Form No. 3358-752 Rev D Groundsmaster® 4500-D or 4700-D Traction Unit Model No. 30856—Serial No. 280000001 and Up Model No. 30856TE—Serial No. 280000001 and Up Model No. 30868—Serial No. 280000001 and Up Model No. 30868TE—Serial No. 280000001 and Up To register your product or download an Operator's Manual or Parts Catalog at no charge, go to www.Toro.com.
Warning CALIFORNIA Proposition 65 Warning Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm. Because in some areas there are local, state, or federal regulations requiring that a spark arrester be used on the engine of this machine, a spark arrester is incorporated with the muffler assembly. Figure 1 Genuine Toro spark arresters are approved by the USDA Forestry Service.
Contents Fuel Pick-up Tube Screen ................................... 36 Bleeding the Fuel System .................................... 36 Bleeding Air from the Injectors........................... 37 Electrical System Maintenance................................ 38 Charging and Connecting the Battery .................. 38 Battery Care ....................................................... 39 Fuses.................................................................. 39 Drive System Maintenance ................
Safety ◊ lack of awareness of the effect of ground conditions, especially slopes; • The owner/user can prevent and is responsible for accidents or injuries occurring to himself or herself, other people, or property. This machine meets or exceeds CEN standard EN 836:1997 (when appropriate decals applied), and ANSI B71.4-2004 specifications in effect at the time of production when equipped with required weights as listed in the weight chart.
• Remember there is no such thing as a safe slope. Travel on grass slopes requires particular care. To guard against overturning: – do not stop or start suddenly when going up or downhill; – machine speeds should be kept low on slopes and during tight turns; – stay alert for humps and hollows and other hidden hazards; – never mow across the face of the slope, unless the mower is designed for this purpose. – Use counterweight(s) or wheel weights when suggested in the operator’s manual.
• Clean grass and debris from cutting units, drives, silencers/mufflers, and engine to help prevent fires. Clean up oil or fuel spillage. • Wearing safety shoes and long pants is advisable and required by some local ordinances and insurance regulations. • Use jack stands to support components when required. • Handle fuel carefully. Wipe up any spills. • Check the safety interlock switches daily for proper operation. If a switch should fail, replace the switch before operating the machine.
Vibration Level Maintenance and Storage • Make sure all hydraulic line connectors are tight and all hydraulic hoses and lines are in good condition before applying pressure to the system. • Keep your body and hands away from pin hole leaks or nozzles that eject hydraulic fluid under high pressure. Use paper or cardboard, not your hands, to search for leaks. Hydraulic fluid escaping under pressure can have sufficient force to penetrate the skin and cause serious injury.
Safety and Instructional Decals Safety decals and instructions are easily visible to the operator and are located near any area of potential danger. Replace any decal that is damaged or lost. 108–5278 1. Read the Operator’s Manual. 105-3888 1. 2. 93-7275 1. 2. Read the Operator’s Manual. Do not use starting aids. 3. Read the Operator’s Manual. To lock the parking brake, secure the brake pedals with the locking pin, press the brake pedals, and pull out the parking brake knob.
105-9830 (Affix for CE) 1. Lock 2. Unlock 105-7506 1. 2. 3. Read the Operator’s Manual. Engine—stop On 4. Engine—preheat 5. Engine—start 93-6686 1. Hydraulic oil 2. Read the Operator’s Manual. Battery Symbols Some or all of these symbols are on your battery 93-6699 1. Machine speed 3. 2. Slow 4. Continuous variable setting Fast 1. Explosion hazard 2. No fire, open flame, or smoking. 3. Caustic liquid/chemical burn hazard Wear eye protection 4. 5. 106-6754 1. 2.
112-5297 1. 2. 3. 4. 5. 6. Warning—read the Operator’s Manual, do not operate this machine unless you are trained. Warning—read the Operator’s Manual before towing the machine.
