. Front hood tube 19. LH hood frame tube 36. Spring washer
3. Front shroud 20. LH support 37. Hood receiver spacer
4. Shroud divider 21. Rear hood tube 38. Axle stop
5. Hair pin 22. Flange head screw 39. Flat washer
6. Screen 23. Hood receiver 40. Hood latch
7. Keeper 24. LH tube cover 41. Pop rivet
8. Hood 25. Cap screw 42. Cap screw
9. Flat washer 26. Bumper weight 43. Cap screw
10. Lock nut 27. Rear bumper 44. Draw latch
11. Pop rivet 28. Rubber bumper 45. Hood lock pin
12. RH tube cover 29. Flange head screw 46. Pop rivet
13. Lock nut 30. Bumper weight clamp 47. Latch plate
14. Cap screw 31. Back washer 48. Foam seal
15. Cap screw 32. Foam seal 49. Foam seal
16. RH support 33. Lock nut 50. Foam seal
17. Flange nut 34. Cap screw 51. Pop rivet

Removal

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. Hood latch
3. Check hood alignment for correct operation of hood
latches and dust seals.
Figure 12
1. Hood lock pin 2. Lanyard
Chassis


Chapter 8
Cutting Units
Table of Contents
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 SERVICE AND REPAIRS . . . . . . . . . . . . . . . . . . . . . . 8
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . 3 Blade Spindle Assembly . . . . . . . . . . . . . . . . . . . . . 8
Factors That Can Affect Quality of Cut . . . . . . . . . 3 Blade Spindle Service . . . . . . . . . . . . . . . . . . . . . . 10
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Rear Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Rear Roller Service (Non--Greasable Bearings) 13
Blade Stopping Time . . . . . . . . . . . . . . . . . . . . . . . . 5 Rear Roller Service (Greasable Bearings with
Blade Plane Inspection and Adjustment . . . . . . . . 6 Retaining Ring) . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Rear Roller Service (Greasable Bearings with
Bearing Nut) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Front Roller Service . . . . . . . . . . . . . . . . . . . . . . . . 18
Cutting Deck Carrier Frame . . . . . . . . . . . . . . . . . . 20
Cutting Units
Groundsmaster 4500--D/4700--D Page 8 -- 1 Cutting Units (Rev. B)

Rev. D
Specifications
MOUNTING: All cutting units are supported by indepen- DISCHARGE: Clippings are discharged from the rear of
dent lift arms and are interchangeable to any cutting unit the mowing decks. Pre--drilled mounting holes allow at-
positions. The Groundsmaster 4700--D (shown above) tachment of optional mulching baffle.
uses 7 cutting units. The Groundsmaster 4500--D uses
5 cutting units. CUTTING UNIT LIFT: Cutting units on the Ground-
smaster 4500--D are controlled with one lift lever. The
CONSTRUCTION: Deck chamber is welded 7, 10, and Groundsmaster 4700--D uses three lift levers: one for
12 gauge steel. Deck frame is welded 1--1/2 inch square the right wing deck, one for the left wing deck, and the
tubing with 7 gauge side supports. third (center) lever for the remaining five decks.
HEIGHT--OF--CUT RANGE: 3/4 to 4 inch (1.91 to 10.16 SUSPENSION SYSTEM: A fully floating suspension
cm) in 1/4 inch (.64 cm) increments. Height--of--cut ad- with hydraulic counterbalance. Main center pivot allows
justment is made by repositioning deck on deck frame. side--to--side deck oscillation. Individual decks sup-
ported with two front rollers and one, full width, rear roll-
DECK DRIVE: Closed loop, integrated relief, hydraulic er.
system operates cutting deck hydraulic motors. Blade
spindles are 1--1/4 inch (31.7 mm) shafts supported by WEIGHT: Complete cutting unit weighs 190 lb (86 kg).
greaseable, tapered roller bearings.
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 stan-
dard 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 un- Remember that the “effective” or actual height--of--cut
satisfactory quality of cut, some of which may be turf depends on cutting unit weight, counterbalance setting,
conditions. Turf conditions such as excessive thatch, and turf conditions. Effective height--of--cut will be differ-
“sponginess”, uneven ground conditions, or attempting ent than the bench set height--of--cut.
to cut off too much grass height may not always be over-
come by adjusting the machine. It is important to re-
member that the lower the height--of--cut, the more
critical these factors are.
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.
Adjust height--of--cut setting to remove only 1 inch (2.5

cm) or 1/3 of the grass blade when cutting.
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
Cutting Units
or damaged.
9. Grass Conditions. Mow when grass is dry for best cutting results.

