Form No. 3437-521 Rev C Groundsmaster® 4500-D or 4700-D Rotary Mower Model No. 30885—Serial No. 400000000 and Up Model No. 30887—Serial No. 400000000 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 Diesel Particulate Filter Regeneration............... 41 Operating the Engine-Cooling Fan.................... 53 Operating Tips ................................................. 54 After Operation .................................................... 55 General Safety ................................................. 55 Using the Cutting-Unit Storage Lanyard............ 55 Using the Transport Latches ............................. 56 Hauling the Machine .........................................
Safety Brake Maintenance ............................................. 80 Adjusting the Service Brakes ............................ 80 Belt Maintenance ................................................ 80 Servicing the Alternator Belt ............................. 80 Hydraulic System Maintenance ........................... 81 Hydraulic System Safety................................... 81 Servicing the Hydraulic Fluid ............................ 81 Checking the Hydraulic Lines and Hoses......................
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. decal120-8947 decal117-4764 120–8947 117-4764 1. Warning—read the Operator’s Manual. 1. Thrown object hazard—keep bystanders away. 2.
decal127-3700 127-3700 For Groundsmaster 4700 Only decal121-3884 121–3884 1. Engine—stop 1. Raise the left cutting unit. 3. Engine—start 4. Set the cruise control. 2. Raise the center cutting 5. Disengage the cruise units. control. 3. Raise the right cutting unit. 2. Engine—preheat decalbatterysymbols decal121-3887 Battery Symbols Some or all of these symbols are on your battery. 121–3887 1. Read the Operator’s Manual. 1. Explosion hazard 6. Keep bystanders away from the battery. 2.
decal136-3185 136-3185 1. Headlights—Off 5. Low 2. Headlights—On 6. Lower the left cutting unit. 3. High/Low—Auto 7. Lower the center cutting unit. 8. Lower the right cutting unit. 4. Traction controls decal136-3338 136-3338 1. TEC—7.5 A 2. Power—10 A 6. Power seat—10 A 7. Engine—10 A 3. InfoCenter—2 A 4. Auxiliary power—10 A 8. TEC—2 A 9. Telematics—10 A 5. Work lights—10 A 8 10.
decal138-6978 138-6978 1. Read the Operator’s Manual. decal121-3627 121-3627 1.
Affix over Part No. 112-5297 for CE* for 4500 series machines (Model No. 30885) 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 (Model No. 30887) 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.
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).
g012628 Figure 4 g279018 Figure 3 1. Warning decal 1. Hood-latch bracket 2. Rivets 3. Production-year decal 2. CE decal 3. Remove the hood-latch bracket from the hood. 4. While aligning the mounting holes, position the CE lock bracket and the hood-latch bracket onto the hood (Figure 5). 2 Note: The lock bracket must be against the hood. Do not remove the bolt and nut from the lock-bracket arm.
3 Adjusting the Roller Scraper Optional g012630 Figure 6 No Parts Required 1. Hood latch Procedure 8. Install the bolt into the other arm of the hood-latch bracket to lock the latch in position (Figure 7). Tighten the bolt but do not tighten the nut. 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 g012631 Figure 7 1.
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. For Groundsmaster 4500 and 4700 machines, release the No. 4 and No. 5 cutting-unit cables (Figure 70). 3. For Groundsmaster 4700 machines, release the No. 6 and No. 7 cutting-unit latches (Figure 73). 4. Lower the cutting units. 5. Engage the parking brake. 6. Shut off the engine and remove the key. 7.
Parking-Brake Pedal Product Overview 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. To release the parking brake, press 1 of the brake pedals until the parking brake latch retracts. Controls Key Switch The key switch (Figure 11) has 3 positions: OFF, ON/PREHEAT , and START . g009979 Figure 10 1. Brake pedal 4. Traction pedal 2. Pedal-locking latch 5. Tilt-steering pedal 3.
Note: If you have the switch in the H/L AUTO position, you cannot lower the decks from the fully-raised position unless the traction pedal is in neutral and the machine is stopped. Cruise-Control Switch The cruise-control switch locks in the cruise control to maintain the desired ground speed (Figure 12). Pressing the rear of the switch turns off the cruise control, the middle position of the switch enables the cruise-control function, and the front of the switch sets the desired ground speed.
Armrest Adjustment Knob Rotate the knob to adjust the armrest angle (Figure 14). Seat-Back Adjustment Lever Move the lever to adjust the seat-back angle (Figure 14). Weight Gauge The weight gauge indicates when the seat is adjusted to the operator’s weight (Figure 14). Adjust the height by positioning the suspension within the range of the green region. Weight Adjustment Lever Use this lever to adjust the seat to your weight (Figure 14).