108-4044 1. Lower the cutting unit(s). 2. Raise the cutting unit(s). 3. Right cutting unit (GM 4700-D only) 4. Center cutting units 5. Left cutting unit (GM 4700-D only) 6. Fast 7. Continuous variable setting 10. 11. 12. 13. 14. 15. 16. 8. Slow 17. 9. Engage Disengage Power Take-off (PTO) High Low Transmission Warning—read the Operator’s Manual.
105-9895 12
Setup Loose Parts Use the chart below to verify that all parts have been shipped. Procedure Description Qty. 1 1 Seat Kit, Model 30398 (sold separately) Seat Suspension Kit, Model 30312 (Mechanical) or 30313 (Air) (sold separately) Seat belt Capscrew, 7/16-20 x 1 inch Lockwasher, 7/16 inch Manual Tube R-clamp 1 2 2 1 2 Install the seat, seat belt, and manual tube. No parts required – Grease the machine.
Important: Make sure that the seat switch is connected to the seat switch connector on the harness. 4 3. Slide the seat completely forward and backward to ensure proper operation and that seat switch wires and connectors are not pinched or do no contact any moving parts.
Product Overview Figure 4 1. Steering wheel 2. Brakes 3. Cutting unit 4. Traction pedal 5. Manual tube 6. Hood/engine compartment 7. ROPS (Rollover Protection System) Controls Charge Indicator Traction Pedal The charge indicator (Figure 5) illuminates when the system charging circuit malfunctions. The traction pedal (Figure 5) controls forward and reverse operation. Depress the top of the pedal to move forward and the bottom to move backward. Ground speed depends on how far the pedal is depressed.
obtaining better side hill traction. A latch connects the pedals for parking brake operation and transport. Figure 7 1. 2. Brake pedals Pedal locking latch 3. Parking brake latch Figure 5 1. 2. Traction pedal Forward speed control 3. 4. Key switch Engine oil pressure warning light Pedal Locking Latch 5. Charge indicator 6. Engine coolant temperature warning light 7. Glow plug indicator light The pedal locking latch (Figure 7) connects the pedals together to engage the parking brake.
PTO Switch The PTO switch (Figure 8) has two positions: On (engage) and Off (disengage). Push the PTO switch forward to the On position to start the implement or cutting unit blades. Push the switch backward to the Off position to stop implement operation. Hi-Lo Speed Control The switch (Figure 8) allows the speed range to increase for transport of the machine. Cutting decks will not operate in high range. Figure 8 Model 4500-D 1. 2. 3. 4. Throttle control 5. 6. Lift lever Hour meter 7.
Figure 11 Model 4500-D 1. Cutting unit lift latch Figure 12 Model 4700-D 1.
Specifications Note: Specifications and design are subject to change without notice. Traction Unit Specifications 4500-D 4700-D Width of cut 109 inches (2.8 m) 150 inches (3.8 m) Overall width, cutting units down 112.8 inches (286 cm) 153.8 inches (391 cm) Overall width, cutting units up (transport) 88.25 inches (224 cm) 88.25 inches (224 cm) Overall length 145.8 inches (370 cm) 145.
Operation Note: Determine the left and right sides of the machine from the normal operating position. This machine produces sound levels in excess of 85 dBA at the operator’s ear and can cause hearing loss through extended periods of exposure. Figure 13 1. Wear hearing protection when operating this machine. Dipstick 4. If the oil is below the FULL mark, remove the fill cap (Figure 14) and add oil until the level reaches the FULL mark. Do not overfill.
flash point and cold flow characteristics which will ease starting and reduce fuel filter plugging. If the engine has been running, the pressurized, hot coolant can escape and cause burns. Use of summer grade fuel above 20° F (-7° C) will contribute toward longer fuel pump life and increased power compared to winter grade fuel. • Do not open the radiator cap when the engine is running. Important: Do not use kerosene or gasoline instead of diesel fuel.
