Form No. 3376-494 Rev F Groundsmaster® 4500-D and 4700-D Traction Unit Model No. 30881—Serial No. 313000001 and Up Model No. 30882—Serial No. 313000001 and Up Register at www.Toro.com.
Read this information carefully to learn how to operate and maintain your product properly and to avoid injury and product damage. You are responsible for operating the product properly and safely. This product complies with all relevant European directives, for details please see the separate product specific Declaration of Conformity (DOC) sheet. WARNING You may contact Toro directly at www.Toro.
information and Note emphasizes general information worthy of special attention.
Contents Checking the Fuel Lines and Connections.................................................. 49 Servicing the Water Separator ......................... 49 Servicing the Fuel Filter .................................... 49 Fuel Pick-up Tube Screen................................. 50 Electrical System Maintenance ........................... 50 Charging and Connecting the Battery ............... 50 Battery Care ..................................................... 52 Fuses................................
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 B71.4-2012 specifications in effect at the time of production. • The owner/user can prevent and is responsible Improper use or maintenance can result in injury.
• Before attempting to start the engine, disengage • • • • • • • Look behind and down before backing up to be all blade attachment clutches and engage the parking brake. 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. To help guard against overturning: – Do not stop or start suddenly when going up or downhill.
• Use care when checking the blades. Wear gloves • When operating a machine with ROPS (rollover 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.
Sound Power Level • For major repairs, warranty work, updates to the system, or assistance, contact your Toro Distributor. This unit has a guaranteed sound power level of 105 dBA, which includes an Uncertainty Value (K) of 0.7 dBA. • Use only Toro-approved attachments and replacement parts. The warranty may be voided if used with unapproved attachments. Sound power level was determined according to the procedures outlined in ISO 11094.
Safety and Instructional Decals Safety decals and instructions are easily visible and are located near any area of potential danger. Replace any decal that is damaged or lost. decal121-3887 121–3887 1. Read the Operator’s Manual. decal117-4763 117-4763 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. press the parking brake pedals and engage the toe pedal.
decal106-6755 106-6755 decal125-4604 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. 125–4604 Groundsmaster 4700 Shown 3. Raise right deck 1. Raise left deck 2. Raise center deck decal117-4765 117-4765 1. Read the Operator's Manual. decal117-4764 117-4764 2. Do not use starting aids. 1. Thrown object hazard—keep bystanders a safe distance from the machine. 2.
decal106-6754 106-6754 1. Warning—do not touch the hot surface. decal112-5298 112-5298 (Place over Par Number 112–5297 for CE*) 2. Cutting/dismemberment hazard, fan and entanglement hazard, belt—stay away from moving parts. * This safety decal includes a slope warning required on the machine for compliance to the European Lawn Mower Safety Standard EN 836:1997. The conservative maximum slope angles indicated for operation of this machine are prescribed by and required by this standard. 1.
decal93-7272 93-7272 1. Cutting/dismemberment hazard; fan—stay away fro moving parts. decal117-2718 117–2718 decal112-5019 112-5019 decal125-4605 125–4605 1. Power seat, 10 A 6. Power supplied, 10 A 2. Work light, 10 A 7. GM4700 controller, 2 A 3. Engine, 10 A 8. Power supplied, 7.5 A 4. Cigarette lighter, 10 A 9. GM4500 controller, 2 A 5. Infocenter, 2 A decal93-6681 93-6681 1. Cutting/dismemberment—hazard, fan-stay away from moving parts. 10.
decal125-4606 125–4606 1. Read the Operator’s Manual for information on maintenance. decal104-1086 104-1086 1.
Setup Loose Parts Use the chart below to verify that all parts have been shipped. Procedure Description Use Qty. 1 Warning decal 1 Used only on machines requiring European CE Compliance. 2 Lock bracket Rivet Washer Screw, 1/4 x 2 inches Locknut, 1/4 inch 1 2 1 1 1 Install the hood latch (CE). No parts required – Grease the machine. No parts required – Check the rear axle lubricant, hydraulic fluid, and engine-oil levels. 3 4 Media and Additional Parts Description Use Qty.