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 Spanner Wrench

TOR4065 Inner Oil Seal Installer
TOR4066 Bearing Installer
TOR4067 Shaft Support Tool
TOR4068 Inner Seal Installer
TOR4869 Outer Seal Installer
TOR4071 Outer Oil Seal Installer
TOR4072 Shaft Seal Protector
TOR4073 Handle
TOR4074 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
Bearing Installation
roller that has greasable bearings and a bearing lock nut Washer
used to retain the bearings.
115--0852 Inner Seal Tool

115--0853 Bearing/Outer Seal Tool
107--8133 Bearing Installation Washer
Inner Seal Bearing/Outer Seal

Tool Tool
Figure 3

Rev. D
Adjustments
CAUTION
Never install or work on the cutting units or lift
arms with the engine running. Always stop en-
gine 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.
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.
Cutting Units

Blade Plane Inspection and Adjustment
If a solid object is struck by the cutting deck, the blade 6. Determine if one or both (RH and LH) height--of--cut
plane of the deck should be inspected. 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
Blade Plane Inspection front height, then no adjustment is needed for that side.
Adjust other side (if needed) to within + .090 inch (+ 2.3
1. Remove cutting unit to be inspected (see Cutting mm) of correct side.
Unit Operator’s Manual).
7. Adjust right and/or left height--of--cut brackets by re-
2. Use hoist (or minimum of two people) and place cut- peating steps 1 thru 3.
ting deck on flat table.
8. Secure right and/or left height--of--cut brackets with
3. Mark one end of blade with paint pen or marker. Use carriage bolts and flange nuts.
this end of blade to check all heights.
9. Verify 12, 3, and 9 o’clock heights.
4. Position cutting edge of marked end of blade at 12
o’clock (straight ahead in direction of mowing). Measure 10.Reinstall cutting unit (see Cutting Unit Operator’s
height from table to cutting edge of blade. Manual).
5. Rotate marked end of blade to the 3 and 9 o’clock

positions and measure heights. FRONT OF DECK
6. Compare 12 o’clock measured height to the height-- 12 o’clock
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. 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)

6 o’clock
from deck frame.
REAR OF DECK
2. Position .060 inch (1.5 mm) and/or .030 inch (.8 mm) Figure 1
shims between the deck frame and bracket to achieve
the desired blade height setting.
3. Install height--of--cut bracket to deck frame with re-

maining shims assembled below the height--of--cut
1
bracket.
NOTE: Socket head bolt and spacer for front bracket

are held together with Loctite to prevent spacer from fal-
ling 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 2. Shims

Cutting Units

Service and Repairs
CAUTION
Never install or work on the cutting units or lift
arms with the engine running. Always stop en-
gine and remove key first.
Blade Spindle Assembly
1
2 13
12
3
11
5
RIGHT
6
FRONT
7
85 to 110 ft--lb
(115 to 149 N--m)
8
9 10
Figure 3
1. Flange nut 6. Spindle assembly 10. Blade bolt
2. Socket head screw (motor mounting) 7. Cap screw 11. Rubber flap (if equipped)
3. Spindle plate 8. Cutting blade 12. Flap plate (if equipped)
4. Cutting deck 9. Anti--scalp cup 13. Pop rivet (steel) (if equipped)
5. O--ring

Removal
1. Park machine on a level surface, lower cutting units, 2

2. Remove two socket head screws that secure hy-

draulic motor to the cutting unit (Fig. 4). Remove hydrau- 1
lic motor and O--ring from deck.
1
3. Cover top of spindle to prevent contamination.
Spindle plug (Toro Part No. 94--2703) can be used to
cover spindle.
Figure 4
4. Start the engine and raise the cutting unit. Stop en- 1. Socket head screw 2. Hydraulic motor
gine 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
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 assem-
bly 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 cut-
ting 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).
3. Position O--ring to top of spindle housing. Install hy-

draulic motor to the cutting unit with two socket head
screws.
Cutting Units

Blade Spindle Service
Disassembly
2
1. Remove blade spindle from cutting deck (see Blade 6
Spindle Removal).
4
2. Loosen and remove spindle nut from top of spindle 130 to 160 ft--lb
shaft. (177 to 216 N--m) 11
10
3. Press the spindle shaft out of the spindle housing us-
ing an arbor press. The shaft spacer remains on the 12 9
spindle shaft as the shaft is being removed.
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
5
cups out of the spindle housing. Also, remove the large
spacer from the housing.
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 Figure 5

used spindle housing that has the original large 1. Spindle housing 7. Grease fitting
2. Spindle plug 8. Bearing
snap ring installed, discard the snap ring that 3. Spindle shaft 9. Spacer ring
comes with the new bearings because it is not nec- 4. Oil seal 10. Spacer set (2 piece)
5. Shaft spacer 11. Bearing
essary to replace the original snap ring. If a spindle 6. Spindle nut 12. Large snap ring
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
PRESS
spacer set and snap ring. These parts cannot be
purchased separately.
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.
IMPORTANT: If bearings are being replaced, make 1 3

sure to use the large spacer, inside spacer, and 2 6
spacer ring that are included in bearing set. 5
2. Install large spacer into top of spindle housing. The

spacer should fit against the snap ring.
Figure 6
3. Using an arbor press, push the bearing cups into the 1. Bearing cups 4. Arbor press
2. Large snap ring 5. Support
top and bottom of the spindle housing. The top bearing 3. Large spacer 6. Arbor press base
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).
4. Pack the bearing cones with grease. Apply a film of

grease on lips of seals.

