Form No. 3417-109 Rev A Groundsmaster® 4500-D and 4700-D Traction Unit Model No. 30881—Serial No. 401333001 and Up Model No. 30882—Serial No. 401333001 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. This product complies with all relevant European directives; for details, please see the separate product specific Declaration of Conformity (DOC) sheet.
Contents Maintenance ........................................................... 51 Recommended Maintenance Schedule(s) ........... 51 Daily Maintenance Checklist............................. 52 Service Interval Chart ....................................... 53 Pre-Maintenance Procedures .............................. 54 Pre-Maintenance Safety ................................... 54 Preparing the Machine for Maintenance............ 54 Lifting the Machine ...........................................
Safety Replacing the Hydraulic Filters ......................... 75 Checking the Hydraulic Lines and Hoses............................................................ 76 Cutting Unit Maintenance ..................................... 76 Removing the Cutting Units .............................. 76 Installing the Cutting Units ................................ 77 Servicing the Front Roller ................................. 77 Blade Maintenance .............................................. 78 Blade Safety ....
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 missing. decal93-7818 93-7818 decal107-1971 107–1971 1. Warning—read the Operator's Manual for instructions on torquing the blade bolt/nut to 115 to 149 N∙m (85 to 110 ft-lb). decal98-4387 98-4387 decal107-1972 1. Warning—wear hearing protection. 107-1972 1.
decal117-2718 117-2718 decal117-4765 117-4765 1. Read the Operator's Manual. 2. Do not use starting aids. decal117-4766 117-4766 1. Cutting/dismemberment hazard; fan—stay away from moving parts, keep all guards and shields in place. 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.
decal121-3887 121-3887 1. Read the Operator’s Manual. decal120-8947 120-8947 1. Warning—read the Operator’s Manual. 4. If the roll bar is raised, wear the seat belt. decal136-2931 136-2931 For Groundsmaster 4500 Only 2. There is no rollover 5. If the roll bar is lowered, protection when the roll do not wear the seat belt. bar is down. 3. There is rollover protection 6. Drive slowly when turning. when the roll bar is up. 1. Raise the decks. 3. Disengage the cruise control. 2.
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. Power port (10 A) 9. GM4500 controller (2 A) 5. Infocenter (2 A) decal125-4606 125-4606 1. Read the Operator’s Manual for information on maintenance. 10. Cab (60 A) decalbatterysymbols Battery Symbols Some or all of these symbols are on your battery 1. Explosion hazard 2. No fire, open flame, or smoking 3.
decal121-3627 121-3627 1. Height-of-cut settings decal127-6447 127-6447 (Affix over Part No. 112-5297 for CE* for 4500 series machines) Note: This machine complies with the industry standard stability test in the static lateral and longitudinal tests with the maximum recommended slope indicated on the decal.
decal127-6448 127-6448 (Affix over Part No. 112-5297 for CE* for 4700 series machines) Note: This machine complies with the industry standard stability test in the static lateral and longitudinal tests with the maximum recommended slope indicated on the decal. Review the instructions for operating the machine on slopes in the Operator's Manual and the conditions in which the machine is being operated to determine whether the machine can be operated in the conditions on that day and at that site.
Setup Loose Parts Use the chart below to verify that all parts have been shipped. Procedure Description Use Qty. 1 Warning decal 1 Replace the warning decal (CE machines only). 2 Hood-latch bracket Rivet Washer Screw (1/4 x 2 inches) Locknut (1/4 inch) 1 2 1 1 1 Install the hood latch (CE machines only). No parts required – Adjust the roller scraper (optional). No parts required – Install the mulching baffle (optional). No parts required – Prepare the machine.
2. Remove the 2 rivets securing the hood-latch bracket to the hood (Figure 3). Remove the hood-latch bracket from the hood. g012630 Figure 5 1. Hood latch 7. g012628 Figure 3 1. Hood-latch bracket 3. 2. Rivets Screw the bolt into the other arm of the hood-latch bracket to lock the latch in position (Figure 6). Tighten the bolt but do not tighten the nut. While aligning the mounting holes, position the CE lock bracket and the hood-latch bracket onto the hood (Figure 4).
