Form No. 3434-126 Rev B Groundsmaster® 4500-D or 4700-D Traction Unit Model No. 30857—Serial No. 310000001 and Up Model No. 30858—Serial No. 310000001 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. injury and product damage. You are responsible for operating the product properly and safely. You may contact Toro directly at www.Toro.com for product and accessory information, help finding a dealer, or to register your product.
Contents Battery Care ..................................................... 36 Fuses................................................................ 36 Drive System Maintenance .................................. 37 Checking the Torque of the Wheel Nuts .............................................................. 37 Checking for End Play in the Planetary Drives............................................................ 37 Checking the Planetary Gear Drive Oil .............................................
Safety ◊ lack of awareness of the effect of ground conditions, especially slopes; 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. • The owner/user can prevent and is responsible Improper use or maintenance by the operator or owner can result in injury.
• Look behind and down before backing up to be • Do not put hands or feet near or under rotating • • • • • • • parts. Keep clear of the discharge opening at all times. Remember there is no such thing as a safe slope. Travel on grass slopes requires particular care.
• Use care when checking the blades. Wear gloves • • • and use caution when servicing them. Keep hands and feet away from moving parts. If possible, do not make adjustments with the engine running. Charge batteries in an open well ventilated area, away from spark and flames. Unplug charger before connecting or disconnecting from battery. Wear protective clothing and use insulated tools.
• To ensure safety and accuracy, have an Authorized Measured values were determined according to the procedures outlined in EN 836. Toro Distributor check the maximum engine speed with a tachometer. Whole Body • If major repairs are ever needed or if assistance is Measured vibration level = .46 m/s2 desired, contact an Authorized Toro Distributor. • Use only Toro-approved attachments and Uncertainty Value (K) = 0.5 m/s2 replacement parts.
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. decal106-6754 106-6754 1. Warning—do not touch the hot surface. 2. Cutting/dismemberment hazard, fan; entanglement hazard, belt—stay away from moving parts. decal106-6755 106-6755 1. Engine coolant under pressure. 3. Warning—do not touch the hot surface. 2. Explosion hazard—read the Operator's Manual. 4. Warning—read the Operator's Manual. decal112-5297 112-5297 1.
decalbatterysymbols Battery Symbols Some or all of these symbols are on your battery. decal112-5298 112-5298 1. Warning—read the Operator's Manual, do not operate this machine unless you are trained. 2. Warning—read the Operator's Manual before towing the machine. 3. Tipping hazard—do not operate on slopes greater than 15°; lower the cutting units when operating on slopes; wear the safety belt. 4.
decal117-4758 117-4758 11
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 Hood lock bracket Rivets Screw (1/4 x 1–1/2 inch) Flatwasher 1/4 inch) Locknut (1/4 inch) Throttle stop 1 2 1 1 1 1 Set screw 1 Used only on machines requiring European CE Compliance when installing optional high lift blades. No parts required – Grease the machine.
1 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. g009984 Figure 3 1. Hood latch 2 2. Remove the (2) rivets securing the hood latch bracket to the hood (Figure 4). Remove the hood latch bracket from the hood.
3 4 Installing the Throttle Stop Greasing the Machine for CE Compliance when No Parts Required Installing Optional High Lift Blades Procedure Before the machine is operated, it must be greased to ensure proper lubrication. Refer to Lubrication section. Failure to properly grease the machine will result in premature failure of critical parts. Parts needed for this procedure: 1 Throttle stop 1 Set screw 5 Procedure 1. Loosen the set screw on the throttle stop (Figure 5). 2.
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 7) to limit the amount the traction pedal can be depressed in the forward or reverse direction to limit speed. Two foot pedals (Figure 6) 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 HI 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. Hi-Lo Speed Control Throttle Control The switch (Figure 8) allows the speed range to increase for transport of the machine. Cutting decks will not operate in high range.
Engine Cooling Fan Switch 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 9) has two positions R (manual reverse) and Auto (normal) . Refer to Engine Cooling Fan Operation in the Operation Section of manual. Bag Holder Use the bag holder (Figure 9) for storage. Hour Meter The hour meter (Figure 9) 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 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 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 12).
Filling the Fuel Tank Checking the Cooling System Use only clean, fresh diesel fuel or biodiesel fuels with low (<500 ppm) or ultra low (<15 ppm) sulfur content. The minimum cetane rating should be 40. Purchase fuel in quantities that can be used within 180 days to ensure fuel freshness. Service Interval: Before each use or daily Check level of coolant at the beginning of each day. Capacity of system is 13 qt. (12.3 l). 1. Fuel tank capacity: 22 gallons (83 l). Carefully remove the radiator cap.
DANGER 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. Add fuel to the fuel tank until the level is 1 in. (25 mm) below the top of the tank, not the filler neck.
5. Industry Specifications: Vickers I-286-S (Quality Level), Vickers M-2950-S (Quality Level), Denison HF-0 Install the dipstick and cap onto the filler neck. Checking the Tire Pressure Note: Many hydraulic fluids are almost colorless, making it difficult to spot leaks. A red dye additive for the hydraulic system oil is available in 2/3 oz. (20 ml) bottles. One bottle is sufficient for 4-6 gal (15-22 1) of hydraulic oil. Order part no. 44-2500 from your authorized Toro distributor.
Stopping the Engine not crank. If the engine cranks, there is a malfunction in the interlock system that should be corrected before beginning operation. Important: Allow engine to idle for 5 minutes before shutting it off after a full load operation. This allows the turbo charger to cool down before shutting the engine off. Failure to do so may lead to turbo-charger trouble. Note: Lower cutting units to the ground whenever machine is parked.
