Form No. 3434-499 Rev B Groundsmaster® 4500-D and 4700-D Rotary Mower Model No. 30881—Serial No. 403450001 and Up Model No. 30882—Serial No. 403450001 and Up Register at www.Toro.com.
This product complies with all relevant European directives; for details, please see the separate product specific Declaration of Conformity (DOC) sheet. Visit www.Toro.com for product safety and operation training materials, accessory information, help finding a dealer, or to register your product.
Contents Daily Maintenance Checklist............................. 54 Pre-Maintenance Procedures .............................. 55 Lifting the Machine ........................................... 55 Opening the Hood ............................................ 56 Accessing the Hydraulic Lift Compartment ................................................ 57 Lubrication .......................................................... 57 Greasing the Bearings and Bushings ................ 57 Engine Maintenance ........
Safety Blade Maintenance .............................................. 80 Blade Safety ..................................................... 80 Servicing the Blade Plane................................. 80 Removing and Installing the Cutting-Unit Blade(s) ........................................................ 81 Inspecting and Sharpening the Cutting Unit Blade(s) ........................................................ 82 Storage ...................................................................
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 decal107-1972 107-1972 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). 1. Thrown object hazard—use a standard blade when the mulch baffle is installed; do not use a high-lift blade when the mulch baffle is installed.
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 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. pedals and engage the toe pedal. decal120-4159 120-4159 decal117-4764 117-4764 1. Off 8. High 2. Lights 9. Traction drive 3. On 4. Light-switch location 10.
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.
decal133-8062 133-8062 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) 10. Cab (60 A) decalbatterysymbols Battery Symbols Some or all of these symbols are on your battery. 1. Explosion hazard 6. Keep bystanders away from the battery. 2. No fire, open flame, or smoking 7.
decal121-3627 121-3627 1. Height-of-cut settings Affix over Part No. 112-5297 for CE* for 4500 series machines decal127-6447 127-6447 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.
Affix over Part No. 112-5297 for CE* for 4700 series machines decal127-6448 127-6448 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 as well as the conditions in which you would operate the machine to determine whether you can operate the machine 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 1 2 3 4 5 Use Qty. Warning decal CE decal Production-year decal Hood-latch bracket Rivet Washer Screw (1/4 x 2 inches) Locknut (1/4 inch) 1 1 1 1 2 1 1 1 No parts required – Adjust the roller scraper (optional). No parts required – Install the mulching baffle (optional). No parts required – Prepare the machine. Replace the decals (CE machines only).
2 Installing the Hood Latch CE Machines Only Parts needed for this procedure: 1 Hood-latch bracket 2 Rivet 1 Washer 1 Screw (1/4 x 2 inches) 1 Locknut (1/4 inch) g012629 Figure 5 1. CE lock bracket Procedure 1. Unhook the hood latch from the hood-latch bracket. 2. Remove the 2 rivets securing the hood-latch bracket to the hood (Figure 4). 2. Bolt and nut 5. Align the washers with the holes on the inside of the hood. 6. Rivet the brackets and the washers to the hood (Figure 5). 7.
3 Adjusting the Roller Scraper Optional g012631 Figure 7 1. Bolt 2. Nut No Parts Required 3. Arm of hood-latch bracket Procedure The optional rear roller scraper functions best when there is an even gap of 0.5 to 1 mm (0.02 to 0.04 inch) between the scraper and the roller. 1. Loosen the grease fitting and the mounting screw (Figure 8). g011346 Figure 8 1. Roller scraper 3. Grease fitting 2. Mounting screw 13 2. Slide the scraper up or down until you obtain a gap of 0.5 to 1 mm (0.02 to 0.
4 5 Installing the Mulching Baffle Preparing the Machine No Parts Required Optional Procedure No Parts Required 1. Park the machine on a level surface. 2. Lower the cutting units. Procedure 3. Engage the parking brake. Contact your authorized Toro distributor for the correct mulching baffle. 4. Shut off the engine and remove the key. 5. Check the tire pressure before use; refer to Checking the Tire Pressure (page 27). 1.
Product Overview the most comfortable position, and release the pedal (Figure 10). To move the steering wheel away from you, press the foot pedal and release it when the steering wheel reaches the desired operating position. Controls Parking-Brake Pedal To engage the parking brake, (Figure 10) connect the pedals together with the pedal-locking latch and push down on the right brake pedal while engaging the toe pedal.
