Form No. 3385-829 Rev A Groundsmaster® 4500-D and 4700-D Rotary Mower Model No. 30857N—Serial No. 314000001 and Up Model No. 30858N—Serial No. 314000001 and Up Register at www.Toro.com.
Whenever you need service, genuine Toro parts, or additional information, contact an Authorized Service Dealer or Toro Customer Service and have the model and serial numbers of your product ready. Figure 1 identifies the location of the model and serial numbers on the right front frame member of the product. Write the numbers in the space provided.
Contents Changing the Planetary Gear Drive Oil ......................37 Checking the Rear Axle Lubricant .............................38 Changing the Rear Axle Lubricant.............................38 Adjusting the Traction Drive for Neutral....................38 Checking the Rear Wheel Toe-in ...............................39 Cooling System Maintenance ......................................40 Servicing the Engine Cooling System ........................40 Brake Maintenance .................................
Safety • Thoroughly inspect the area where the equipment is to be used and remove all objects which may be thrown by the machine. Improper use or maintenance by the operator or owner can result in injury. To reduce the potential for injury, comply with these safety instructions and always pay attention to the safety alert symbol, which means Caution, Warning, or Danger—personal safety instruction. Failure to comply with the instruction may result in personal injury or death.
• Do not remove the ROPS. • Any alterations to a ROPS must be approved by the – stop the engine and remove the key. • • • • • • • • • • Important: Allow the engine to idle for 5 minutes before shutting it off after a full-load operation. Failure to do so may lead to turbocharger trouble. Stop the engine in the following conditions: – before fuelling; – before making height adjustment.
• Wearing safety shoes and long pants is advisable and for all movement to stop before adjusting, cleaning, or repairing. required by some local ordinances and insurance regulations. • Clean grass and debris from cutting units, drives, • Handle fuel carefully. Wipe up any spills. • Check the safety interlock switches daily for proper silencers/mufflers, and engine to help prevent fires. Clean up oil or fuel spillage. • Use jack stands to support components when required.
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. Seek immediate medical attention if fluid is injected into skin. • Before disconnecting or performing any work on the hydraulic system, all pressure in the system must be relieved by stopping the engine and lowering the cutting units and attachments to the ground. • Check all fuel lines for tightness and wear on a regular basis.
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. 117–2385 3. Engine—preheat 1. Read the Operator’s Manual. 2. Engine—start 117-4763 4. Engine—stop 1. To engage the parking 2. To disengage the parking brake, secure the brake brake, disengage the pedals with the locking pin, locking pin and release the press the parking brake pedals.
117-4766 93-7818 1. Cutting/dismemberment hazard; fan—stay away from moving parts. 1. Warning—read the Operator's Manual for instructions on torquing the blade bolt/nut to 115-149 N-m (85-110 ft-lb). 106-6754 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. 1. Warning—do not touch the hot surface. 2.
117–2718 117-4761 1. Starter, 20A 2. Work light, 10A 6. GM4500 controller, 2A 7. Power supplied, 7.5A 3. Seat, 10A 4. Power point, 10A 8. GM4700 controller, 2A 9. Engine preheat, 60A 5. Gauges, 10A Battery Symbols Some or all of these symbols are on your battery 1. Explosion hazard 6. Keep bystanders a safe distance from the battery. 2. No fire, open flame, or smoking. 7. Wear eye protection; explosive gases can cause blindness and other injuries 3. Caustic liquid/chemical burn hazard 4.
104-1086 1.
Setup Media and Additional Parts Description Use Qty. Operator's Manual 1 Read before operating machine Engine Operator's Manual 1 Read before operating engine Parts Catalog 1 Use to reference part numbers Operator Training Material 1 View before operating machine Note: Determine the left and right sides of the machine from the normal operating position. Adjusting the Height-of-Cut 5.
Greasing the Machine 1 Before the machine is operated, it must be greased to ensure proper lubrication. Failure to properly grease the machine will result in premature failure of critical parts. 2 3 Checking Fluid Levels G011346 Figure 5 1. Roller scraper 1. Check the rear-axle lubricant level before the engine is first started, refer to Checking the Rear Axle Lubricant. 3. Grease fitting 2. Mounting screw 2.
