Form No. 3385-815 Rev B Groundsmaster® 4500-D and 4700-D Rotary Mower Model No. 30857—Serial No. 314000001 and Up Model No. 30858—Serial No. 314000001 and Up Register at www.Toro.com.
This product complies with all relevant European directives; for details, please see the separate product specific Declaration of Conformity (DOC) sheet. in commercial applications. It is primarily designed for cutting grass on well-maintained lawns in parks, golf courses, sports fields, and on commercial grounds. It is not designed for cutting brush, mowing grass and other growth alongside highways, or for agricultural uses.
g000502 Figure 2 Safety-alert symbol This manual uses 2 words to highlight information. Important calls attention to special mechanical information and Note emphasizes general information worthy of special attention.
Contents Checking the Fuel Lines and Connections.................................................. 40 Servicing the Water Separator ......................... 40 Servicing the Fuel Pickup Tube Screen ............. 41 Bleeding Air from the Injectors .......................... 41 Electrical System Maintenance ........................... 42 Charging and Connecting the Battery ............... 42 Servicing the Battery......................................... 43 Servicing the Fuses ...............................
Preparation Safety • While mowing, always wear substantial footwear, long trousers, hard hat, safety glasses, and hearing protection. Long hair, loose clothing, or jewelry may get tangled in moving parts. Do not operate the equipment when barefoot or wearing open sandals. 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. Improper use or maintenance by the operator or owner can result in injury.
• Never operate the machine with damaged guards, • • and locked position and use the seat belt when operating the machine. shields, or without safety protective devices in place. Be sure all interlocks are attached, adjusted properly, and functioning properly. Do not change the engine governor settings or overspeed the engine. Operating the engine at excessive speed may increase the hazard of personal injury.
Hauling • If fuel is spilled on clothing, change clothing • immediately. Never overfill fuel tank. Replace fuel cap and tighten securely. • Use care when loading or unloading the machine • Maintenance and Storage • • Keep all nuts, bolts and screws tight to be sure the • • • • • • • • • • • • • • • • equipment is in safe working condition. Never store the equipment with fuel in the tank inside a building where fumes may reach an open flame or spark.
• If major repairs are ever needed or if assistance is • When operating a machine with ROPS (rollover • • • • • • desired, contact an Authorized Toro Distributor. protection system) never remove the ROPS and always use the seat belt. Raise the cutting units when driving from one work area to another. Do not touch the engine, silencer/muffler, or exhaust pipe while the engine is running or soon after it has stopped because these areas could be hot enough to cause burns.
Uncertainty Value (K) = 0.5 m/s2 Measured values were determined according to the procedures outlined in EN 836.
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. decal117-2385 117–2385 3. Engine—preheat 1. Read the Operators Manual. 2. Engine—start decal117-4763 117-4763 4. Engine—stop 2. To disengage the parking 1. To engage the parking brake, disengage the brake, secure the brake locking pin and release the pedals with the locking pin, pedals.
decal117-4766 117-4766 1. Cutting/dismemberment hazard; fan—stay away from moving parts, keep all guards and shields in place. decal117-4764 117-4764 1. Thrown object hazard—keep bystanders a safe distance from the machine. 2. Cutting hazard of hand, mower blade—stay away from moving parts, keep all guards and shields in place. decal106-6755 3. Cutting hazard of foot, mower blade—stay away from moving parts, keep all guards and shields in place. 106-6755 1. Engine coolant under pressure. 3.
decal112-5297 112-5297 1. Warning—read the Operator's Manual; do not operate the machine unless you are trained. 2. Warning—read the Operator's Manual before towing the machine. 3. Tipping hazard— turn at low speeds; do not turn at high speeds; lower the cutting unit when driving down slopes; use a roll over protection system and wear the seatbelt. 4.
decal104-1086 104-1086 1.
Setup Loose Parts Use the chart below to verify that all parts have been shipped. Procedure Description Use Qty. Used only on machines requiring European CE Compliance. 1 Warning decal 1 2 Lock bracket Rivet Washer Screw, 1/4 x 2 inches Locknut, 1/4 inch Throttle stop 1 2 1 1 1 1 Setscrew 1 This procedure applies only to machines requiring European CE Compliance when installing optional high-lift blades.
2. 1 Remove the 2 rivets securing the hood-latch bracket to the hood (Figure 3). Replacing the Warning Decal for CE Compliance Parts needed for this procedure: 1 Warning decal Procedure On machines requiring European CE Compliance, replace the warning decal, part no. 112–5297 with the warning decal part no. 112-5298. g012628 Figure 3 1. Hood-latch bracket 2 2. Rivets 3. Remove the hood-latch bracket from the hood. 4.
