Form No. 3356-331 Rev E Groundsmaster® 4500-D or 4700-D Traction Unit Model No. 30856—Serial No. 260000801 and Up Model No. 30868—Serial No. 260000801 and Up Register at 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 Water Separator ................................................. 35 Replacing the Fuel Pre-Filter............................... 35 Fuel Pick-up Tube Screen ................................... 36 Bleeding the Fuel System .................................... 36 Bleeding Air from the Injectors........................... 36 Electrical System Maintenance................................ 37 Charging and Connecting the Battery .................. 37 Battery Care ..........................................
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.
• On multi-spindle mowers, take care as rotating one blade can cause other blades to rotate. Engine exhaust contains carbon monoxide, which is an odorless, deadly poison that can kill you. • Disengage drives, lower the cutting units, set parking brake, stop engine and remove key and disconnect spark plug wire (gas engine only). Wait for all movement to stop before adjusting, cleaning or repairing. Do not run engine indoors or in an enclosed area.
• If the machine stalls when climbing a slope, do not turn the machine around. Always back slowly, straight down the slope. Sound Pressure Level for a 4700-D • When a person or pet appears unexpectedly in or near the mowing area, stop mowing. Careless operation, combined with terrain angles, ricochets, or improperly positioned guards can lead to thrown object injuries. Do not resume mowing until the area is cleared.
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. Read the Operator’s Manual. 2. To lock the parking brake, secure the brake pedals with the locking pin, press the brake pedals, and pull out the parking brake knob. 3. To unlock the parking brake, press the brake pedal. 93-7275 1. Read the Operator’s Manual. 2.
105-7506 1. Read the Operator’s Manual. 2. Engine—stop 3. On 4. Engine—preheat 105-9223 5. Engine—start 1. Warning-read the Operator’s Manual. 2. To start the engine (read the Operator’s Manual), sit in the operators’ position, turn the ignition key to the Engine-run position until the Engine-preheat light turns off, turn the ignition key to the Engine-start position, and press the brake pedal. 3.
5-3889 107-1983 (Affix over part no. 105–3889 for CE) * This safety decal includes a slope warning required on the machine for compliance to the European Lawn Mower Safety Standard EN836:1997. The conservative maximum slope angles indicated for operation of this machine are prescribed by and required by this standard. 1. 2. 3. 4. 5. Warning—read the Operator’s Manual. Warning—lock the parking brake, stop the engine, and remove the ignition key before leaving the machine.
108-4044 1. 2. 3. 4. 5. Lower the cutting unit(s). Raise the cutting unit(s). Right cutting unit (GM 4700-D only) Center cutting units Left cutting unit (GM 4700-D only) 6. 7. 8. 9. 10. Fast Continuous variable setting Slow Engage Disengage 11. 12. 13. 14. Power Take-off (PTO) High Low Transmission 106–9290 1. 2. 3. 4. Input Backlap High temp shutdown High temp warning (not used) 5. 6. 7. 8. In seat PTO switch Park brake off Neutral 9. 10. 11. 12. 11 Output PTO Start ETR 13. Start 14.
Battery Symbols Some or all of these symbols are on your battery 1. Explosion hazard 2. No fire, open flame, or smoking. 3. Caustic liquid/chemical burn hazard 4. Wear eye protection 5. Read the Operator’s Manual. 6. Keep bystanders a safe distance from the battery. 7. Wear eye protection; explosive gases can cause blindness and other injuries 8. Battery acid can cause blindness or severe burns. 9. Flush eyes immediately with water and get medical help fast. 10. Contains lead; do not discard.
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 Warning Decal 1 Used only on machines outside the U.S.A. No parts required – Grease the machine.
4 Checking Fluid Levels No Parts Required Procedure 1. Check the rear axle lubricant level before the engine is first started, refer to Checking the Rear Axle Lubricant in Drive System Maintenance , page 39. Figure 3 1. Manual tube 2. R-clamp 2. Check the hydraulic fluid level before the engine is first started, refer to Checking the Hydraulic Fluid Level in Operation , page 20. 3. Seat belt retractor 4. Seat belt buckle 3.