In certain conditions, fuel is extremely flammable and highly explosive. A fire or explosion from fuel can burn you and others and can damage property. • Fill the fuel tank outdoors, in an open area, when the engine is cold. Wipe up any fuel that spills. • Never fill the fuel tank inside an enclosed trailer. • Never smoke when handling fuel, and stay away from an open flame or where fuel fumes may be ignited by a spark. Figure 16 1.
hydraulic fluid. Check the level of the hydraulic fluid before the engine is first started and daily thereafter. The recommended replacement fluid is as follows: Toro Premium All Season Hydraulic Fluid (Available in 5 gallon pails or 55 gallon drums. See parts catalog or Toro distributor for part numbers.) Alternate fluids: If the Toro fluid is not available, other fluids may be used provided they meet all the following material properties and industry specifications.
Refer to Bleeding the Fuel System in , page . 1. Move the throttle control backward to the Slow position. 2. Move the PTO lever to the Off position. 3. Set the parking brake. 4. Rotate the ignition key to Off. 5. Remove the key from the switch to prevent accidental starting. 1. Remove your foot from the traction pedal and ensure that it is in neutral. Ensure that the parking brake is set. 2. Move the throttle control to the low idle position. 3. Turn the ignition key to the Run position.
engine does not kill, there is a malfunction in the interlock system that should be corrected before beginning operation. Note: The safety interlock switches can also be checked using the diagnostic LED’s on the SCM. Pushing or Towing the Machine In an emergency, the machine can be moved forward by actuating the bypass valve in the variable displacement hydraulic pump and pushing or towing the machine. Do not push or tow the machine for more than 1/4 mile (0.4 km). Figure 18 1. Bypass valve 3.
Another characteristic to consider is the operation of the pedals that are connected to the brakes. The brakes can be used to assist in turning the machine. However, use them carefully, especially on soft or wet grass because the turf may be torn accidentally. Another benefit of the brakes is to maintain traction. For example, in some slope conditions, the uphill wheel slips and loses traction.
Figure 19 1. Input 2. Backlap 3. High temp shutdown 4. High temp warning (Not used) 5. In seat 6. PTO switch 7. Park brake off 8. Neutral 9. Output 10. PTO 11. Start 12. ETR Here are the logical troubleshooting steps for the SCM device. 13. Start 14. Power 5. If specific output LED is illuminated without appropriate output function, check output harness, connections, and component. Repair as required. 6. If specific output LED is not illuminated, check both fuses. 7.
device is not energized, measure available voltage at the output device, continuity of the disconnected device, and potential voltage on the ground circuit (floating ground). Repairs will vary depending on your findings. allowed to build up in the mower housing, cutting performance will decrease. Note: Lower cutting units to the ground whenever machine is parked. This relieves the hydraulic load from the system, prevents wear on system parts and also prevents accidental lowering of the cutting units.
Maintenance Note: Determine the left and right sides of the machine from the normal operating position. Recommended Maintenance Schedule(s) Maintenance Service Interval Maintenance Procedure After the first 8 hours • Torque the wheel nuts. After the first 50 hours • Change the engine oil and filter. After the first 200 hours • Change the planetary gear drive oil. • Change the rear axle lubricant. • Change the hydraulic filters. Before each use or daily • • • • • • • • Check the engine oil level.
Daily Maintenance Checklist Duplicate this page for routine use. Maintenance Check Item For the week of: Mon. Tues. Wed. Thurs. Fri. Sat. Check the safety interlock operation. Check the brake operation. Check the engine oil and fuel level. Check the cooling system fluid level. Drain the water/fuel separator. Check the air filter restriction indicator. Check the radiator, oil cooler, and screen for debris. Check unusual engine noises.1 Check unusual operating noises.
Service Interval Chart Figure 21 If you leave the key in the ignition switch, someone could accidently start the engine and seriously injure you or other bystanders. Remove the key from the ignition before you do any maintenance.