3 4 Adjusting the Roller Scraper (Optional) Installing the Mulching Baffle (Optional) No Parts Required No Parts Required Procedure 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 to 0.040 inch) between the scraper and roller. 1. 1. Thoroughly clean debris from the mounting holes on the rear wall and left wall of the chamber. 2. Install the mulching baffle in the rear opening and secure it with 5 flange-head bolts (Figure 8).
Product Overview 5 Controls Preparing the Machine No Parts Required Procedure 1. Park the machine on a level surface. 2. Lower the cutting units. 3. Engage the parking brake. 4. Shut off the engine and remove the key. 5. Check the tire pressure before use; refer to Checking the Tire Pressure (page 26). g009979 Figure 9 Important: Maintain pressure in all tires 7. The traction pedal (Figure 9) controls forward and reverse operation.
or decrease the engine speed in 100 rpm increments. Hold down the switch to automatically move to High or Low idle, depending on which end of the switch you press. down on the right brake pedal while engaging the toe pedal. To release the parking brake, press 1 of the brake pedals until the parking brake latch retracts. Tilt-Steering Pedal PTO Switch Press the tilt-steering pedal to tilt the steering wheel to the desired position, then release the pedal to lock the adjustment (Figure 9).
Power Point Use the power point (Figure 12) to power optional 12 V electrical accessories. g024916 Figure 13 1. Weight gauge 2. Weight adjustment lever g036845 Figure 12 1. Power point 4. Seat-back adjustment lever 5. Armrest adjustment knob 3. Seat adjustment lever 2. Bag holder Armrest Adjustment Knob Bag Holder Rotate the knob to adjust the armrest angle (Figure 13). Use the bag holder for storage (Figure 12).
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 14). There is a splash screen and main information screen of the InfoCenter. You can switch between the splash screen and main information screen at any time by pressing any of the InfoCenter buttons and then selecting the appropriate directional arrow.
InfoCenter Icon Description (cont'd.) InfoCenter Icon Description (cont'd.) Start the engine. Operator should change to indicated state The PTO is on. Symbols are often combined to form sentences. Some examples are shown below The cruise control is on.
Using the Menus To access the InfoCenter menu system, press the menu access button while at the main screen. This brings you to the main menu. Refer to the following tables for an overview of the options available from the menus: Main Menu—Menu Item Description Faults Contains a list of the recent machine faults; refer to the Service Manual for more information.
About—Menu Item Description 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 Protected Menus There are 6 operating configuration settings that are adjustable within the Settings Menu of the InfoCenter: auto idle, maximum mowing ground speed, maximum transport ground speed, Smart Power, cutting unit counterbalance, and Turnaround. These settings are in the Protected Menu.
When finished with the Protected Menu, press the left button to exit to the Main Menu, then press the left button to exit to the Run Menu. 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 PIN code, use the right button to change the Protect Settings to OFF. 3.
Specifications g198614 Figure 17 22
Machine Specifications Specifications Table Description 4500-D Figure 17 reference 4700-D Figure 17 reference Width of cut 280 cm (110 inches) D 380 cm (150 inches) F Cutting units down 286 cm (113 inches) E 391 cm (154 inches) G Cutting units up (transport) 224 cm (88 inches) A 224 cm (88 inches) A Front 224 cm (88 inches) B 224 cm (88 inches) B Rear 141 cm (56 inches) M 141 cm (56 inches) M 226 cm (88.8 inches) C 226 cm (88.
Checking the Engine-Oil Level Operation Note: Determine the left and right sides of the machine from the normal operating position. Before you start the engine and use the machine, check the oil level in the engine crankcase; refer to Checking the Engine-Oil Level (page 58). Before Operation Checking the Cooling System Before Operation Safety Before you start the engine and use the machine, check the cooling system; refer to Checking the Cooling System (page 70).
Filling the Fuel Tank Biodiesel This machine can also use a biodiesel blended fuel of up to B20 (20% biodiesel, 80% petroleum diesel). Fuel Tank Capacity Fuel tank capacity: 83 L (22 US gallons) Sulfur content: Ultra-low sulfur (<15 ppm) Fuel Specification Biodiesel fuel specification: ASTM D6751 or EN14214 Blended fuel specification: ASTM D975, EN590, or JIS K2204 Important: Use only ultra-low sulphur diesel fuel.