2. 1 Remove the (2) rivets securing the hood-latch bracket to the hood (Figure 3). Remove the hood-latch bracket from the hood. 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 3. Installing the Hood Latch (CE Only) 2.
4 Checking Fluid Levels No Parts Required Procedure g012630 Figure 5 1. Check the rear axle lubricant level before the engine is first started; refer to Checking the Rear Axle Lubricant (page 54). 2. Check the hydraulic-fluid level before the engine is first started; refer to Checking the Hydraulic-Fluid Level (page 27). 3. Check the engine-oil level before and after the engine is first started; refer to Checking the Engine-Oil Level (page 47). 1. Hood latch 7.
Key Switch Product Overview The key switch (Figure 8) has 3 positions: OFF, ON/PREHEAT , and START . Controls PTO Switch Brake Pedals The PTO switch (Figure 8) has 2 positions: Out (start) and In (stop). Pull the PTO button out to engage the cutting unit blades. Push in the button to disengage the cutting unit blades. 2 foot pedals (Figure 7) operate individual wheel brakes for turning assistance and to aid in obtaining better side hill traction.
Lift Switches Seat Adjustments The lift switches (Figure 8) raise and lower the cutting units. Press the switches forward to lower the cutting units and backward to raise the cutting units. When starting the machine, with the cutting units in the down position, press the lift switch down to allow the cutting units to float, and mow. Fore and Aft Adjusting Lever Pull out on the lever to slide the seat fore or aft (Figure 10).
Using the InfoCenter LCD Display InfoCenter Icon Description SERVICE DUE The InfoCenter LCD display shows information about your machine such as the operating status, various diagnostics, and other information about the machine (Figure 11). There is a splash screen and a main information screen on the InfoCenter. Press any of the InfoCenter buttons and then select the appropriate directional arrow to switch between the splash screen and the main information screen.
InfoCenter Icon Description (cont'd.) InfoCenter Icon Description (cont'd.) Stop the engine. Operator should put machine in neutral. Engine Engine start is denied. Key switch Engine shutdown Cutting units are lowering. Engine coolant is too hot. Cutting units are raising. Hydraulic oil is too hot. PIN code DPF ash accumulation notification; refer to Servicing the Diesel-Oxidation Catalyst (DOC) and the Soot Filter (page 48).
About Service Menu Item Description Menu Item Description Hours Lists the total number of hours that the machine, engine and fan have been on, as well as the number of hours the machine has been transported and overheated. Model Lists the model number of the machine. SN Lists the serial number of the machine. S/W Rev Lists the software revision of the master controller. Counts Lists the number of starts, deck PTO cycles, and fan reversals the machine has experienced.
Viewing and Changing the Protected Menu Settings 1. In the Protected Menu, scroll down to Protect Settings. 2. To view and change the settings without entering a passcode, use the right button to change the Protect Settings to OFF. 3. To view and change the settings with a passcode, use the left button to select ON, set the passcode, and turn the key in the ignition switch to the OFF position and then to the ON position. Setting the Auto Idle 1. In the Settings Menu, scroll down to Auto Idle. 2.
Specifications Note: Specifications and design are subject to change without notice. 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 CAUTION This machine produces sound levels that can cause hearing loss through extended periods of exposure. Note: Determine the left and right sides of the machine from the normal operating position. Wear hearing protection when operating this machine. 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. g009027 Figure 14 CAUTION 1.
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. • 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. • Store fuel in an approved container and keep it out of the reach of children.
Fuel Tank Capacity Sulfur content: Ultra-low sulfur (<15 ppm) Fuel tank capacity: 83 L (22 US gallons) Biodiesel fuel specification: ASTM D6751 or EN14214 Fuel Specification Blended fuel specification: ASTM D975, EN590, or JIS K2204 Important: Use only ultra-low sulphur diesel fuel. Fuel with higher rates of sulfur degrades the diesel oxidation catalyst (DOC), which causes operational problems and shortens the service life of engine components.