Speed-limiter Screws Product Overview Controls Adjust the screw(s) (Figure 8) to limit the extent to which you can press the traction pedal in the forward or reverse direction to limit speed. Brake Pedals Important: The speed-limiter screw must stop the traction pedal before the pump reaches full stroke, or damage to the pump may occur. 2 foot pedals (Figure 7) operate individual wheel brakes for turning assistance and to aid in obtaining better side-hill traction.
Light Switch the high range. Also, the decks cannot be lowered from the transport position when the switch is in the high range. Press the lower edge of the switch (Figure 9) to turn on the lights. Press the upper edge of the switch to turn off the lights. Glow-plug Indicator Light When lit, the glow-plug indicator light (Figure 9) indicates that the glow plugs are on. Coolant-temperature Warning Light The light (Figure 9) illuminates and the cutting units shut down (PTO disengages).
Fuel Gauge 5 4 The fuel gauge (Figure 11) indicates the level of fuel in the tank. 3 2 1 Figure 11 G024916 1. Fuel gauge Figure 12 Seat Adjustments 1. Weight-adjusting lever 4. Seat-back adjusting lever 2. Weight gauge 5. Armrest adjusting knob 3. Fore and aft adjusting lever Fore and Aft Adjusting Lever Pull out on the lever to slide the seat fore or aft (Figure 12). Weight-adjusting Lever Seat Armrest Adjusting Knob Adjust for operator weight (Figure 12).
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 The oil level should be in the safe range (Figure 13). Note: Determine the left and right sides of the machine from the normal operating position. CAUTION 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. Wear hearing protection when operating this machine.
Checking the Cooling System Filling the Fuel Tank Service Interval: Before each use or daily 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. 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.
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. In certain conditions during fueling, static electricity can be released, causing a spark which can ignite the fuel vapors. 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.
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.
Checking the Interlock Switches 2. Move the throttle control to the low idle position. 3. Turn the ignition key to the Run position. The glow indicator will light. Service Interval: Before each use or daily 4. When the glow indicator dims, turn the ignition key to the Start position. CAUTION Important: Do not run the starter motor more than 15 seconds at a time or premature starter failure may result.
Important: If the machine must to be pushed or towed in reverse, the check valve in the 4-wheel-drive manifold must also be bypassed. To bypass the check valve, connect a hose assembly (hose part 95-8843, coupler fitting 95-0985 [qty 2], and hydraulic fitting 340-77 [qty 2]) to the reverse traction pressure test port and the reverse 4-wheel-drive pressure port. and will automatically reverse to blow debris off the rear screen.
Choosing Accessories Optional Equipment Configurations Angle Sail Blade High Lift Parallel Sail Blade (Do not use with the mulching baffle) Mulching Baffle Roller Scraper Grass Cutting: 1.9 to 4.4 cm (0.75 to 1.75 inch) Height-of-Cut Recommended in most applications May work well in light or sparse turf Grass Cutting: 5 to 6.4 cm (2.00 to 2.50 inch) Height-of-Cut Recommended for thick or lush turf Recommended for light or sparse turf Grass Cutting: 7 to 10 cm (2.75 to 4.
Adjusting the Counterbalance WARNING The counterbalance system maintains hydraulic back pressure on the deck lift cylinders. This counterbalance pressure transfers cutting deck weight to the mower's drive wheels to improve traction. The counterbalance pressure has been factory set to an optimal balance of after-cut appearance and traction capability in most turf conditions. Decreasing the counterbalance setting can produce a more stable cutting deck, but can decrease the traction capability.
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. 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. Check the hydraulic system oil level.
Service Interval Chart Figure 19 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 Premaintenance Procedures Greasing the Bearings and Bushings Removing the Hood Service Interval: Every 50 hours 1. Release hood latches (Figure 20) 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.
• Cutting-unit spindle-shaft bearings (2 per cutting unit) • Steering-cylinder ball joints (2) (Figure 23) (Figure 25) 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). Figure 25 Figure 23 1.
Engine Maintenance 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. Servicing the Air Cleaner Service Interval: Every 400 hours Check the air-cleaner body for damage which could cause an air leak. Replace it if it is damaged.
2. Remove the oil filter (Figure 32). Note: Apply a light coat of clean oil to the new filter seal before screwing it on. Do not overtighten the filter. Figure 30 1. Air-cleaner safety filter 5. Clean the dirt-ejection port located in the removable cover. Figure 32 6. Remove the rubber outlet valve from the cover, clean the cavity, and install the outlet valve. 1. Engine oil filter 7.