Adding Fuel Checking the Tire Pressure Service Interval: Before each use or daily The correct air pressure in the tires is 138 kPa (20 psi). Important: Maintain the recommended pressure in all tires to ensure a good quality of cut and proper machine performance. Do not under-inflate the tires. Check the air pressure in all the tires before operating the machine.
not use the seat belt when the roll bar is in the lowered position. Lowering the Roll Bar Important: Lower the roll bar only when necessary. g033359 Important: Ensure that the seat is secured with Figure 21 Rear Wheels the seat latch. WARNING Failing to maintain proper torque of the wheel lug nuts could result in personal injury. Torque the wheel lug nuts to the proper torque value.
Adjusting the Height of Cut Important: The cutting units often cut approximately 6 mm (1/4 inch) lower than a reel cutting unit with the same bench setting. It may be necessary to set the cutting-unit bench measurement at 6 mm (1/4 inch) above that of reel cutting units cutting in the same area. 7. Install the bolt finger-tight. 8. Repeat steps 4 through 7 for each side adjustment. 9. Torque all 3 bolts to 41 N∙m (30 ft-lb). Always tighten the front bolt first. Note: Adjustments of more than 3.
High-Lift, Parallel Sail Note: The InfoCenter displays "traction denied" and the machine should not move. If the machine does move, there is a malfunction in the interlock system. Correct this malfunction before operating the machine. The blade generally performs better in the higher heights of cut—7 to 10 cm (2 to 4 inches). Attributes: • It has more lift and a higher discharge velocity. Checking the Blade-Stopping Time • Sparse or limp turf is picked up significantly at higher heights of cut.
Choosing Accessories 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 (3/4 to 1-3/4 inches) height of cut Recommended in most applications May work well in light or sparse turf Grass Cutting—5 to 6.
During Operation • Before leaving the operating position (including to empty the catchers or to unclog the chute), do the following: During Operation Safety – Park the machine on a level surface. General Safety – Disengage and lower the cutting units and lower the attachments. • The owner/operator can prevent and is responsible – Engage the parking brake. • • • • • • • • • • • • • • • • for accidents that may cause personal injury or property damage.
include surveying the site to determine which slopes are safe for machine operation. Always use common sense and good judgment when performing this survey. starter failure may result. If the engine fails to start after 15 seconds, turn the key to the OFF position, check the controls and procedures, wait 15 additional seconds, and repeat the starting procedure. • Slopes are a major factor related to loss-of-control and tip-over accidents, which can result in severe injury or death.
6. • Passive regeneration occurs continuously while Press the PTO switch to prepare cutting units for operation. 7. Use the joystick to raise the cutting units off the ground. 8. Begin moving the machine toward the cutting area and lower the cutting units. the engine is running—run the engine at full engine speed when possible to promote DPF regeneration.
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 that cause 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 that cause DPF regeneration DPF description of operation Recovery Occurs because the operator ignored requests for a parked regeneration and continued operating the machine, adding more soot to the DPF • When the reset-standby/parked or recovery regeneration icon or ADVISORY #190 displays in the InfoCenter, a recovery regeneration is requested.
press the right button to select the Technician entry (Figure 33). DPF Operation Table (cont'd.) State Description Reset Regen The engine computer is running a reset regeneration. Parked Stby The engine computer is requesting that you run a parked regeneration. Parked Regen You initiated a parked regeneration request and the engine computer is processing the regeneration. Recov. Stby The engine computer is requesting that you run a recovery regeneration. Recov.
Assist DPF Regeneration • The icon displays in the InfoCenter while the reset regeneration is processing. • The engine computer adjusts engine settings to • Whenever possible, do not shut off the engine or raise the exhaust temperature. reduce engine speed while the reset regeneration is processing. • While operating the machine, run the engine at full engine speed and high load when possible to promote DPF regeneration.
g227304 g224394 Figure 38 2. Figure 40 Press the right button to change the inhibit regeneration setting from On to Off (Figure 38) or from Off to On (Figure 39). Note: If the engine exhaust temperature is too low, the InfoCenter displays ADVISORY #186 (Figure 41) to inform you to set the engine to full throttle (high idle).