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 Engine Oil Pressure Warning Light Traction Pedal The light (Figure 5) illuminates when the engine oil pressure is dangerously low. 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.
Figure 6 1. Forward speed limiter screw 2. Reverse speed limiter screw Brake Pedals Two foot pedals (Figure 7) operate individual wheel brakes for turning assistance, parking, and to aid in obtaining better side hill traction. A latch connects the pedals for parking brake operation and transport. Figure 5 1. Traction pedal 2. Forward speed control 3. Key switch 4. Engine oil pressure warning light 5. Charge indicator 6. Engine coolant temperature warning light 7.
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.
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. Dipstick Wear hearing protection when operating this machine. 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.
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. Figure 16 1. Fuel tank cap 2. Fill the tank to about 1 inch (25 mm) below the top of the tank, not the filler neck, with No. 2 diesel fuel. Then install the cap. Under certain conditions, diesel fuel and fuel vapors are highly flammable and explosive.
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. We do not recommend the use of synthetic fluid.
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 PTO lever to the Off position. 3. Set the parking brake. 4. Rotate the ignition key to Off. 2. Move the throttle control to the low idle position. 5. Remove the key from the switch to prevent accidental starting. 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.
Jacking Points engine does not kill, there is a malfunction in the interlock system that should be corrected before beginning operation. • On the front of the machine on the frame on the inside of each drive tire • On the rear of the machine at the center of the axle Pushing or Towing the Machine Tie Downs 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.
The module monitors inputs including neutral, parking brake, PTO, start, backlap, and high temperature. The module energizes outputs including PTO, Starter, and ETR (energize to run) solenoid. This product is designed to drive objects into the ground where they lose energy quickly in grass areas. However, careless operation, combined with terrain angle, ricochets, or improperly positioned safety guard can lead to thrown object injuries. The module is divided into inputs and outputs.
2. Move key switch to "ON" and ensure the red "power" LED is illuminated. 3. Move all input switches to ensure all LED’s change state. 4. Position input devices at appropriate position to achieve the appropriate output. Use the following logic chart to determine the appropriate input condition. 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.
which impairs growth and increases susceptibility to diseases. Transporting (Groundsmaster 4700–D Only) Use the two rear transport latches when transporting over long distances, rough terrain, or when trailering. After Operating To ensure optimum performance, clean the underside of the mower housing after each use. If residue is allowed to build up in the mower housing, cutting performance will decrease. 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. 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. 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 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 2. Loosen the drain plug on the bottom of the filter canister (Figure 38). Tighten the plug after draining. 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.
3. Open the air bleed screw on the fuel injection pump (Figure 40). Figure 39 1. Fuel pre-filter Figure 40 3. Slide the hose clamps onto the ends of the fuel lines. Push the fuel lines onto the fuel filter and secure them with the hose clamps. Be sure that the arrow on the side of the filter points toward the injection pump. 1. Fuel injection pump bleed screw 4. Turn the key in the ignition switch to the On position.
Electrical System Maintenance Charging and Connecting the Battery Figure 41 Warning 1. No. 1 injector nozzle CALIFORNIA Proposition 65 Warning Battery posts, terminals, and related accessories contain lead and lead compounds, chemicals known to the State of California to cause cancer and reproductive harm. Wash hands after handling. 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.
Battery Care Service Interval: Every 50 hours Charging the battery produces gasses that can explode. Important: Before welding on the machine, disconnect the cable from the negative battery post to prevent damage to the electrical system. Never smoke near the battery and keep sparks and flames away from battery. 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.
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. Pump rod 3. Remove the (3) oil level check plugs and main axle vent cap to ease in draining of the oil. 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.
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. Figure 59 1. Test port B (Counter balance) Test Port I (Figure 62) located on front traction circuit hard line. Used to measure forward traction pressure 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 in Operation , page 20. 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 (Rev.
Electrical Schematic - GM 4700 (Rev.
Hydraulic Schematic (Rev.
Hydraulic Schematic (Rev.
Notes: 53
Notes: 54
Notes: 55
The 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.