Engine-Speed Switch Light Switch The engine-speed switch (Figure 11) has 2 modes to change the engine speed. Tap the switch to increase 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. Press the lower edge of the switch (Figure 11) to turn on the lights. Press the upper edge of the switch to turn off the lights.
Using the InfoCenter LCD Display The InfoCenter LCD display shows information about your machine, such as the operating status, various diagnostics and other information about the machine (Figure 15). 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. g024916 Figure 14 1. Weight gauge 2.
InfoCenter Icon Description SERVICE DUE InfoCenter Icon Description (cont'd.) Indicates when scheduled service should be performed Hours remaining until service Start the engine. Reset the service hours The PTO is on. The status of the engine rpm The cruise control is on.
InfoCenter Icon Description (cont'd.) Operator should change to indicated state Symbols are often combined to form sentences. Some examples are shown below Operator should put machine in neutral Engine start is denied Engine shutdown Engine coolant is too hot Hydraulic fluid is too hot DPF ash accumulation notification.
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.
2. To view and change the settings without entering a PIN code, use the right button to change the Protect Settings to OFF. 3. To view and change the settings with a PIN code, use the left button to select ON, set the PIN code, and turn the key to the OFF position and then to the ON position. In the Settings Menu, scroll down to Auto Idle. 2. Press the right button to change the auto idle time between Off, 8S, 10S, 15S, 20S, and 30S.
Specifications g198614 Figure 18 23
Machine Specifications Specifications Table Description 4500-D Figure 18 reference 4700-D Figure 18 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 60). Before Operation Checking the Cooling System Before Operation Safety General Safety Before you start the engine and use the machine, check the cooling system; refer to Checking the Cooling System (page 25).
Filling the Fuel Tank Fuel Table Diesel fuel specification Fuel Tank Capacity ASTM D975 Fuel tank capacity: 83 L (22 US gallons) No. 1-D S15 Location USA No. 2-D S15 Fuel Specification 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. Failure to observe the following cautions may damage the engine.
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 22 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 7. Install the bolt finger-tight. Important: The cutting units often cut 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. 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. Note: Adjustments of more than 3.
• Sparse or limp turf is picked up significantly at Note: The InfoCenter displays "traction denied" higher heights of cut 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. • Wet or sticky clippings are discharged more efficiently reducing congestion in the cutting unit.
Choosing Accessories Optional Equipment Configurations Angle Sail Blade High-Lift, Parallel-Sail Blade (Do not use with the mulching baffle) (Not CE Compliant) 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 • Never leave a running machine unattended. • Before you leave the operator’s position, do the During Operation Safety following: General Safety – Disengage the power takeoff and lower the attachments. • The owner/operator can prevent and is responsible – Engage the parking brake. • • • • • • • • • • • • • • • – Park the machine on a level surface. for accidents that may cause personal injury or property damage.
operation. Operating the machine on any slope requires extra caution. • Evaluate the site conditions to determine if the slope is safe for machine operation, including surveying the site. Always use common sense and good judgment when performing this survey. 2. Press down and hold the engine-speed switch to set the engine to low-idle speed. 3. Turn the key to the RUN position. The glow indicator should illuminate. 4. When the glow indicator dims, turn the key to the START position.
2. Ensure that the PTO switch is set to the DISABLE position. throttle) engine speed generally produces adequate exhaust temperature for DPF regeneration. 3. Move the lever for the mow-speed limiter forward. Important: Minimize the amount of time that you 4. Press the throttle-speed switch to set the engine speed to HIGH IDLE. idle the engine or operate the engine at low-engine speed to help reduce the accumulation of soot in the soot filter. 5.
Engine Warning Messages—Soot Accumulation Indication Level Level 1: Engine Warning Fault Code g213866 Engine Power Rating Recommended Action The computer de-rates the engine power to 85%. Perform a parked regeneration as soon as possible; refer to Performing a Parked or Recovery Regeneration (page 43). The computer de-rates the engine power to 50%. Perform a recovery regeneration as soon as possible; refer to Performing a Parked or Recovery Regeneration (page 43).
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 34). 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 39 2. Figure 41 Press the right button to change the inhibit regeneration setting from On to Off (Figure 39) or from Off to On (Figure 40). Note: If the engine exhaust temperature is too low, the InfoCenter displays ADVISORY #186 (Figure 42) to inform you to set the engine to full throttle (high idle).