Parked or Recovery Regeneration regeneration required—power takeoff disabled ADVISORY #189 (Figure 45). • When the engine computer requests either a parked regeneration or a recovery regeneration, the regeneration request icon (Figure 42) displays in the InfoCenter. g224398 Figure 45 Important: Perform a parked regeneration to restore the PTO function; refer to Preparing to Perform a Parked or Recovery Regeneration (page 41) and Performing a Parked or Recovery Regeneration (page 41).
Important: Perform a recovery regeneration 2. to restore the PTO function; refer to Preparing to Perform a Parked or Recovery Regeneration (page 41) and Performing a Parked or Recovery Regeneration (page 41). Move the machine outside to an area away from combustible materials. 3. Park the machine on a level surface. 4. Ensure that the traction control or motion-control levers are in the NEUTRAL position. 5. If applicable, shut off the PTO, and lower the cutting units or accessories. 6.
3. At the DPF checklist screen, verify that the parking brake is engaged and that the engine speed is set to low idle (Figure 53). g224402 g224407 g224629 Figure 51 2. At the VERIFY FUEL LEVEL screen, verify that you have 1/4 tank of fuel if you are performing the parked regeneration or 1/2 tank of fuel if you are performing the recovery regeneration, and press the right button to continue (Figure 52). g227679 Figure 53 4.
5. The InfoCenter displays the INITIATING DPF REGEN message (Figure 55). Check Message and Corrective Action Table (cont'd.) g224411 Corrective Action: Start and run the engine. g227681 Figure 55 6. Corrective Action: Run the engine to warm the coolant temperature to 60°C (140°F). The InfoCenter displays the time to complete message (Figure 56). Corrective Action: Change the engine speed to low idle. g224406 Corrective Action: Troubleshoot the engine computer condition and retry DPF regeneration.
Canceling a Parked or Recovery Regeneration displays ADVISORY #183 (Figure 58). Press the left button to exit to the home screen. Use the Parked Regen Cancel or Recovery Regen Cancel setting to cancel a running parked or recovery regeneration process. 1. Access the DPF Regeneration menu (Figure 60). g224392 Figure 58 g227305 Note: If the regeneration fails to complete, the Figure 60 InfoCenter displays Advisory #184 (Figure 58). Press the left button to exit to the home screen. 2.
Understanding the Operating Characteristics of the Machine Operating the Engine-Cooling Fan The engine cooling fan is normally controlled by the machine. The machine can reverse the fan to blow debris off the rear screen. Under normal operating conditions, the machine controls the fan speed and direction based on coolant and hydraulic-fluid temperature, and the fan automatically reverses direction to blow debris off the rear screen.
Using Cruise Control Operating Tips The cruise-control switch locks in the pedal position to maintain the desired ground speed. Pressing the rear of the switch turns the cruise control off, the middle position of the switch enables the cruise-control function, and the front of the switch sets the desired ground speed. Operating the Machine • Start the engine. If the AUTO IDLE function is turned off, run it at HALF IDLE until it warms up.
Checking the Condition of the Mower Deck Resolving After-Cut Appearance Refer to the After-cut Appearance Troubleshooting Guide available at www.Toro.com. Ensure that the cutting chambers are in good condition. Straighten any bends in the chamber components to ensure correct blade tip/chamber clearance. Using Proper Mowing Techniques • To begin cutting, engage the mower decks, then approach the mowing area slowly. Once the front mower decks are over the mowing area, lower the mower decks.
Securing the Cutting Units After Operation 1. Ensure that the PTO is disengaged. After Operation Safety 2. Park the machine on a level surface. • Clean grass and debris from the cutting units, 3. Engage the parking brake. 4. Fully raise the cutting units. 5. Align the lanyard to the carrier shaft of the lift arm for the forward outer-cutting unit (Figure 65). mufflers, and engine compartment to help prevent fires. Clean up oil or fuel spills.
4. With the cutting units lowered, slip the loop of the lanyard into the slot in the reinforcement plate of the roller support (Figure 66). g036666 g225685 g225485 Figure 67 Figure 66 1. Reinforcement-plate slot (roller support) 1. Bypass valves 2. Lanyard loop 2. Hauling the Machine Note: Do not open more than 3 turns. Because fluid is bypassed, you can slowly move the machine without damaging the transmission. • Use care when loading or unloading the machine into a trailer or a truck.