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. Lu-
bricate 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 1
installed fully.
9. Thread spindle nut onto shaft and tighten nut from Figure 7
130 to 160 ft--lb (177 to 216 N--m). 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.
11. Install blade spindle to cutting deck (see Blade

Spindle Installation).
Cutting Units

Rear Roller
Three types of rear rollers have been used on the
10
Groundsmaster 4500--D and 4700--D. One roller design
6 9
has sealed bearings with no grease fittings on the roller
shaft. The second design has grease fittings in the roller 5
shaft ends. The third design has grease fittings incorpo- 4 7
8
rated into the roller fasteners. Removal and installation 1
6
of the rear roller from the cutting deck is the same, re-
gardless of roller type. 7
Removal (Fig. 8) 3

stop engine, engage parking brake, and remove key 2
2. If cutting deck is equipped with a roller scraper, re-

move fasteners securing left and right scraper rod
brackets to roller mounts. Remove scraper rod assem- Figure 8
bly. 1. Deck frame 6. Cap screw
2. Rear roller assembly 7. Scraper plate
3. Remove four (4) flange head screws securing roller 3. Flange head screw 8. Roller scraper
4. Flange head screw 9. Cap screw (if equipped)
mounts to rear of deck frame. Remove roller mounts and 5. Roller mount 10. Grease fitting
rear roller assembly from deck frame.
4. Loosen fasteners securing each end of roller to roller

mounts. Remove mounts from roller.
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).

Rev. D
Rear Roller Service (Non--Greasable Bearings)
Seal Removal (Fig. 9) 5. Install second spiral retaining ring onto roller shaft to
secure second bearing.
1. Using a 1/4 inch thick, 3” X 3” square piece of steel,
make a seal removal tool as shown in Figure 10. 6. Install new seals to .030 inch (.76 mm) recessed into
roller.
2. Slide seal removal tool over roller shaft.
3. Using the tool as a template, locate, mark, and drill

two 7/64 inch (.109 inch diameter) holes in outer face of 2
seal.
3 4
5
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

1
removal tool.
6. Alternately tighten cap screws to pull seal out of roller

Figure 9
assembly. 1. Roller 4. Retaining ring
2. Roller shaft 5. Oil seal
NOTE: Seals will be destroyed when servicing the rear 3. Bearing
roller. Do not re--use seals that have been removed.
Bearing Removal (Fig. 9) .188” dia. (2)
NOTE: The bearings are pressed onto the roller shaft .625” dia.
and loose fit into the roller.
.625”
1. Remove seals from roller. Remove retaining rings
from roller shaft: catch ring removal notch with pick and .625”
pull ring from shaft. Tap 1/4--20
UNC (2)
2. Loosely secure roller assembly in bench vise and
lightly tap one end of roller shaft until free from bearing
and housing. 1.05” 1.05”
3. Remove second bearing from shaft by supporting Figure 10

bearing on inner race and tapping on roller shaft.
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.
2. Place spiral retaining ring on same end of shaft as

Cutting Units
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.

Rear Roller Service (Greasable Bearings with Retaining Ring)
10
4
1 6
1 2
3
4
5
3
5
9 8 7 6
10
Figure 11
1. Roller shaft 5. Grease fitting 8. Ball bearing
2. Outer seal 6. Washer 9. Inner oil seal
3. Retaining ring 7. Inner seal 10. Roller tube
4. Outer oil seal

Rev. 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 re- 5. Install retaining ring so that side with sharp edges
move seals and bearing from one end of roller. Hit other faces end of roller (out).
end of roller shaft to remove seals and bearing from oth-
er end of roller. Be careful not to drop roller shaft. 6. Use tool TOR4071 to install outer oil seal.
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 bot-
tom 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, 9. Use a hand operated grease gun and No. 2 general
however use of a press is recommended. purpose lithium base grease to lubricate bearings until
grease appears at washer. Wipe off excess grease.
1. Use installation tool TOR4065 and handle TOR4073
to install inner oil seal into each end of roller tube.
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 out-
side 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.
D. Use tool TOR4067 to install second ball bearing.
Cutting Units

Rev. D
Rear Roller Service (Greasable Bearings with Bearing Nut)
2 50 to 60 ft--lb
1. Remove bearing lock nut from each end of roller (68 to 81 N--m)
3
shaft.
4
5
2. Loosely secure roller assembly in bench vise and
lightly tap one end of roller shaft until outer seals and 6
bearing are removed from opposite end of roller tube. 7
Remove second set of outer seals and bearing from roll- 1
er tube by tapping on opposite end of shaft. Remove
shaft from roller tube. 2 3 4 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) 7