Note: If possible, fill the fuel tank after each use; this US gallons) containers or 208 L (55 US gallons) drums from your Mobil Distributor. will minimize possible buildup of condensation inside the fuel tank. Important: Many hydraulic fluids are almost colorless, making it difficult to spot leaks. A red dye additive for the hydraulic system oil is available in 20 ml (2/3 oz) bottles. 1 bottle is sufficient for 15 to 22 L (4 to 6 US gallons) of hydraulic oil.
Starting and Stopping the Engine Cutting Grass with the Machine Important: You must bleed the fuel system before starting the engine if the engine has stopped due to lack of fuel, or you have performed maintenance on the fuel system. Note: Cutting grass at a rate that loads the engine promotes DPF regeneration. Starting the Engine 1. Move the machine to the job site. 2. Whenever possible, set the engine-speed switch to high idle.
Diesel Particulate Filter Regeneration Important: Minimize the amount of time that you idle the engine or operate the engine at low-engine speed to help reduce the accumulation of soot in the soot filter. The diesel particulate filter (DPF) is part of the exhaust system. The diesel-oxidation catalyst of the DPF reduces harmful gasses and the soot filter removes soot from the engine exhaust.
DPF Ash Accumulation • When enough ash accumulates, the engine • The lighter ash is discharged through the exhaust system; the heavier ash collects in the soot filter. • Ash is a residue of the regeneration process. Over • time, the diesel particulate filter accumulates ash that does not discharge with the engine exhaust. • • The computer for the engine calculates the amount of ash accumulated in the DPF.
Types of Diesel Particulate Filter Regeneration Types of diesel particulate filter regeneration that are performed while the machine is operating: Type of Regeneration Conditions for DPF regeneration DPF description of operation Passive Occurs during normal operation of the machine at high-engine speed or high-engine load The InfoCenter does not display an icon indicating passive regeneration.
Types of diesel particulate filter regeneration that require you to park the machine: (cont'd.) Type of Regeneration Conditions for DPF regeneration DPF description of operation Recovery Occurs as a result of ignoring parked regeneration requests and continuing operation, adding more soot when the DPF is already in need of a parked regeneration When the recovery-regeneration icon is displayed in the InfoCenter, a recovery regeneration is requested.
Parked Regeneration Reset Regeneration g214713 g214711 Figure 25 Assist/reset-regeneration icon Figure 26 Parked-regeneration request icon • The assist/reset-regeneration icon displays in the • The parked-regeneration requested icon displays in the InfoCenter (Figure 26). If a parked regeneration is needed, the InfoCenter displays engine warning SPN 3719, FMI 16 (Figure 27) and the engine computer derates engine power to 85%. InfoCenter (Figure 25).
6. Engage the parking brake. 7. Set the throttle to the low IDLE position. Performing a Parked Regeneration Note: For instructions on unlocking protected menus, refer to Accessing Protected Menus (page 21). 1. Access the protected menu and unlock the protected settings submenu (Figure 28); refer to Accessing Protected Menus (page 21). g212138 Figure 30 4. When the “Initiate DPF Regen. Are you sure?” message displays, press the center button (Figure 31). g028523 Figure 28 2.
g211986 g212405 Figure 32 6. Figure 34 Move the throttle control to LOW IDLE and press the center button (Figure 33). B. The “Waiting on (Figure 35). ” message displays g212372 g212406 Figure 33 7. Figure 35 The following messages display as the parked regeneration process begins: A. C. The “Initiating DPF Regen.” message displays (Figure 34). The computer determines whether the regeneration runs.
The engine is cold—wait. The engine is warm—wait. The engine hot—regeneration in progress (percent complete). 9. g213424 The parked regeneration is complete when the “Regen Complete” message displays in the InfoCenter. Press the left button to exit to the home screen (Figure 38). Figure 36 • If the regeneration process is not allowed by the engine computer, the “DPF Regen Not Allowed” message displays in the InfoCenter (Figure 37).