Locating the Tie-Down Points Note: Use properly-rated DOT-approved straps in 4 corners to tie down the machine.
Maintenance Important: Refer to your engine owner’s manual for additional maintenance procedures. Important: If you are performing maintenance on the machine and run the engine with an engine exhaust-extraction duct, set the inhibit regen setting to ON; refer to Setting the Inhibit Regen (page 38). Note: Download a free copy of the electrical or hydraulic schematic by visiting www.Toro.com and searching for your machine from the Manuals link on the home page.
Maintenance Service Interval Every 6,000 hours Before storage Yearly Maintenance Procedure • Disassemble, clean, and assemble the soot filter of the DPF or clean the soot filter if engine faults SPN 3251 FMI 0, SPN 3720 FMI 0, or SPN 3720 FMI 16 display in the InfoCenter. • • • • • Drain and clean the fuel tank. Check the tire pressure. Check all fasteners. Grease or oil all grease fittings and pivot points. Paint chipped surfaces. • Inspect the fuel lines and connections.
For the week of: Maintenance Check Item Monday Tuesday Wednesday Thursday Friday Saturday Sunday Lubricate all the grease fittings.2 Touch up any damaged paint. 1Check the glow plug and injector nozzles if starting is hard, there is excess smoke, or rough running is noted. 2Immediately after every washing, regardless of the interval listed. Important: Refer to your engine operator’s manual for additional maintenance procedures.
Pre-Maintenance Procedures Important: Do not support the machine at the wheel-drive motors. Keep the lifting equipment clear of hydraulic tubing and hoses. Pre-Maintenance Safety • Before adjusting, cleaning, repairing, or leaving the machine, do the following: – Park the machine on a level surface. – Press down and hold the engine-speed switch to set the engine to low-idle speed. – Disengage and lower the cutting units. – Ensure that the traction is in neutral. – Engage the parking brake.
Accessing the Hydraulic Lift Compartment Opening the Hood Tilt the hood to access the chassis as shown in Figure 73. Tilt the seat to access the hydraulic lift compartment as shown in Figure 74.
Lubrication • Steering-cylinder ball joints (2) as shown in Figure 77 Greasing the Bearings and Bushings Service Interval: Every 50 hours (also after every washing). Grease specification: No. 2 lithium grease The grease fitting locations and quantities are as follows: • Brake-shaft pivot bearings (5) as shown in Figure 75 g009706 Figure 77 g009704 1.
Engine Maintenance • Cutting-unit spindle-shaft bearings (2 per cutting unit) as shown in Figure 79 Note: You can use either fitting, whichever is more accessible. Pump grease into the fitting until a small amount appears at the bottom of the spindle housing (under the cutting unit). Engine Safety • Shut off the engine before checking the oil or adding oil to the crankcase. • Do not change the governor speed or overspeed the engine.
g198631 g009712 Figure 83 1. Air-cleaner safety filter 2. Reset the indicator (Figure 81) if it shows red. Servicing the Engine Oil Oil Specification Use high-quality, low-ash engine oil that meets or exceeds the following specifications: • API service category CJ-4 or higher • ACEA service category E6 • JASO service category DH-2 Important: Using engine oil other than API CJ-4 or higher, ACEA E6, or JASO DH-2 may cause the diesel particulate filter to plug or cause engine damage.
Crankcase Oil Capacity If the engine oil level is above the Full mark, change the engine oil. Approximately 5.7 L (6 US qt) with the filter. The best time to check the engine oil is when the engine is cool before it has been started for the day. If it has already been run, allow the oil to drain back down to the sump for at least 10 minutes before checking. If the oil level is at or below the Add mark on the dipstick, add oil to bring the oil level to the Full mark. Do not overfill the engine with oil.
Servicing the Diesel-Oxidation Catalyst (DOC) and the Soot Filter Fuel System Maintenance DANGER Service Interval: Every 6,000 hours—Disassemble, clean, and assemble the soot filter of the DPF or clean the soot filter if engine faults SPN 3251 FMI 0, SPN 3720 FMI 0, or SPN 3720 FMI 16 display in the InfoCenter. 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.