1
1. Install inner seals into roller tube making sure that Figure 12
seal lip (and garter spring) faces end of tube. Use inner 1. Roller tube 5. Outer seal
2. Roller shaft 6. Bearing lock nut
seal tool (see Special Tools) and soft face hammer to ful- 3. Inner seal 7. Set screw
ly seat seals against roller shoulder (Fig. 13). Apply a 4. Bearing
small amount of grease around the lip of both inner seals
after installation. 1 2 3
IMPORTANT: During assembly process, frequently

check that bearings rotate freely and do not bind. If
any binding is detected, consider component re-
moval 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 Figure 13
a soft face hammer to fully seat bearing against roller 1. Roller tube 3. Inner seal tool
2. Inner seal
shoulder (Fig. 14). After bearing installation, make
sure that it rotates freely with no binding.
1 2 3
B. Apply a small amount of grease around the lip of
4
both outer seals.
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.
Figure 14
D. Using the same process, install second outer 1. Roller tube 4. Washer
seal making sure to not crush the installed outer seal. 2. Inner seal 5. Bearing/outer seal tool
3. Bearing
Again, make sure that bearing still freely rotates.
Rev. D
3. From the roller tube end with only the inner seal NOTE: After roller is installed to cutting deck, lubricate
installed, carefully install the roller shaft into the roller roller grease fittings, rotate roller to properly distribute
tube. Make sure that seals are not damaged as shaft is grease in bearings and clean excess grease from roller
installed. ends. A properly assembled roller should rotate with
less than 5 in--lbs (0.68 N--m) resistance.
4. Install new bearing and outer seals into second end
of roller tube: 1 2 3 4
5
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 Figure 15
washer from roller. 1. Roller tube 4. Outer seal
2. Inner seal 5. Bearing/outer seal tool
3. Bearing
C. Apply a small amount of grease around the lip of
both outer seals.
1 2 3 4 5
D. Carefully install first outer seal into roller tube 6
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 ro-
tate after seal installation.
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. Figure 16
IMPORTANT: Make sure that all grease is removed 1. Roller tube 4. Bearing
2. Roller shaft 5. Washer
from shaft threads to prevent bearing lock nut loos- 3. Inner seal 6. Bearing/outer seal tool
ening.
5. Thoroughly clean threads on both ends of roller 1 5

2 3 4
shaft.
6
NOTE: If original bearing lock nut(s) are being used,
apply Loctite #242 (or equivalent) to threads of lock
nut(s).
6. Install bearing lock nut onto each end of the roller

shaft. Make sure that outer seals are not damaged dur-
ing nut installation. Torque lock nuts from 50 to 60 ft--lb
(68 to 81 N--m).
Cutting Units
Figure 17
7. If set screw was removed from either end of roller 1. Roller tube 4. Bearing
shaft, apply Loctite #242 (or equivalent) to threads of re- 2. Roller shaft 5. Outer seal
moved set screw and install into roller shaft. Tighten set 3. Inner seal 6. Bearing/outer seal tool
screw until it bottoms in shaft and is recessed in shaft.
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.
Rev. D
Front Roller Service
1. Remove roller mounting bolt.
2. Remove roller assembly from carrier frame.
3. To remove bearings and spacer: 1
A. Insert punch through end of roller and drive oppo-

site bearing out by alternating taps to opposite side of 2
inner bearing race. There should be a lip of inner race
80 ft--lb
exposed for this process. 3 (108 N--m)
B. Remove spacer. Remove second bearing from
4 2
roller using a press.
Figure 18
4. Inspect roller housing, bearings, and bearing spacer
1. Mounting bolt 3. Spacer
for damage or wear. Replace components as needed. 2. Bearing 4. Front roller
Assembly (Fig. 18) NOTE: Securing roller assembly with a gap larger than
.060 inch (1.5 mm) creates a side load on bearings and
1. Install bearings and bearing spacer into roller:
can lead to premature bearing failure.
A. Press first bearing into housing. Press on outer
3. Verify that there is no more than a .060 inch (1.5 mm)
race only or equally on inner and outer races.
gap between roller assembly and the roller mount brack-
B. Insert bearing spacer. ets of the deck frame. If this gap is larger than .060 inch
(1.5 mm), shim excess clearance with 5/8” washers.
C. Press second bearing into roller housing press-
ing equally on inner and outer races until the inner 4. Insert mounting bolt and tighten to 80 ft--lb (108
race comes in contact with the spacer. N--m).
2. Install roller assembly into deck frame.

Rev. D
Cutting Units

Rev. D
Cutting Deck Carrier Frame
Decks #1, #4, and #5 Decks #2 and #3
3
8
7
6
1 5
Decks #6 and #7
4 14
3
13
RIGHT
12
3
FRONT 1
11
10
Figure 19
1. Carrier frame 6. Cap screw 11. Flat washer
2. Lynch pin 7. Rebound washer 12. Compression spring
3. Thrust washer 8. Pivot shaft 13. Pivot shaft
4. Pivot shaft 9. Lift arm (#2 shown) 14. Lift arm (#6 shown)
5. Lift arm (#4 shown) 10. Lock nut

Rev. D
Installation
Each cutting deck is suspended from a carrier frame. 1

Decks should be attached to the carrier frame using the
lower hole in deck bracket (Fig. 20).
The cutting deck carrier frame is attached to the lift arm 3