Premaintenance Procedures Lubrication Greasing the Bearings and Bushings Removing the Hood Service Interval: Every 50 hours To gain additional access to engine compartment, the hood may be removed from traction unit. The machine has grease fittings that must be lubricated regularly with No. 2 General Purpose Lithium Base Grease. If the machine is operated under normal conditions, lubricate all bearings and bushings after every 50 hours of operation or immediately after every washing. 1.
Figure 28 • Cutting unit carrier arm bushings (1 per cutting unit) (Figure 28) • Rear roller bearings (2 per cutting unit) (Figure 29 or Figure 30 ) Figure 26 1. Top fitting on king pin • Tie rod ball joints (2) (Figure 26) • King pin bushings (2) (Figure 26). The top fitting on the king pin should only be lubricated annually (2 pumps).
Engine Maintenance which could force dirt through the filter into the intake tract. Servicing the Air Cleaner This cleaning process prevents debris from migrating into the intake when the primary filter is removed. 3. Remove and replace the primary filter (Figure 33). Service Interval: Every 400 hours Cleaning of the used element is not recommended due to the possibility of damage to the filter media. Inspect the new filter for shipping damage, checking the sealing end of the filter and the body.
Adjusting the Throttle 5. Install the cover orienting the rubber outlet valve in a downward position—between approximately 5:00 to 7:00 when viewed from the end. 6. Reset the indicator (Figure 31) if it shows red. Adjust the throttle cable (Figure 37) so that the governor lever on the engine contacts the low and high speed set bolts before the throttle lever contacts the slot in the seat base.
Fuel System Maintenance 1. Place a clean container under the fuel filter. 2. Loosen the drain plug on the bottom of the filter canister. Under certain conditions, diesel fuel and fuel vapors are highly flammable and explosive. A fire or explosion from fuel can burn you and others and can cause property damage. • Use a funnel and fill the fuel tank outdoors, in an open area, when the engine is off and is cold. Wipe up any fuel that spills. • Do not fill the fuel tank completely full.
4. Tighten the pipe connector securely. 5. Repeat the procedure on the remaining nozzles. Figure 39 1. Fuel injection pump bleed screw 4. Turn the key in the ignition switch to the On position. The electric fuel pump will begin operation, thereby forcing air out around the air bleed screw. Leave the key in the On position for 15 seconds. Air and fuel will be internally drained back to fuel tank. Tighten the screw and turn the key to Off.
Electrical System Maintenance Charging the battery produces gasses that can explode. Charging and Connecting the Battery Never smoke near the battery and keep sparks and flames away from battery. 5. Install the positive cable (red) to the positive (+) terminal and the negative cable (black) to the negative (-) terminal of the battery (Figure 42). Secure cables to posts with capscrews and nuts.
Battery terminals or metal tools could short against metal components causing sparks. Sparks can cause the battery gasses to explode, resulting in personal injury. • When removing or installing the battery, do not allow the battery terminals to touch any metal parts of the machine. Figure 43 • Do not allow metal tools to short between the battery terminals and metal parts of the machine. Incorrect battery cable routing could damage the machine and cables causing sparks.
Drive System Maintenance Checking the Torque of the Wheel Nuts Service Interval: After the first 8 hours Every 200 hours Figure 44 Failure to maintain proper torque of the wheel nuts could result in failure or loss of wheel and may result in personal injury. 1. Check/drain plug 2. Remove the plug on the planetary (Figure 44). Oil should be at the bottom of the check plug hole on the back side of the brake. Torque the front and rear wheel nuts to 85-100 ft.-lb.
Checking the Rear Axle Lubricant Service Interval: Every 400 hours The rear axle is shipped from the factory filled with SAE 85W-140 wt. gear lube. Check the oil level before the engine is first started and every 400 hours thereafter. The capacity is 80 oz. (2.4 l). Visually inspect for leaks daily. 1. Position the machine on a level surface. 2. Remove a check plug from one end of the axle (Figure 47) and make sure that the lubricant is up to the bottom of the hole.