Replacing the Fuel-Filter Canister Servicing the Fuel-Water Separator Service Interval: Every 400 hours—Replace the fuel-filter canister. Replace the fuel-filter canister as shown in Figure 89. g198661 Figure 87 Draining Water from the Fuel/Water Separator Service Interval: Before each use or daily—Drain water or other contaminants from the fuel filter/water separator Drain water from the fuel/water separator as shown in (Figure 88).
Servicing the Fuel Filter Service Interval: Every 400 hours 1. Clean the area around the fuel-filter head (Figure 90). g036687 Figure 91 1. Fitting (fuel-pickup tube) 4. Rubber bushing 2. Hose clamp 5. Screen 3. Fuel supply hose g028799 2. Separate the hose from the fitting (Figure 91). 3. Lift the fuel-pickup tube from the fuel tank (Figure 91). Figure 90 1. Fuel-filter head Note: Lift the tube straight from the bushing in the tank. 2. Fuel filter 2.
Charging and Connecting the Battery Electrical System Maintenance 1. Electrical System Safety Unlatch and raise the operator's console panel (Figure 92). • Disconnect the battery before repairing the machine. Disconnect the negative terminal first and the positive last. Connect the positive terminal first and the negative last. • Charge the battery in an open, well-ventilated area, away from sparks and flames. Unplug the charger before connecting or disconnecting the battery.
WARNING 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. Charging the battery produces gasses that can explode. Never smoke near the battery and keep sparks and flames away from battery. • 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.
Drive System Maintenance g225611 Figure 97 g009985 Figure 95 1. Latch 2. Checking for End-Play in the Planetary Drives 2. Right storage box Replace the open fuse(s) as needed (Figure 96). 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.
The oil level should be at the bottom of the check-plug hole. g028798 Figure 98 1. Front drive wheels 4. Repeat step 3 for the other drive wheel. 5. If either wheel moves, contact your authorized Toro distributor to have the planetary drive rebuilt. g225606 Figure 100 1. Check-plug hole 2. Check plug Checking the Planetary Gear-Drive Lubricant 3. If the oil level is low, remove the fill plug at the 12 o’clock position and add oil until it begins to flow out of the hole at the 3 o’clock position.
Filling the Planetary-Gear-Drive with Lubricant 1. Through the fill-plug hole, slowly fill the planetary with 0.65 L (22 fl oz) of high quality SAE 85W-140 wt gear lube. Important: If the planetary fills before the 0.65 L (22 fl oz) of oil is added, wait 1 hour or install the plug and move the machine approximately ten feet to distribute the oil through the brake system. Then, remove the plug and add the remaining oil. g225609 Figure 101 1. Drain-plug hole 3. Check plug 2. Fill plug 4. Drain plug 3.
Checking the Rear Axle and Gearbox for Leaks Service Interval: Before each use or daily Visually inspect the rear axle and rear-axle gearbox for leaks. g009716 Figure 106 2. Fill plug 1. Check plug Changing the Rear-Axle Lubricant Service Interval: After the first 200 hours Every 800 hours Lubricant specification: high-quality SAE 85W-140 gear lubricant g036704 Figure 105 Axle capacity: 2.4 L (80 fl oz) Checking the Rear-Axle Lubricant 1.
Checking the Rear Wheel Toe-In lube or until the lubricant is up to the bottom of the hole. 7. Install the check plug. Service Interval: Every 800 hours/Yearly (whichever comes first) Checking the Rear-Axle-Gearbox Lubricant 1. Park the machine on a level surface, engage the parking brake, lower the mower decks, shut off the engine, and remove the key. 2. Measure the center-to-center distance (at axle height) at the front and rear of the steering tires (Figure 109).
Cooling System Maintenance revolution and tighten the clamp at the connected end of the tie rod. 7. Install the ball joint in the axle-case support, tighten the nut finger-tight, and measure the toe-in. 8. Repeat procedure if necessary. 9. Tighten the nut and install a new cotter pin when the adjustment is correct. Cooling System Safety • Swallowing engine coolant can cause poisoning; keep out of reach from children and pets.
3. Clean the screen thoroughly of all debris. g198662 Figure 112 g009702 Figure 111 1. Rear-screen latch 1. Expansion tank 4. 3. 4. 5. Check the coolant level in the radiator. The radiator should be filled to the top of the filler neck and the expansion tank filled to the FULL mark (Figure 111). If the coolant is low, add a 50/50 mixture of water and ethylene glycol anti-freeze. Do not use water only or alcohol/methanol based coolants. Install the radiator cap and expansion-tank cap.