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).
Figure 20
1. Carrier frame 3. Deck bracket
2. Carrier frames for the center two cutting decks (#2 2. Lower hole
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).
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).
#2 #3 #7 Deck
#6 Deck
Deck Deck (GM4700)
(GM4700)

Figure 21
Cutting Units

Rev. D

Rev. D
Chapter 9
Electrical Diagrams
Table of Contents
ELECTRICAL SCHEMATICS . . . . . . . . . . . . . . . . . . . 3
Serial Number Below 220999999 . . . . . . . . . . . . 3
Serial Number From 230000001 to 260000600 4
Serial Number Above 260000600 . . . . . . . . . . . 5
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
Engine Wire Harness Drawing
Cutting Deck 6 and 7 Wire Harness Drawing
(Groundsmaster 4700--D) . . . . . . . . . . . . . . . . . 30
Diagrams
Electrical
Groundsmaster 4500--D/4700--D Page 9 - 1 Electrical Diagrams (Rev. A)

Rev. D
Electrical Diagrams (Rev. A) Page 9 - 2 Groundsmaster 4500--D/4700--D

GN
LOW OIL PRESSURE

W BU/W OR
ALTERNATOR
OVER TEMP
GLOW
CLUSTER GAUGE
GLOW RELAY
CONTROLLER
GLOW PLUG
KUBOTA
(IN 4WD)
START RELAY K5
(OFF)
(SEAT VACANT)
DECK UP
FRONT PTO
(DECKS 2, 3, 5)
POSITION POSITION
(DECK RAISED) (DECK RAISED)
FRONT PTO
(DECKS 1,4)
(NOT IN NEUTRAL)
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
Page 9 - 4
Rev. D
Serial Number Above 260000600
Page 9 - 5
Rev. D
GN
LOW OIL PRESSURE

ALTERNATOR
OVER TEMP
GLOW
CLUSTER GAUGE
GLOW RELAY
CONTROLLER
GLOW PLUG
KUBOTA
(IN 4WD)
START RELAY K5
(OFF)
DECK UP
LEFT PTO
(DECK 6)
LEFT DECK
(SEAT VACANT) POSITION
(DECK RAISED)
DECK UP
FRONT PTO
(DECKS 2, 3, 5)
POSITION POSITION
FRONT PTO
(DECKS 1,4)
DECK UP

(NOT IN NEUTRAL)
RIGHT PTO
(DECK 7)
RIGHT DECK
POSITION
(DECK RAISED)
Page 9 - 6
Rev. D
GLOW RELAY
Page 9 - 7
Rev. D
Page 9 - 8
Rev. D
GN
LOW OIL PRESSURE

W BU/W OR
ALTERNATOR
OVER TEMP
GLOW
CLUSTER GAUGE
NOTE: The wire harness and relays of the GM 4500-- D and GM 4700-- D
GLOW RELAY
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

FRONT PTO
(DECKS 2, 3, 5)

POSITION POSITION
(DECK RAISED) (DECK RAISED) FRONT PTO
(DECKS 1,4)
(NOT IN NEUTRAL)
Glow Plug Circuit
Power Current
Control Current
Indicator/Gauge Current
Page 9 - 9
Rev. D
GN
LOW OIL PRESSURE

W BU/W OR
ALTERNATOR
OVER TEMP
GLOW
CLUSTER GAUGE
GLOW RELAY
CONTROLLER
GLOW PLUG
KUBOTA
(IN 4WD)
START RELAY K5
(OFF)
(SEAT OCCUPIED)
DECK UP
FRONT PTO
(DECKS 2, 3, 5)

POSITION POSITION
(DECK RAISED) (DECK RAISED) FRONT PTO
(DECKS 1,4)
(IN NEUTRAL)
Crank Circuit
Power Current
Control Current
Page 9 - 10
Rev. D
GN
LOW OIL PRESSURE

W BU/W OR
ALTERNATOR
OVER TEMP
GLOW
CLUSTER GAUGE
GLOW RELAY
CONTROLLER
GLOW PLUG
KUBOTA
(IN 2WD)
(OFF)
START RELAY K5
(OFF)
(SEAT OCCUPIED)
DECK UP
FRONT PTO
(DECKS 2, 3, 5)
POSITION POSITION
FRONT PTO
(DECKS 1,4)
(NOT IN NEUTRAL)
Run (Transport) Circuit
Power Current
Control Current
Page 9 - 11
Rev. D
GN
LOW OIL PRESSURE