Mow Speed • Perform a recovery-regeneration whenever • • there is a loss of engine power and a parked regeneration cannot effectively clean the DPF of soot. A recovery regeneration requires up to 4 hours to complete. You need a distributor technician to perform the recovery regeneration process; contact your Authorized Toro Distributor. Supervisor (Protected Menu) Allows the supervisor to set the machines maximum mowing speed, in increments of 50%, 75% or 100%, at which the operator can mow (low range).
During different times of the mowing season or when turf conditions vary, the amount of counterbalance (upward lift) required on the cutting decks can be changed to meet the conditions. machine does move, there is a malfunction in the interlock system. Correct this malfunction before operating the machine. Refer to Using the InfoCenter LCD Display, in the Operation section of this manual, to set the counterbalance pressure.
3. Operating Characteristics Close the bypass valves before starting the engine. Torque to 70 N-m (52 ft-lb) to close the valve. Practice driving the machine because it has a hydrostatic transmission and its characteristics are different than many turf maintenance machines. Some points to consider when operating the traction unit and cutting units are the transmission, engine speed, load on the cutting blades and the importance of the brakes.
Operating Tips 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. Mow When Grass is Dry Mow either in the late morning to avoid the dew, which causes grass clumping, or in late afternoon to avoid the damage that can be caused by direct sunlight on the sensitive, freshly mowed grass.
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 200 hours Before each use or daily • Change the planetary gear drive oil. • Change the rear axle lubricant. • Change the hydraulic filters. • • • • • • • • • Check the cooling system. Check the hydraulic-fluid level. Check the tire pressure.
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 decal125-4606 Figure 41 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 switch before you do any maintenance.
Lubrication Pre-Maintenance Procedures Greasing the Bearings and Bushings Removing the Hood 1. Service Interval: Every 50 hours (or after every washing). Release the hood latches (Figure 42) and pivot the hood open. The machine has grease fittings that must be lubricated regularly with No. 2 lithium grease. The grease fitting locations and quantities are as follows: • Brake shaft pivot bearings (5) (Figure 43) g009984 g009704 Figure 42 Figure 43 1. Hood latch (2) 2.
• Steering cylinder ball joints (2) (Figure 45) • Cutting unit spindle-shaft bearings (1 per cutting unit) (Figure 47) g009708 Figure 47 • Cutting unit carrier-arm bushings (1 per cutting unit) (Figure 47) g009706 Figure 45 • Rear-roller bearings (2 per cutting unit) (Figure 48 ) 1. Top fitting on king pin • Tie-rod ball joints (2) (Figure 45) • King-pin bushings (2) (Figure 45). The top fitting on the king pin should only be lubricated annually (2 pumps).
Engine Maintenance 3. Servicing the Air Cleaner Service Interval: Every 400 hours Use low pressure 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. Note: This cleaning process prevents debris Check the air-cleaner body for damage which could cause an air leak. Replace if damaged.
The engine is shipped with oil in the crankcase; however, the oil level must be checked before and after the engine is first started. Important: Check the engine oil daily. If the engine-oil level is above the Full mark on the dipstick, the engine oil may be diluted with fuel; If the engine oil level is above the Full mark, change the engine oil. The best time to check the engine oil is when the engine is cool before it has been started for the day.
Crankcase Oil Capacity Servicing the Diesel-Oxidation Catalyst (DOC) and the Soot Filter Approximately 5.7 L (6 US qt) with the filter. Changing the Engine Oil and Filter Service Interval: Every 6,000 hours or clean the soot filter if engine faults SPN 3720 FMI 16, SPN 3720 FMI 0, or SPN 3720 FMI 16 display in the InfoCenter. • If advisory message ADVISORY 179 displays in the InfoCenter, the DPF is nearing the recommended point for servicing the diesel-oxidation catalyst and the soot filter.
Fuel System Maintenance Every 400 hours—Replace the fuel filter canister. DANGER 1. Place a clean container under the fuel filter (Figure 58). 2. Loosen the drain plug on the bottom of the filter canister and open the vent on the top of the canister mount. 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.