Brake Maintenance damage to components and compacts debris. 5. Close the rear screen and secure it with the latch. Adjusting the Service Brakes 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 you feel braking resistance. 1. Park the machine on a level surface, engage the parking brake, lower the mower decks, shut off the engine, and remove the key. 2.
Belt Maintenance Hydraulic System Maintenance Servicing the Alternator Belt Hydraulic System Safety • Ensure that all hydraulic-fluid hoses and lines are Service Interval: Every 100 hours in good condition and all hydraulic connections and fittings are tight before applying pressure to the hydraulic system. Proper tension of the belt allows 10 mm (3/8 inch) of deflection when a force of 4.5 kg (10 lb) is applied on the belt midway between the pulleys.
High Viscosity Index/Low Pour Point Anti-Wear Hydraulic Fluid, ISO VG 46 Material Properties: Viscosity, ASTM D445 Viscosity Index ASTM D2270 Pour Point, ASTM D97 Industry Specifications: cSt @ 40°C (104°F) 44 to 50 cSt @ 100°C (212°F) 7.9 to 9.1 140 to 160 g198718 -37°C to -45°C (-34°F to -49°F) Vickers I-286-S (Quality Level), Vickers M-2950-S (Quality Level), Denison HF-0 Important: The ISO VG 46 Multigrade fluid has been found to offer optimal performance in a wide range of temperature conditions.
Changing the Hydraulic Fluid Replacing the Hydraulic Filters Service Interval: Every 800 hours Service Interval: After the first 200 hours 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. Use Toro replacement filters Part No. 94-2621 for the rear (mower decks) of the machine and Part No. 75-1310 for the front (charge) of the machine.
Cutting Unit Maintenance Removing the Cutting Units 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. Disconnect and remove the hydraulic motor from the cutting unit (Figure 119). Cover the top of the spindle to prevent contamination. g036709 g011351 Figure 119 1. Motor-mounting screws 3.
Assembling the Front Roller Installing the Cutting Units 1. Press the first bearing into the roller housing (Figure 121). Press on the outer race only or equally on the inner and outer race. 2. Insert the spacer (Figure 121). 3. Install the hydraulic motor to the cutting unit (Figure 119). Make sure that the O-ring is in position and not damaged. Press the second bearing into the roller housing (Figure 121). Pressing equally on the inner and outer race until the inner race contacts the spacer. 4.
Blade Maintenance 5. Rotate the marked end of the blade to the 3 and 9 o’clock positions (Figure 122) and measure the heights. Blade Safety 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 1.6 to 6.0 mm (0.060 to 0.240 inch) higher than the 12 o’clock setting and within 2.2 mm (0.090 inch) of each other.
Inspecting and Sharpening the Cutting-Unit Blade(s) Note: If the 3 or 9 o’clock side is 1.6 to 6.0 mm (0.060 to 0.240 inch) higher than the new front height then no adjustment is needed for that side. Adjust the other side to within ± 2.2 mm (0.090 inch) of the correct side. 7. Adjust the right and/or left height-of-cut brackets by repeating steps 1 through 4. 8. Secure the carriage bolts and flange nuts. 9. Verify the 12, 3, and 9 o’clock heights.
Note: Remove the blades and sharpen them on a grinder. After sharpening the cutting edges, install the blade with the anti-scalp cup and blade bolt; refer to Removing and Installing the Cutting-Unit Blade(s) (page 79). g004653 Figure 125 1. Cutting edge 3. Wear/slot forming 2. Curved area 4. Crack 3. Examine the cutting edges of all the blades and sharpen the cutting edges if they are dull or nicked (Figure 126).
Storage 10. Preparing for Seasonal Storage Mower Deck If the mower decks are separated from the traction unit for any length of time, install a spindle plug in the top of the spindles to protect the spindles from dust and water. Traction Unit 1. Thoroughly clean the traction unit, mower decks, and the engine. 2. Check the tire pressure; refer to Checking the Tire Pressure (page 26). 3. Check all fasteners for looseness; tighten as necessary. 4. Grease or oil all grease fittings and pivot points.
Notes:
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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).