W BU/W OR
ALTERNATOR
OVER TEMP
GLOW
CLUSTER GAUGE
GLOW RELAY
CONTROLLER
GLOW PLUG
KUBOTA
(IN 4WD)
(OFF)
START RELAY K5
(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
FRONT PTO
(DECKS 2, 3, 5)
POSITION POSITION
(DECK LOWERED) (DECK LOWERED)
FRONT PTO
(DECKS 1,4)
(NOT IN NEUTRAL)
Run (Mow) Circuit
Power Current
Control Current
Page 9 - 12
Rev. D
Page 9 - 13
Rev. D
GLOW RELAY
ALT. B+ SEAT SWITCH PARKING BRAKE INTERCONNECT TO ENGINE
NEUTRAL SWITCH
P3 J1 J2 J3 P15 P6 P17 P5 P4
BLACK
BLACK
BLACK
BLACK
BLUE/WHITE
RED/BLACK
GRAY
YELLOW
ORANGE
RED/BLACK
P20 FUEL PUMP
YELLOW
oil pressure
GREEN
WARNING LIGHTS P1
YELLOW
alt ”L”
WHITE
YELLOW
YELLOW YELLOW
over temp.
BLUE/WHITE
WARNING LIGHTS P2
YELLOW
glow
PINK
RED
BLACK
BLUE
RED BROWN
STARTER B+ P18 RED ORANGE
TAN
ORANGE
GREEN
BLUE/WHITE
BLACK RED/BLACK
GREEN
YELLOW
INTERCONNECT
P19 ORANGE P23
TO CONSOLE
GREEN
VIOLET
IGNITION SWITCH YELLOW
WHITE
BLACK
J4 BLACK
SHIELDED CABLE
BROWN
GREEN
VIOLET
PINK
ORANGE
GREEN
GRAY
PINK BLACK
BLACK BLACK SHIELD GROUND
BLACK
BLUE GREEN
PINK
P8 P9 P27 P10 P30 P13 P14

CENTER DECK SWITCH #1 CENTER DECK SWITCH #2 DIODE 3 2 WD COIL INTERCONNECT TO GM 4700 CENTER DECK PTO CENTER DECK PTO
(2, 3, 5) (1, 4) Groundsmaster 4500--D/4700--D
Main Wire Harness
Page 9 - 14
Rev. D
J3
ALTERNATOR B+
P15
SEAT SWITCH
P27
DIODE 3
J2
GLOW P13
B A
P18 RELAY CENTER DECK
P3
P10 STARTER B+ PTO (2, 3, 5)
2WD COIL GLOW
RELAY
1 2
P19 P14
1
IGNITION SWITCH CENTER DECK (1, 4)
2 P30
5 P23
INTERCONNECT INTERCONNECT TO 4700 J1
4 3
TO CONSOLE GLOW
RELAY
P2 SP4 SP2 SP6

WARNING LIGHTS 1 2
(OVER TEMP) SP5 P20
SP1 P23
SP7 FUEL PUMP
J4 INTERCONNECT TO ENGINE
IGNITION
SWITCH P6
NEUTRAL SWITCH SP3
P17
PARKING BRAKE
P1
WARNING LIGHTS
P4
(OIL PRESSURE/ALT ”L”) INTERCONNECT
TO ENGINE
P8 P9
CENTER DECK CENTER DECK
SWITCH #1 SWITCH #2
Main Wire Harness
Page 9 - 15
Rev. D
BLACK
BLACK
BLACK
BLACK
GRAY
RED/BLACK
BLUE/WHITE
PINK
ORANGE
RED/BLACK
PINK
GREEN
PINK
WHITE
PINK
PINK PINK
BLUE/WHITE
PINK
BROWN
RED
BLACK
BLUE
RED BROWN
RED ORANGE
GRAY
ORANGE
GREEN
BLUE/WHITE
BLACK RED/BLACK
GREEN
YELLOW
ORANGE
GREEN
VIOLET
YELLOW
WHITE
BLACK
BLACK
BROWN
GREEN
TAN
BLUE
ORANGE
YELLOW
WHITE
BLACK
BLACK BLACK CABLE SHIELD
BLACK
BROWN
BLUE GREEN
BROWN
Main Wire Harness
Page 9 - 16
Rev. D
Main Wire Harness
Page 9 - 17
Rev. D
BLACK
BLACK
BLACK
BLACK
GRAY
RED/BLACK
BLUE/WHITE
ORANGE
RED/BLACK
PINK
PINK
GREEN
PINK
WHITE
PINK
PINK PINK
BLUE/WHITE
PINK
BROWN
RED
BLACK
BLUE
RED BROWN
RED ORANGE
GRAY
ORANGE
GREEN
BLUE/WHITE
BLACK RED/BLACK
GREEN
YELLOW
ORANGE
GREEN
VIOLET
YELLOW
WHITE
BLACK
BLACK
BROWN
GREEN
TAN
BLUE
ORANGE
YELLOW
WHITE
BLACK
BLACK BLACK CABLE SHIELD
BLACK
BROWN
BLUE GREEN
BROWN
Main Wire Harness
Page 9 - 18
Rev. D
SN 280000001
AND UP
Main Wire Harness
Page 9 - 19
Rev. D
TEMPERATURE GAUGE GLOW CONTROLLER 2WD/4WD SWITCH K6 HIGH TEMP PTO SWITCH
K7 PARKING BRAKE
P3 P14 P15 P5
P2 J1 P4
GREEN
VIOLET
YELLOW
YELLOW
PINK
PINK
BLACK
BLACK
BLACK BLACK
YELLOW
YELLOW RED
WHITE P28 RAMP--UP MODULE
BLUE
GND
GREEN
K1 RELAY P7 ORANGE
GREEN
LEFT PTO SHIELDED CABLE
BROWN
BLACK VIOLET
YELLOW
VIOLET
PINK
BLUE BLUE
BLACK
K2 RELAY P8 BLUE
CENTER PTO
BLACK
BLACK
BLUE ORANGE
TAN
K3 RELAY P9 ORANGE
RIGHT PTO
GREEN
BLACK BLUE/WHITE
GREEN
VIOLET
YELLOW YELLOW
BLUE
ORANGE ORANGE
P23 INTERCONNECT TO MAIN
GREEN
HARNESS
VIOLET VIOLET
WHITE YELLOW
K5 RELAY
P11 PINK
START
WHITE
BLACK
VIOLET
BLACK
GRAY
GRAY
YELLOW
POWER POINT P22 WHITE GREEN