Specifications g198614 Figure 15 1. Cutting unit 1 3. Cutting unit 3 5. Cutting unit 5 2. Cutting unit 2 4. Cutting unit 4 6. Cutting unit 6 (4700 only) 19 7.
Machine Specifications Specifications Table Description 4500-D Figure 15 reference 4700-D Figure 15 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 Raised 226 cm (88.8 inches) C 226 cm (88.8 inches) C Lowered 165 cm (65.
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 65). 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 78).
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 19 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 rotary 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 rotary cutting-unit bench measurement at 6 mm (1/4 inch) above that of reel cutting units cutting in the same area.
• 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) 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.
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 24). 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.) Shut off 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 fluid is too hot PIN code DPF ash accumulation notification.
Using the Menus Settings 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.
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. Accessing Protected Menus Note: The factory default PIN code for you machine is either 0000 or 1234. If you changed the PIN code and forgot the code, contact your authorized Toro distributor for assistance. 1.
Viewing and Changing the Protected Menu Settings 1. 2. 3. 4. Turning the Smart Power ON/OFF In the Protected Menu, scroll down to Protect Settings. To view and change the settings without entering a PIN code, use the right button to change the Protect Settings to OFF. 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.
During Operation • Before you leave the operator’s position, do the following: – Park the machine on a level surface. During Operation Safety – Disengage the power takeoff and lower the attachments. General Safety – Engage the parking brake. • The owner/operator can prevent and is responsible – Shut off the engine and remove the key. • • • • • • • • • • • • • • • • for accidents that may cause personal injury or property damage.
• Lower a folding roll bar temporarily only when • • necessary. Do not wear the seat belt when the roll bar is folded down. Be aware that there is no rollover protection when a folded roll bar is in the down position. Check the area that you will be mowing and never fold down a folding roll bar in areas where there are slopes, drop-offs, or water.
Understanding the Operating Characteristics of the Machine operate in low speed range. This setting is preferable for operation in a shop area, loading or unloading from a trailer, climbing steep inclines, or any other operation where the higher traction speeds of the high speed range is not desired. • This machine has an automotive-style throttle that • If an obstacle is in the way, lift the cutting units to is controlled by the traction pedal. mow around it.
Using the High and Low Speed Range Switch This machine is equipped with 2 traction speed ranges; low and high. The speed range switch allows you to select the following positions (Figure 27): • High/Low Auto range: Selecting the H/L AUTO position allows the machine to automatically select between the low and high speed ranges. The H/L AUTO position is comparable to selecting D (drive) in your car with an automatic transmission.
is limited from 0 to 75% and matched to the full stroke of the traction pedal. This setting increases the traction pedal resolution, resulting in improved control. How far you move the traction pedal changes how much the machine's speed changes. Using the Brake Pedals Important: In emergency braking situations, remove your foot from the traction pedal and then press the brake pedals. g321522 Figure 28 In the low speed range only, you can use the brakes individually for turning or to improve traction.
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. After the cruise control switch is enabled and the speed is set (Figure 31), use the InfoCenter to adjust the speed setting of the cruise control (Figure 24 and Figure 32).
Understanding the Turnaround Mode Understanding Toro Smart Power™ The turnaround mode allows you convenient, 1-touch control to raise the cutting units above the turf while temporarily stopping the blades, allowing you to focus on driving the machine at the end of a mowing pass, or while navigating other obstacles. With Smart Power, the operator does not have to listen to the engine speed in heavy load conditions.
Shutting Off the Engine rocker switch once the front cutting units are over the mowing area. Important: Allow the engine to idle for 5 minutes before shutting it off after a full-load operation. This allows the turbocharger to cool down before shutting off the engine. Failure to do so may lead to premature turbocharger failure. Note: Practice to ensure the cutting units do not lower early or mow an unintended area. 9. 10.
Diesel Particulate Filter Regeneration Operate and maintain your machine with the function of the DPF in mind. Engine load at high idle (full throttle) engine speed generally produces adequate exhaust temperature for DPF regeneration. 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 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.
Access the DPF Regeneration menu, press the center button to scroll down to the TECHNICIAN option, and press the right button to select the Technician entry (Figure 39). DPF Operation Table (cont'd.) g227348 Figure 39 State Description Reset Stby The engine computer is trying to run a reset regeneration, but 1 of the following conditions prevents regeneration: The regen inhibit setting is set to ON. The exhaust temperature is too low for regeneration.