2. Slide the throttle stop onto the high-idle stop screw (Figure 7). Ensure that the chamfered end of the throttle stop is outward. g012630 Figure 5 1. Hood latch 8. Screw the bolt into the other arm of hood-lock bracket to lock the latch in position (Figure 6). g010522 Figure 7 1. Throttle stop Note: Tighten the bolt securely but do not 2. Setscrew tighten the nut. 3. Start the engine and allow it to run for 5 to 10 minutes. 4.
2. Loosen the bolt securing each height-of-cut bracket to the height-of-cut plate (front and each side) (Figure 8). 3. Beginning with front adjustment, remove the bolt. 5 Adjusting the Roller Scraper (Optional) No Parts Required Procedure The optional rear roller scraper is designed to work best when there is an even gap of 0.5 to 1 mm (0.020–0.040 inch) between the scraper and roller. 1. Loosen the grease fitting and the mounting screw (Figure 10). g011344 Figure 8 1. Height of cut bracket 3.
g011347 Figure 11 1. Mulching baffle 3. Verify that mulching baffle does not interfere with the tip of the blade and does not protrude inside the surface of the rear chamber wall. WARNING Do not use the high lift blade with the mulching baffle. The blade could break, resulting in personal injury or death. 7 Greasing the Machine No Parts Required Procedure Before the machine is operated, it must be greased to ensure proper lubrication. Refer to Lubrication (page 36).
Product Overview toward you to the most comfortable position and then release the pedal. Controls Speed Limiter Screws Brake Pedals Adjust the screw(s) (Figure 13) to limit the amount the traction pedal can be depressed in the forward or reverse direction to limit speed. Two foot pedals (Figure 12) operate individual wheel brakes for turning assistance and to aid in obtaining better side hill traction.
Note: The decks will not lower while in the high-speed range, and they will not raise or lower if the operator is out of the seat when the engine is running. engage the cutting unit blades. Push in the button to disengage the cutting unit blades. High-low Speed Control Throttle Control The switch (Figure 14) allows the speed range to increase for transport of the machine. The cutting decks will not operate in the high-speed range.
Engine-cooling-fan Switch adjustments by positioning the suspension within the range of the green region. The machine is equipped with a hydraulically driven auto-reversing engine-cooling fan. The fan switch (Figure 15) has 2 positions: R (manual reverse) and Auto (normal). Refer to Operating the Engine Cooling Fan (page 29). Bag Holder Use the bag holder (Figure 15) for storage. Hour Meter The hour meter (Figure 15) shows the total hours that the machine has been operated.
Specifications Note: Specifications and design are subject to change without notice. Traction Unit Specifications 4500-D 4700-D Width of cut 2.8 m (109 inches) 3.8 m (150 inches) Overall width, cutting units down 286 cm (112.8 inches) 391 cm (153.8 inches) Overall width, cutting units up (transport) 224 cm (88.25 inches) 224 cm (88.25 inches) Overall length 370 cm (145.8 inches) 370 cm (145.
Operation 1. Park the machine on a level surface. 2. Unlock the engine cover latches and open the engine cover. 3. Remove the dipstick, wipe it clean, install the dipstick into the tube, and pull it out again. Note: Determine the left and right sides of the machine from the normal operating position. CAUTION The oil level should be in the safe range (Figure 18).
Checking the Cooling System 4. Service Interval: Before each use or daily Check the coolant level at the beginning of each day. The capacity of the system is 12.3 L (13 US qt). 1. Carefully remove the radiator cap. CAUTION If the engine has been running, the pressurized, hot coolant can escape and cause burns. • Do not open the radiator cap when the engine is running. • Use a rag when opening the radiator cap, and open the cap slowly to allow steam to escape. g009702 Figure 20 1. Expansion tank 2.
Filling the Fuel Tank DANGER 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. • Use a funnel and 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. • Do not fill the fuel tank completely full.
High Viscosity Index/Low Pour Point Anti-wear Hydraulic Fluid, ISO VG 46 Material Properties: Viscosity, ASTM D445 cSt @ 40°C (104°F) 44 to 48 cSt @ 100°C (212°F) 7.9 to 9.
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. The glow indicator will light. 4. When the glow indicator dims, turn the ignition key to the Start position. Important: Do not run the starter motor more than 15 seconds at a time or premature starter failure may result.
Checking the Interlock Switches Important: Do not push or tow the machine faster than 3 to 4.8 km/h (2 to 3 mph), because internal transmission damage may occur. The bypass valve must be open whenever the machine is pushed or towed. Service Interval: Before each use or daily Important: If the machine must to be pushed CAUTION or towed in reverse, the check valve in the 4-wheel-drive manifold must also be bypassed.
Operating the Engine Cooling Fan Attributes: The engine cooling fan switch has 2 positions for controlling the operation of the fan. The 2 positions are R and Auto. The fan has the ability to reverse to blow debris off the rear screen. Under normal operating conditions, the switch should be in the Auto position. In Auto, the fan speed will be controlled by the coolant or hydraulic-oil temperature and will automatically reverse to blow debris off the rear screen.