YELLOW
ORANGE
YELLOW
RED
GREEN
FUSE BLOCK #1 P12
RED
P6 DIODE PACK
YELLOW PINK
YELLOW
YELLOW
RED/BLACK
GREEN
TAN
RED/BLACK
BROWN
YELLOW
GREEN
WHITE
ORANGE
BLACK
VIOLET
VIOLET
VIOLET
VIOLET
P13 P1 P16 P17 J2 J3 P18 P19 P21 P20

OPT. FUSE BLOCK #2 HOUR METER K8 SEAT K9 NEUTRAL CAPACITOR DIODE 8 LEFT DECK CENTER DECKS RIGHT DECK
Console Wire Harness
Page 9 - 20
Rev. D
P9
K3 RELAY:
RIGHT PTO
P8
K2 RELAY:
5 1 CENTER PTO
P12
FUSE BLOCK #1
4 2
3 P7
P15
P11 K1 RELAY:
K7 PARKING BRAKE
K5 RELAY: LEFT PTO
P14 START
K6 HIGH TEMP
1
3
J3 P13
2
CAPACITOR OPT. FUSE BLOCK #2
P28 J2
RAMP UP MODULE CAPACITOR P17
P1
HOUR METER K9 NEUTRAL
P21
CENTER DECKS
P16 P20
K8 SEAT RIGHT DECK
SP8
SP1 SP3
SP4
SP7 SP6
SP9 SP5
P4
2WD/4WD SWITCH
P23
INTERCONNECT TO
MAIN HARNESS
A B
SP2
P5 P18
PTO SWITCH P22 DIODE 8
POWER POINT
2
P6
DIODE PACK P19
LEFT DECK
P3
GLOW CONTROLLER
1
3 J1
2 1 TEMPERATURE GAUGE
5 4
6
P2
TEMPERATURE GAUGE
3
1
Page 9 - 21
Rev. D
BLACK
BLACK
PINK
PINK BLACK
RED
BLUE BLACK WHITE
GND
GREEN
ORANGE
PINK SHIELDED CABLE
BROWN
BLACK TAN
PINK
PINK
BLUE BLUE
BLACK
BROWN
BLACK BLACK
BLUE
BLUE ORANGE
GRAY
ORANGE
VIOLET
GREEN
BLACK BLUE/WHITE
GREEN GREEN
BLACK
PINK
YELLOW YELLOW
ORANGE ORANGE
WHITE/BLACK GREEN
YELLOW
PINK
RED
TAN
GRAY
PINK
BLUE
ORANGE
WHITE YELLOW
BLACK
RED
RED
WHITE
PINK
PINK
RED/BLACK
VIOLET
VIOLET
GREEN
YELLOW
RED
BROWN
PINK
VIOLET
BLACK
PINK
YELLOW
ORANGE
GREEN
BLACK
WHITE
PINK
Page 9 - 22
Rev. D
Page 9 - 23
Rev. D
BROWN
PINK
BLACK
BLACK
PINK BLACK
RED
BROWN BLACK WHITE
GND
GREEN
ORANGE
PINK TAN SHIELDED CABLE
BLACK
PINK
BROWN
BROWN BROWN
BLACK
BLACK BLACK
BLUE
BROWN ORANGE
VIOLET
GRAY
ORANGE
GREEN
BLACK BLUE/WHITE
BLACK
PINK
GREEN GREEN
YELLOW YELLOW
ORANGE ORANGE
WHITE/BLACK GREEN
YELLOW
PINK
RED
TAN
GRAY
PINK
BLUE
ORANGE
WHITE YELLOW
BLACK
RED
RED
WHITE
VIOLET
PINK
RED/BLACK
PINK
VIOLET
YELLOW
RED
GREEN
BROWN
PINK
VIOLET
BLACK
PINK
YELLOW
BLACK
WHITE
GREEN
ORANGE
PINK
Page 9 - 24
Rev. D
Page 9 - 25
Rev. D
RUN SOLENOID
OIL PRESSURE
P1 OVER TEMPERATURE
HOLD PULL GROUND J5 J4
RED/BLACK
BLACK
BLUE/WHITE
WHITE FUSIBLE LINK P2 STARTER ”G”
WHITE
GREEN
INTERCONNECT P4
TO MAIN HARNESS
BLUE
GRAY
BLACK J3 GROUND
BLACK
ORANGE
INTERCONNECT P5
TO MAIN HARNESS BLACK
YELLOW
BLUE
R L
J2 J1 P7 J6
GLOW TEMPERATURE SENDER DIODE STARTER P6
ALTERNATOR
Engine Wire Harness
Page 9 - 26
Rev. D
P1
FUEL SOLENOID
J5
TEMPERATURE
SWITCH
B A
J2
GLOW PLUGS
SP2 P5
TO MAIN HARNESS
SP1
J1
TEMPERATURE P4
SENDER TO MAIN HARNESS
P2
STARTER ”G”
J4
OIL PRESSURE
J6
STARTER ”S”
P6
ALTERNATOR
2 1
P7
DIODE
J3
GROUND
Engine Wire Harness
Page 9 - 27
Rev. D
BLACK
BLUE/WHITE
RED/BLACK
WHITE FUSIBLE LINK
WHITE
GREEN
BLUE
GRAY
BLACK
ORANGE
BLACK
PINK
Engine Wire Harness
Page 9 - 28
Rev. D
Engine Wire Harness
Page 9 - 29
Rev. D
PINK
GREEN
YELLOW
VIOLET
PINK PINK
ORANGE
BLACK
BLACK
BLACK BLACK
BLACK
VIOLET
YELLOW
Deck 6 and 7 Wire Harness
Page 9 - 30
Rev. D