Figure 48 1. Drain plug location Figure 49 1. 3. Remove the (3) oil level check plugs and main axle vent cap to ease in draining of the oil. Pump rod 2. Pump control tube 5. After wheel rotation ceases, tighten jam nuts to secure adjustment. 6. Stop the engine and release the right brake. Remove jack stands and lower the machine to the shop floor. Test drive the machine to make sure it does not creep. 4. Remove the drain plugs and allow the oil to drain into the pans. 5. Install the plugs. 6.
Cooling System Maintenance 5. Rotate the entire tie rod assembly the same direction (inward or outward) one (1) complete revolution. Tighten clamp at connected end of tie rod. 6. Install the ball joint in the axle case support and tighten the nut finger tight. Measure toe-in. Servicing the Engine Cooling System 7. Repeat procedure if necessary. 8. Tighten the nut and install a new cotter pin when the adjustment is correct.
Brake Maintenance with compressed air. Start from the front and blow the debris out towards the back. Then clean from the back side and blow towards the front. Repeat procedure several times until all chaff and debris is removed. Adjusting the Service Brakes Adjust the service brakes when there is more than 1 in. (25 mm) of “free travel" of the brake pedal, or when the brakes do not work effectively. Free travel is the distance the brake pedal moves before braking resistance is felt. 1.
Belt Maintenance Hydraulic System Maintenance Servicing the Alternator Belt Service Interval: Every 100 hours Changing the Hydraulic Fluid Check the condition and tension of the belts (Figure 55) after every 100 operating hours. Service Interval: Every 800 hours Change the hydraulic fluid after every 800 operating hours, in normal conditions. If the fluid becomes contaminated, contact your local Toro distributor because the system must be flushed.
3. Lubricate the new filter gasket and fill the filter with hydraulic fluid. Hydraulic fluid escaping under pressure can penetrate skin and cause injury. • Make sure all hydraulic fluid hoses and lines are in good condition and all hydraulic connections and fittings are tight before applying pressure to the hydraulic system. • Keep your body and hands away from pin hole leaks or nozzles that eject high pressure hydraulic fluid. • Use cardboard or paper to find hydraulic leaks.
on operator platform. Used to measure the 4 wheel drive pressure applied to the rear axle (reverse mode) and rear axle dynamic braking. Figure 61 1. Test port F (Decks) 2. Test port G (Decks) Test Port H (Figure 62) located on rear traction circuit hard line. Used to measure reverse traction pressure. Test Port I (Figure 62) located on front traction circuit hard line. Used to measure forward traction pressure Figure 59 1. Test port B (Counter balance) 2.
The traction assist valve (Figure 63) is used to boost the pressure in the counterbalance circuit. Recommended traction assist counterbalance pressure is 700 psi when traction pressure is above 1800 psi. Rotate the screw (Figure 63) clockwise to increase the pressure or counterclockwise to decrease the pressure. Cleaning Important: Traction unit must be at operating temperature when adjusting hydraulic pressure.
Storage Traction Unit 1. Thoroughly clean the traction unit, cutting units, and the engine. 2. Check the tire pressure; refer to Checking the Tire Pressure. 3. Check all fasteners for looseness; tighten as necessary. 4. Grease or oil all grease fittings and pivot points. Wipe up any excess lubricant. 5. Lightly sand and use touch-up paint on painted areas that are scratched, chipped, or rusted. Repair any dents in the metal body. 6. Service the battery and cables as follows: A.
Schematics Electrical Schematic - GM 4500 (Rev.
Electrical Schematic - GM 4700 (Rev.
Hydraulic Schematic (Rev.
Hydraulic Schematic (Rev.
Notes: 54
Notes: 55
Toro General Commercial Products Warranty A Two-Year Limited Warranty Conditions and Products Covered The Toro Company and its affiliate, Toro Warranty Company, pursuant to an agreement between them, jointly warrant your Toro Commercial Product (“Product”) to be free from defects in materials or workmanship for two years or 1500 operational hours*, whichever occurs first. This warranty is applicable to all products with the exception of Aerators (refer to separate warranty statements for these products).