Pros Even discharge at lower height of cut Cleaner look around bunkers and fairways Lower power requirements More lift and higher discharge velocity Sparse or limp turf is picked up at high height of cut Wet or sticky clippings are discharged efficiently May improve dispersion and appearance in certain grass cutting applications Very good for leaf mulching Cons Does not lift the grass well in high height of cut applications Wet or sticky grass has a tendency to build up in the chamber, leading to poor
Mowing at Proper Intervals Cleaning and Parking the Machine after Each Use Under most normal conditions you will need to mow approximately every 4 to 5 days. But remember, grass grows at different rates at different times. This means that in order to maintain the same height of cut, which is a good practice, you will need to cut more frequently in early spring; as the grass growth rate slows in midsummer, cut only every 8 to 10 days.
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.
Note: Looking for an Electrical Schematic or Hydraulic Schematic for your machine? Download a free copy of the schematic by visiting www.Toro.com and searching for your machine from the Manuals link on the home page.
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 decal117-4758 Figure 24 CAUTION 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.
Lubrication Pre-Maintenance Procedures Greasing the Bearings and Bushings Removing the Hood 1. Service Interval: Every 50 hours Release hood latches (Figure 25) and pivot open the hood. The machine has grease fittings that must be lubricated regularly with #2 general-purpose lithium-based 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.
• Steering-cylinder ball joints (2) (Figure 28) • Cutting-unit spindle-shaft bearings (2 per cutting unit) (Figure 30) Note: Either fitting can be used, which ever is more accessible. Pump grease into the fitting until a small amount appears at bottom of the spindle housing (under the deck). g009708 g009706 Figure 30 Figure 28 1.
Engine Maintenance Note: Before removing the filter, use low-pressure air (276 kPa [40 psi], clean and dry) to help remove large accumulations of debris packed between outside of primary filter and the canister. Avoid using high-pressure air which could force dirt through the filter into the intake tract. This cleaning process prevents debris from migrating into the intake when the primary filter is removed.
2. Remove the oil filter (Figure 37). Note: Apply a light coat of clean oil to the new filter seal before screwing it on. Do not overtighten the filter. g009712 Figure 35 1. Air-cleaner safety filter 5. Clean the dirt-ejection port located in the removable cover. 6. Remove the rubber outlet valve from the cover, clean the cavity, and install the outlet valve. 1. Engine oil filter 7.
Adjusting the Throttle Fuel System Maintenance Adjust the throttle cable (Figure 38) so that the governor lever on the engine contacts the high speed set bolt at the same point that the throttle cable contacts the end of the slot in the control arm. DANGER 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.
Drain water or other contaminants from water separator daily. Replace filter canister after every 400 hours of operation. 1. Place a clean container under the fuel filter (Figure 39). 2. Loosen the drain plug on the bottom of the filter canister. g010417 Figure 40 1. #1 injector nozzle g007367 2. Move the throttle to the Fast position. 3. Turn the key in the ignition switch to the Start position and watch the fuel flow around the connector. 4.
Electrical System Maintenance WARNING Charging the battery produces gasses that can explode. Never smoke near the battery and keep sparks and flames away from battery. Charging and Connecting the Battery 1. 5. Unlatch and raise the operator's console panel (Figure 41). Install the positive cable (red) to the positive (+) terminal and the negative cable (black) to the negative (-) terminal of the battery (Figure 42). Note: Secure the cables to the posts with cap screws and nuts.
8. Slide the rubber boot over the positive terminal. 9. Close the console panel and secure the latch. Servicing the Battery Service Interval: Every 50 hours Important: Before welding on the machine, WARNING disconnect the negative cable from the battery to prevent damage to the electrical system. Battery terminals or metal tools could short against metal components causing sparks. Sparks can cause the battery gasses to explode, resulting in personal injury.
Drive System Maintenance Checking for End-Play in the Planetary Drives Service Interval: Every 400 hours There should be no end-play in the planetary drives/drive wheels (i.e., the wheels should not move when you pull or push them in a direction parallel to the axle). 1. Park the machine on a level surface, engage the parking brake, lower the cutting units, shut off the engine, and remove the key. 2. Chock the rear wheels and raise the front of machine, supporting the front axle/frame on jack stands.
Checking the Torque of the Wheel Nuts 5. Repeat steps 1 through 4 on the opposite planetary gear assembly. Changing the Planetary Gear Drive Oil Service Interval: After the first 8 hours Every 200 hours Service Interval: After the first 200 hours Every 800 hours/Yearly (whichever comes first) WARNING Failure to maintain proper torque of the wheel nuts could result in wheel failure or loss of a wheel and may result in personal injury. Change the oil initially after first 200 hours of operation.