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Form No.

Original Instructions (EN)

© THE TORO COMPANY 2018

Technical Publication Manager, Commercial

The Toro Company reserves the right to change product

E The Toro Company - 2002, 2003, 2005, 2007, 2018

General Safety Instructions . . . . . . . . . . . . . . . . . . 1 -- 2 Electrical Schematics and Electrical Harness and

Groundsmaster 4500--D/4700--D Page 1 -- 1 Safety

The Toro Company A. Use an approved fuel container.

4. Do not touch engine, muffler or exhaust pipe while

Groundsmaster 4500--D/4700--D Page 1 -- 3 Safety

Jacking the Front End (Fig. 1)

1. Set parking brake and chock both rear tires to pre-

IMPORTANT: Do not place jack, jack stands, or

2. Position jack securely under the frame, just to the in-

Jacking the Rear End (Fig. 2)

1. Set parking brake and chock both front tires to pre-

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

Safety Page 1 -- 4 Groundsmaster 4500--D/4700--D

Groundsmaster 4500--D/4700--D Page 1 -- 5 Safety

Safety Page 1 -- 6 Groundsmaster 4500--D/4700--D

Product Records and Maintenance

Groundsmaster 4500--D/4700--D Page 2 -- 1 Product Records and Maintenance

Product Records and Maintenance Page 2 -- 2 Groundsmaster 4500--D/4700--D

Grade 1 Grade 5 Grade 8 Class 8.8 Class 10.9

Inch Series Bolts and Screws Metric Bolts and Screws

Groundsmaster 4500--D/4700--D Page 2 -- 3 Product Records and Maintenance

in--lb in--lb N--cm in--lb N--cm in--lb N--cm

# 6 -- 32 UNC 15 + 2 170 + 20 23 + 2 260 + 20

# 8 -- 32 UNC 29 + 3 330 + 30 41 + 4 460 + 45

# 10 -- 24 UNC 42 + 4 475 + 45 60 + 6 675 + 70

1/4 -- 20 UNC 48 + 7 53 + 7 599 + 79 100 + 10 1125 + 100 140 + 15 1580 + 170

ft--lb ft--lb N--m ft--lb N--m ft--lb N--m

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

Product Records and Maintenance Page 2 -- 4 Groundsmaster 4500--D/4700--D

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

Groundsmaster 4500--D/4700--D Page 2 -- 5 Product Records and Maintenance

Recommended Torque Thread Size Recommended Torque**

3/8 -- 16 UNC 35 + 10 ft--lb 18 + 3 ft--lb M12 X 1.25 80 + 10 ft--lb 108 + 14 N--m

** For steel wheels and non--lubricated fasteners.

Type 1, Type 23, or Type F Thread Threads per Inch

Product Records and Maintenance Page 2 -- 6 Groundsmaster 4500--D/4700--D

Kubota Diesel Engine

Groundsmaster 4500--D/4700--D Page 3 -- 1 Kubota Diesel Engine (Rev. A)

Kubota Diesel Engine (Rev. A) Page 3 -- 2 Groundsmaster 4500--D/4700--D

Make / Designation Kubota, 4--Cycle, 4 Cylinder,

Horse Power 58 HP (43.3 kW) @ 2600 RPM

Bore mm (in.) 83.0 (3.27)