Electrical System Maintenance Charging and Connecting the Battery WARNING 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. g021291 Figure 59 1. Fuel-filter head 2. Fuel Filter 2. Remove the filter and clean the filter head mounting surface (Figure 59). 3.
positioned snug to the battery. The cable must not contact the battery cover. DANGER Battery electrolyte contains sulfuric acid which is a deadly poison and causes severe burns. • 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. • Fill the battery where clean water is always available for flushing the skin. 2. Connect a 3 to 4 A battery charger to the battery posts.
Battery Care Service Interval: Every 50 hours—Check the battery condition. Important: Before welding on the machine, disconnect the negative (black) cable from the battery to prevent damage to the electrical system. Note: Keep the terminals and the entire battery case clean to avoid slow discharge. To clean the battery, remove it from the machine, and wash the entire case with a solution of baking soda and water. Rinse with clear water.
Drive System Maintenance Checking the Torque of the Wheel Nuts 3. If the oil level is low, remove the plug at the 12 o’clock position and add oil until it begins to flow out the hole at the 3 o’clock position. 4. Install both plugs. 5. Repeat steps 1 through 4 on the opposite planetary gear assembly.
g009716 Figure 68 2. Fill plug 1. Check plug g019743 Figure 67 1. Brake housing 2. Drain plug 4. When all of the oil has drained from both locations, install the plug in the brake housing. 5. Rotate the wheel until the open plug hole in the planetary, is at the twelve o'clock position. 6. Changing the Rear Axle Lubricant Service Interval: After the first 200 hours Every 800 hours Through the open hole, slowly fill the planetary with 0.65 L (22 oz) of high quality SAE 85W-140 gear lube. 1.
Checking the Rear Wheel Toe-In Service Interval: Every 800 hours/Yearly (whichever comes first) 1. Measure the center-to-center distance (at axle height) at the front and rear of the steering tires. The front measurement must be 3 mm (1/8 inch) less than the rear measurement (Figure 70). g009169 Figure 70 1. Front of traction unit 2. 3 mm (1/8 inch) less than rear of tire 2. 3.
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. Clean them more frequently in dirty conditions. This machine is equipped with a hydraulically driven fan drive system that automatically (or manually) reverses to reduce oil cooler/radiator and screen debris buildup.
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 75) after every 100 operating hours. Note: The belt should deflect 10 mm (3/8 inch).
Hydraulic System Maintenance 2. 3. Changing the Hydraulic Fluid Clean the area around the filter mounting area. Place a drain pan under the filter and remove the filter (Figure 76 and Figure 77). Lubricate the gasket on the new filter and fill the filter with hydraulic fluid. Service Interval: Every 800 hours If the fluid becomes contaminated, contact your Toro Distributor because the system must be flushed. Contaminated fluid looks milky or black when compared to clean oil. 1.
Checking the Hydraulic Lines and Hoses Storage Preparing the Traction Unit Service Interval: Before each use or daily Inspect the hydraulic lines and hoses 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.
Schematics g023509 Hydraulic Schematic-Groundsmaster 4700 (Rev.
g023508 Hydraulic Schematic-Groundsmaster 4500 (Rev.
Notes:
International Distributor List Distributor: Agrolanc Kft Asian American Industrial (AAI) B-Ray Corporation Brisa Goods LLC Casco Sales Company Ceres S.A. CSSC Turf Equipment (pvt) Ltd. Cyril Johnston & Co. Cyril Johnston & Co. Fat Dragon Femco S.A. FIVEMANS New-Tech Co., Ltd ForGarder OU G.Y.K. Company Ltd. Geomechaniki of Athens Golf international Turizm Hako Ground and Garden Hako Ground and Garden Hayter Limited (U.K.) Hydroturf Int. Co Dubai Hydroturf Egypt LLC Irrimac Irrigation Products Int'l Pvt Ltd.
The Toro 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).