Parked or Recovery Regeneration regeneration required—power takeoff disabled ADVISORY #189 (Figure 46). • When the engine computer requests either a parked regeneration or a recovery regeneration, the regeneration request icon (Figure 43) displays in the InfoCenter. g224398 Figure 46 Important: Perform a parked regeneration to restore the PTO function; refer to Preparing to Perform a Parked or Recovery Regeneration (page 43) and Performing a Parked or Recovery Regeneration (page 43).
Important: Perform a recovery regeneration 2. to restore the PTO function; refer to Preparing to Perform a Parked or Recovery Regeneration (page 43) and Performing a Parked or Recovery Regeneration (page 43). 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 54). g224402 g224407 g224629 Figure 52 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 53). g227679 Figure 54 4.
5. The InfoCenter displays the INITIATING DPF REGEN message (Figure 56). Check Message and Corrective Action Table (cont'd.) g224411 Corrective Action: Start and run the engine. g227681 Figure 56 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 57). 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 59). 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 61). g224392 Figure 59 g227305 Note: If the regeneration fails to complete, the Figure 61 InfoCenter displays Advisory #184 (Figure 59). 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 has the ability to 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.
Using Proper Mowing Techniques and damage to the seals and bearings caused by excessive water pressure. Ensure that the radiator and oil cooler are kept free of dirt or grass clippings. After cleaning, inspect the machine for possible hydraulic-fluid leaks, damage, or wear to the hydraulic and mechanical components, and check the cutting-unit blades for sharpness. • To begin cutting, engage the cutting units, then approach the mowing area slowly.
Securing the Cutting Units After Operation 1. Ensure that the PTO is disengaged. General Safety 2. Park the machine on a level surface. • Shut off the engine, remove the key (if equipped), 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 66).
4. 2. With the cutting units lowered, slip the loop of the lanyard into the slot in the reinforcement plate of the roller support (Figure 67). Rotate each valve 3 turns counter-clockwise to open and allow the fluid to bypass internally. Note: Do not open the valve more than 3 turns. Because fluid is bypassed, the machine can be slowly moved without damaging the transmission. g036666 g225485 Figure 67 1. Reinforcement-plate slot (roller support) 2.
Locating the Tie-Down Points Note: Use properly-rated DOT-approved straps in 4 corners to tie down the machine.
Maintenance Note: Determine the left and right sides of the machine from the normal operating position. 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 40). Note: Download a free copy of the electrical or hydraulic schematic by visiting www.Toro.
Maintenance Service Interval Maintenance Procedure Every 200 hours • Torque the wheel lug nuts. Every 250 hours • Change the engine oil and filter. Every 400 hours • Service the air cleaner (earlier if the air cleaner indicator shows red, and more frequently in extremely dirty or dusty conditions). • Inspect the fuel lines and connections. • Replace the fuel-filter canister. • Replace the engine fuel filter. • Check for end-play in the planetary drives.
For the week of: Maintenance Check Item Monday Tuesday Wednesday Thursday Friday Saturday Sunday Drain the water/fuel separator. Check the air filter, dust cup, and burp valve. Check for unusual engine noises.1 Check the radiator and screen for debris Check for unusual operating noises. Check the hydraulic-fluid level. Check the hydraulic hoses for damage. Check for fluid leaks. Check the fuel level. Check the tire pressure. Check the instrument operation. Check the height-of-cut adjustment.
Opening the Hood Tilt the hood to access the chassis as shown in Figure 73. g036670 Figure 71 Rear of the machine—at the center of the axle (Figure 72) Locate the jackstands of the specified capacity at both sides of the gear case and under the axle. Important: Do not support the machine at the tie rod.
Lubrication Accessing the Hydraulic Lift Compartment Greasing the Bearings and Bushings Tilt the seat to access the hydraulic lift compartment as shown in Figure 74. Service Interval: Every 50 hours (also after every washing). Grease specification: No.
• Steering-cylinder ball joints (2) as shown in Figure • Cutting-unit spindle-shaft bearings (2 per cutting 77 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). g009708 Figure 79 g009706 Figure 77 1.
Engine Maintenance Engine Safety • Shut off the engine and remove the key before checking the oil or adding oil to the crankcase. g198631 • Do not change the governor speed or overspeed the engine. 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. Check the whole intake system for leaks, damage, or loose hose clamps.
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. 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.
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—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. Service Interval: Every 250 hours Crankcase oil capacity: approximately 5.7 L (6 US qt) with the filter. 1.
Servicing the Fuel-Water Separator Fuel System Maintenance DANGER Under certain conditions, diesel fuel and fuel vapors are highly flammable and explosive. A fire or explosion from fuel can burn you and others and can cause property damage. • Use a funnel to fill the fuel tank outdoors, in an open area, when the engine is off and is cold. Wipe up any fuel that spills. Figure 87 • Do not fill the fuel tank completely full.