5. Rotate the wheel until the open plug hole in the planetary is at the twelve o'clock position. 6. Through the open hole, slowly fill the planetary with 0.65 L (22 fl oz) of high-quality SAE 85W-140 gear lube. Every 800 hours 1. Position the machine on a level surface. 2. Clean the area around the 3 drain plugs—1 on each end and 1 in the center (Figure 51). Important: If the planetary fills before the 0.
g009987 g009718 Figure 52 1. Pump-rod jam nuts Figure 54 2. Pump-control tube 1. Tie-rod clamp 2. Tie-rod ball joint 6. After wheel rotation ceases, tighten the jam nuts to secure the adjustment. 3. Remove the tie-rod ball joint from the axle-case support. 7. Stop the engine and release the right brake. 4. 8. Remove the jack stands and lower the machine to the shop floor. Loosen the clamps at both ends of the tie rods (Figure 54). 5.
Cooling System Maintenance Servicing the Engine Cooling System Service Interval: Before each use or daily Remove debris from the engine area, oil cooler and radiator daily. Clean them more frequently in dirty conditions. 1. Unlatch and swing open the rear screen (Figure 55). Clean the screen thoroughly of all debris. g009719 Figure 56 Note: To remove the screen, lift it off the hinge pins. 1. Oil-cooler latches 3. Pivot the oil cooler rearward.
Brake Maintenance Belt Maintenance Adjusting the Service Brakes Servicing the Alternator Belt Adjust the service brakes when there is more than 25 mm (1 inch) 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. Service Interval: Every 100 hours 1. 2. Check the condition and tension of the belts (Figure 59) after every 100 operating hours.
Hydraulic System Maintenance 2. 3. 4. Changing the Hydraulic Fluid Clean the area around the filter mounting area. Place a drain pan under the filter and remove the filter (Figure 60 and Figure 61). Lubricate the new filter gasket and fill the filter with hydraulic fluid. 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.
Checking the Hydraulic Lines and Hoses Service Interval: Before each use or daily Inspect the hydraulic lines and hoses daily for leaks, kinked lines, loose mounting supports, wear, loose fittings, weather deterioration, and chemical deterioration. Make all necessary repairs before operating. WARNING Hydraulic fluid escaping under pressure can penetrate skin and cause injury.
8. When the desired setting is attained, rotate the key to the Off position. 9. Unplug the jumper wires, install the cap on the wires and put the wires back into the compartment. 10. Cutting Deck Maintenance Separating the Cutting Decks from the Traction Unit Install the access cover. Note: The machine cannot be operated while in the counterbalance adjustment mode. Once the adjustment has been completed, move the machine to a test area and operate the machine with the new setting.
Mounting the Cutting Decks to the Traction Unit 1. Position machine on a level surface and shut engine off. 2. Move cutting deck into position in front of traction unit. 3. Slide deck carrier frame onto lift arm pivot pin. Secure with lynch pin or retaining nut (GM 4700 only) (Figure 65). 4. Install the hydraulic motor to the deck (Figure 64). Make sure that the O-ring is in position and not damaged. 5. Grease the spindle. g011353 Figure 66 Servicing the Blade Plane 5.
3. Install the height-of-cut bracket to the deck frame with the remaining shims assembled below the height-of-cut bracket. 4. Secure the socket head bolt/spacer and flange nut. Note: Socket head bolt/spacer are held together with Loctite to prevent the spacer from falling inside the deck frame. 5. Verify the 12 o’clock height and adjust if needed. 6. Determine if only one or both (right-hand and left-hand) height-of-cut brackets need to be adjusted. If the 3 or 9 o’clock side is 3.8±2.2 mm (0.150±0.
5. DANGER If the blade is allowed to wear, a slot will form between the sail and flat part of the blade (Figure 69). Eventually a piece of the blade may break off and be thrown from under the housing, possibly resulting in serious injury to yourself or bystanders. • Inspect the blade periodically for wear or damage. • Always replace a worn or damaged blade. Install the blade, sail facing toward cutting deck, with the anti-scalp cup and blade bolt. Tighten the blade bolt to 115–149 N-m (85–110 ft-lb).
4. Cleaning Inspect the roller housing, bearings, and bearing spacer for damage (Figure 71). Replace damaged components and assemble. Servicing the Spark Arrester Muffler Assembling the Front Roller 1. Press the first bearing into the roller housing (Figure 71). Press on the outer race only or equally on the inner and outer race. 2. Insert the spacer (Figure 71). 3. Press the second bearing into the roller housing (Figure 71).
Storage antifreeze as needed for the expected minimum temperature in your area. Preparing the Traction Unit 1. 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.
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The Toro Total Coverage Guarantee A 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).