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.
a certain point. By pressing the fan switch forward into the R position, the fan will complete a manually initiated reverse cycle. It is recommended to reverse the fan when the rear screen is clogged or prior to entering the shop or the storage area. allowed to build up in the mower housing, cutting performance will decline. Note: Lower cutting units to the ground whenever machine is parked.
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.
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 18 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 19) and pivot open the hood. 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.
• Steering cylinder ball joints (2) (Figure 22) • Cutting unit spindle shaft bearings (1 per cutting unit) (Figure 24) g009708 Figure 24 • Cutting unit carrier arm bushings (1 per cutting unit) (Figure 24) g009706 Figure 22 • Rear roller bearings (2 per cutting unit) (Figure 25 ) 1. Top fitting on king pin • Tie rod ball joints (2) (Figure 22) • King pin bushings (2) (Figure 22). The top fitting on the king pin should only be lubricated annually (2 pumps).
Engine Maintenance air (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. Servicing the Air Cleaner Service Interval: Every 400 hours This cleaning process prevents debris from migrating into the intake when the primary filter is removed. Check the air cleaner body for damage which could cause an air leak. Replace if damaged.
g009713 Figure 30 1. Engine oil drain plug g009712 Figure 29 2. 1. Air cleaner safety filter 4. Clean the dirt ejection port located in the removable cover. Remove the rubber outlet valve from the cover, clean the cavity and replace the outlet valve. 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 26) if it shows red. Remove the oil filter (Figure 31).
Adjusting the Throttle Fuel System Maintenance Adjust the throttle cable (Figure 32) 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 33). 2. Loosen the drain plug on the bottom of the filter canister. g010417 Figure 34 1. No. 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.
Electrical System Maintenance DANGER Battery electrolyte contains sulfuric acid which is a deadly poison and causes severe burns. Charging and Connecting the Battery • Do not drink electrolyte and avoid contact with skin, eyes or clothing. Wear safety glasses to shield your eyes and rubber gloves to protect your hands. WARNING • Fill the battery where clean water is always available for flushing the skin.
WARNING Incorrect battery cable routing could damage the machine and cables causing sparks. Sparks can cause the battery gasses to explode, resulting in personal injury. • Always disconnect the negative (black) battery cable before disconnecting the positive (red) cable. • Always connect the positive (red) battery cable before connecting the negative (black) cable. g009986 Battery Care Figure 36 1. Positive battery cable 2.
Drive System Maintenance Unhook latch and raise operator's console panel (Figure 38) to expose the fuses (Figure 39). Checking the Torque of the Wheel Nuts Service Interval: After the first 8 hours Every 200 hours WARNING Failure to maintain proper torque of the wheel nuts could result in failure or loss of wheel and may result in personal injury. Torque the front and rear wheel nuts to 85-100 ft.-lb. (115-136 N·m) after 1-4 hours of operation and again after 8 hours of operation.
3. Grasp 1 of the front drive wheels and push/pull it toward and away from the machine, noting any movement. 4. Repeat steps 1–3 on the opposite gear assembly. Changing the Planetary Gear Drive Oil Service Interval: After the first 200 hours Every 800 hours Yearly Change the oil initially after first 200 hours of operation. Thereafter change the oil every 800 hours, or yearly, whichever occurs first. Use a high quality SAE 85W-140 wt. gear lube. g028798 Figure 40 1. Front drive wheels 1. 4.
Every 800 hours 4. Remove check/drain plugs from the brake housing and allow the oil to drain. 5. When all of the oil has drained, install the bottom plug in the brake housing. 6. Position the wheel so that the plug hole is at the 3 or 9 o'clock position on the planetary. 7. Slowly add approximately 16 oz. (0.5 l) of high quality SAE 85W-140 wt. gear lube to the planetary fill hole (at the ten or two o'clock position) until the level is up to the bottom of the brake housing check hole.
g009987 g009718 Figure 46 1. Pump rod jam nuts Figure 48 2. Pump control tube 1. Tie rod clamp 2. Tie rod ball joint 5. After wheel rotation ceases, tighten jam nuts to secure adjustment. 3. Loosen the clamps at both ends of the tie rods (Figure 48). 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. Rotate the detached ball joint inward or outward one (1) complete revolution.
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 rear screen (Figure 49). Clean the screen thoroughly of all debris. g009719 Figure 50 Note: To remove screen, lift off 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 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. Service Interval: Every 100 hours 1. 2. Check the condition and tension of the belts (Figure 53) after every 100 operating hours.
Hydraulic System Maintenance 3. Lubricate the new filter gasket and fill the filter with hydraulic fluid. Changing the 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. Contaminated fluid looks milky or black when compared to clean oil. 1. Turn the engine off and raise the hood. 2.
Checking the Hydraulic Lines and Hoses Cleaning Servicing the Spark Arrestor Muffler 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. Service Interval: Every 200 hours Every 200 hours operation, clear the muffler of carbon buildup. 1.
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: 7. A.
Schematics g009991 Hydraulic Schematic-Groundsmaster 4700 (Rev.
g009990 Hydraulic Schematic-Groundsmaster 4500 (Rev.
g009992 Electrical Schematic (Rev.
g009993 Electrical Schematic (Rev.
g009994 Electrical Schematic (Rev.
g009995 Electrical Schematic (Rev.