Servicing the Water Separator Fuel System Maintenance Service Interval: Before each use or daily—Drain water or other contaminants from the fuel filter/water separator. DANGER Every 400 hours—Replace the fuel-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. Drain water or other contaminants from water separator daily.
Bleeding Air from the Injectors Electrical System Maintenance Note: This procedure should be used only if the fuel system has been purged of air through normal priming procedures and the engine will not start. Charging and Connecting the Battery 1. Loosen the pipe connection to the #1 injector nozzle and holder assembly at the injection pump (Figure 35).
2. Connect a 3 to 4 ampere battery charger to the battery posts. 3. Charge the battery at a rate of 3 to 4 amperes for 4 to 8 hours. 4. When the battery is charged, disconnect the charger from the electrical outlet and battery posts. 7. Coat both battery connections with Grafo 112X (skin-over) grease, Toro part 505-47, petroleum jelly, or light grease to prevent corrosion. 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, disconnect the negative cable from the battery to prevent damage to the electrical system. Note: Check the battery condition weekly or after every 50 hours of operation. Keep the terminals and the entire battery case clean because a dirty battery will discharge slowly. To clean the battery, remove it from the machine and wash the entire case with a solution of baking soda and water. Rinse it with clear water.
Drive System Maintenance 5. Repeat steps 1 through 4 on the opposite planetary gear assembly. Changing the Planetary Gear Drive Oil Checking the Torque of the Wheel Nuts Service Interval: After the first 200 hours Service Interval: After the first 8 hours Every 200 hours Every 800 hours/Yearly (whichever comes first) Change the oil initially after first 200 hours of operation. Thereafter, change the oil every 800 hours, or yearly, whichever occurs first.
Changing the Rear Axle Lubricant 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. Service Interval: After the first 200 hours Every 800 hours Important: If the planetary fills before the 0.65 L (22 fl oz) of oil is added, wait one hour or install the plug and move the machine approximately 10 feet to distribute the oil through the brake system.
Figure 46 1. Pump-rod jam nuts Figure 48 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. Loosen the clamps at both ends of the tie rods (Figure 48). 8. Remove the jack stands and lower the machine to the shop floor. 5. Rotate the detached ball joint inward or outward 1 complete revolution. 9.
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 49). Clean the screen thoroughly of all debris. Note: To remove the screen, lift it off the hinge pins. Figure 50 1. Oil-cooler latches 3. Pivot the oil cooler rearward. Note: Start from the front and blow the debris out toward the back.
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 Check the condition and tension of the belts (Figure 53) after every 100 operating hours. 1.
Hydraulic System Maintenance 4. 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 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.
Cutting Deck Maintenance 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. The new counterbalanced setting may change the effective height of cut. Separating the Cutting Decks from the Traction Unit 1. Position the machine on a level surface, lower the cutting decks to the floor, shut the engine off, and engage the parking brake. 2.
Mounting the Cutting Decks to the Traction Unit 6. Compare the 12 o’clock measured height to the height-of-cut setting. It should be within 0.7 mm (0.030 inch). The 3 and 9 o’clock heights should be 3.8±2.2 mm (0.150±.090 inch) higher than the 12 o’clock setting and within 2.2 mm (0.090 inch) of each other. 1. Position machine on a level surface and shut engine off. 2. Move cutting deck into position in front of traction unit.
Servicing the Cutter Blade machine. If wear is noticed (Figure 63), replace the blade; refer to Removing the Cutter Blade. Removing the Cutter Blade DANGER The blade must be replaced if a solid object is hit, the blade is out of balance, or if the blade is bent. Always use genuine Toro replacement blades to be sure of safety and optimum performance. Never use replacement blades made by other manufacturers because they could be dangerous. 1.
Assembling the Front Roller 5. 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). 1. Press the first bearing into the roller housing (Figure 65). Press on the outer race only or equally on the inner and outer race. Checking the Blade Stopping Time 2. Insert the spacer (Figure 65). Service Interval: Before each use or daily 3.
Cleaning Storage Servicing the Spark Arrester Muffler Preparing the Traction Unit 1. Thoroughly clean the traction unit, the cutting units, and the engine. 2. Check the tire pressure; refer to Checking the Tire Pressure (page 21). 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.
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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).