Replacing the Fuel-Filter Canister Servicing the Fuel Filter Service Interval: Every 400 hours—Replace the fuel-filter canister. Service Interval: Every 400 hours 1. Replace the fuel-filter canister as shown in Figure 89. Clean the area around the fuel-filter head (Figure 90). g028799 Figure 90 1. Fuel-filter head 2. Fuel filter 2. Remove the filter and clean the filter head mounting surface (Figure 90). 3.
Cleaning the Fuel-Pickup Tube Screen The fuel-pickup tube, located inside the fuel tank, is equipped with a screen to help prevent debris from entering the fuel system. Remove the fuel-pickup tube and clean the screen as required. 1. 5. Screen 3. Fuel supply hose 2. Separate the hose from the fitting (Figure 91). 3. Lift the fuel-pickup tube from the fuel tank (Figure 91). Note: Lift the tube straight from the bushing in the tank. 4.
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 cutting units, 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.
g009702 Figure 111 1. Expansion tank 3. 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). 4. 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. 5. Install the radiator cap and expansion-tank cap.
Cleaning the 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. While this feature can help reduce the time required to clean oil cooler/radiator, it does not eliminate the need for routine cleaning.
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 you feel braking resistance. Service Interval: Every 100 hours 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.
Hydraulic System Maintenance High Viscosity Index/Low Pour Point Anti-wear Hydraulic Fluid, ISO VG 46 (cont'd.) Material Properties: Hydraulic System Safety Viscosity, ASTM D445 • Seek immediate medical attention if fluid is injected into skin. Injected fluid must be surgically removed within a few hours by a doctor.
If the fluid becomes contaminated, contact your authorized Toro distributor, because the system must be flushed. Contaminated fluid looks milky or black when compared to clean oil. 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. Raise the hood. 3. Disconnect the case return line from the bottom of the reservoir and let the hydraulic fluid flow into a large drain pan. 4.
3. Lower and secure the operator’s seat. 4. Replace the return filter at the right side of the machine (Figure 118). 5. Start the engine and let it run for about 2 minutes to purge air from the system. Shut off the engine and check for leaks. Checking the Hydraulic Lines and Hoses Service Interval: Before each use or daily g201858 Every 2 years Figure 117 2.
Cutting Unit Maintenance Installing the Cutting Units 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. 1. Move the cutting unit into position in front of the machine. 2. Slide the cutting unit-carrier frame onto the lift-arm-pivot pin (Figure 120).
Blade Maintenance Assembling the Front Roller 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. 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. Install the roller assembly into the cutting-unit frame. 5. Verify that there is no more than a 1.5 mm (0.
6. side. Adjust the other side to within ± 2.2 mm (0.090 inch) of the correct side. 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. If any of these measurements are not within specification, proceed to Adjusting the Blade Plane (page 81).
Inspecting and Sharpening the Cutting Unit Blade(s) Two areas must be considered when checking and servicing the mower blade—the sail and the cutting edge. Both cutting edges and the sail, which is the turned-up portion opposite of the cutting edge, contribute to a good quality of cut. The sail is important because it lifts the grass up straight, thereby producing an even cut. However, the sail gradually wears down during operation.
Storage 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 81). Storage Safety • Shut off the engine, remove the key (if equipped), and wait for all movement to stop before you leave the operator’s position. Allow the machine to cool before adjusting, servicing, cleaning, or storing it.
2. Remove and discard the oil filter. Install a new oil filter. 3. Refill the oil pan with designated quantity of motor oil. 4. Turn the key in the switch to the ON position, start the engine, and run it at idle speed for approximately 2 minutes. 5. Turn the key in the switch to the OFF position. 6. Thoroughly drain all fuel from the fuel tank, lines, and the fuel filter/water separator assembly. 7. Flush the fuel tank with fresh, clean diesel fuel. 8. Secure all fuel-system fittings. 9.
Notes:
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California Proposition 65 Warning Information What is this warning? You may see a product for sale that has a warning label like the following: WARNING: Cancer and Reproductive Harm—www.p65Warnings.ca.gov. What is Prop 65? Prop 65 applies to any company operating in California, selling products in California, or manufacturing products that may be sold in or brought into California.
The Toro Warranty Two-Year or 1,500 Hours Limited Warranty Conditions and Products Covered Parts 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 2 years or 1,500 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).