Passive DPF Regeneration Important: The high exhaust-temperature icon indicates that the exhaust temperature discharged from of your machine may be hotter than during regular operation. To promote DPF regeneration, mow with the machine to create full engine speed and high load. The icon displays in the InfoCenter while the reset regeneration is processing. Whenever possible, do not shut off the engine or reduce engine speed while the reset regeneration is processing.
option, and press the right button to select the Inhibit Regen entry (Figure 44). g224394 Figure 46 g227304 Figure 44 2. Note: If the InfoCenter displays ADVISORY #186 (Figure 47), set the engine to full throttle (high idle) to allow the reset regeneration to continue. Press the right button to change the inhibit regeneration setting from On to Off (Figure 44) or from Off to On (Figure 45).
Parked or Recovery Regeneration regeneration required—power takeoff disabled ADVISORY #189 (Figure 51). • When the engine computer requests either a parked regeneration or a recovery regeneration, the regeneration request icon (Figure 48) displays in the InfoCenter. g224398 Figure 51 Important: Perform a parked regeneration to restore the PTO function; refer to Preparing to Perform a Parked or Recovery Regeneration (page 49) and Performing a Parked or Recovery Regeneration (page 49).
Preparing to Perform a Parked or Recovery Regeneration 1. Ensure that the machine has fuel in the tank for the type of regeneration you are performing: • Parked Regeneration: Ensure that you g224399 Figure 55 have 1/4 tank of fuel before performing the parked regeneration. • Recovery Regeneration: Ensure that you Important: Perform a recovery regeneration have 1/2 tank of fuel before performing the recovery regeneration.
3. At the DPF checklist screen, verify that the parking brake is engaged and that the engine speed is at low idle (Figure 60). Note: Do not press the traction pedal during a parked or recovery regeneration. g224402 g224407 g224629 Figure 58 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 59).
g224406 g224406 Figure 63 7. g224626 Note: If you attempt to do a forced parked regeneration before 50 hours of the last sucessful regeneration this message will appear. If the machine is requesting a regeneration and this message appears contact your authorized Toro distributor for service. g224630 Figure 61 5. The engine computer checks the engine state and fault information.
Check Message and Corrective Action Table (cont'd.) Corrective Action: Change the engine speed to low idle. g224392 Figure 65 Corrective Action: Troubleshoot the engine computer condition and retry DPF regeneration. 8. Note: If the regeneration fails to complete, the InfoCenter displays Advisory #184 (Figure 65). Press the left button to exit to the home screen.
Operating the Engine-Cooling Fan Canceling a Parked or Recovery Regeneration Use the Parked Regen Cancel or Recovery Regen Cancel setting to cancel a running parked or recovery regeneration process. 1. 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.
Operating Tips Checking the Condition of the Cutting Unit Changing Mowing Patterns Ensure that the cutting chambers are in good condition. Straighten any bends in the chamber components to ensure correct blade tip/chamber clearance. Ensure all rollers and pivoting joints do not have play in them to prevent turf damage or poor after cut appearance. Change mowing patterns often to minimize a poor after-cut appearance from repeatedly mowing in the same direction.
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, and wait 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 71). • • • • • • for all movement to stop before you leave the operator’s position.
4. With the cutting units lowered, slip the loop of the lanyard into the slot in the reinforcement plate of the roller support (Figure 72). g225485 Figure 72 1. Reinforcement-plate slot (roller support) g038610 2. Lanyard loop Figure 73 Using the Transport Latches Hauling the Machine Groundsmaster 4700 Only • Use the 2 rear-transport latches for the No. 6 and 7 cutting units (Figure 15) when moving the machine over long distances, rough terrain, when transporting, or storing the machine.
2. Locating the Tie-Down Points 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 Note: Use properly-rated DOT-approved straps in 4 turns. Because fluid is bypassed, you can move the machine slowly without damaging the transmission. corners to tie down the machine. • On each side of the frame by the operator’s platform • On the rear bumper g036666 g208989 Figure 75 g020510 Figure 74 1. Bypass valve (2) 3.
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 46). Note: Download a free copy of the electrical or hydraulic schematic by visiting www.Toro.
Maintenance Service Interval Maintenance Procedure Every 50 hours • Grease the bearings and bushings (also after every washing). • Check the battery condition. Every 100 hours • Check the condition and tension of the alternator belt. Every 200 hours • Torque the wheel lug nuts. 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.
Daily Maintenance Checklist Duplicate this page for routine use. For the week of: Maintenance Check Item Monday Tuesday Wednesday Thursday Friday Saturday Check the safety-interlock operation. Check the brake operation. Check the engine-oil level. Check the cooling-system-fluid level. 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.
Pre-Maintenance Procedures Lifting the Machine Use the following as points to lift the machine: Front of the machine—at the frame of the machine, forward of the wheel-drive motors (Figure 77) Important: Do not support the machine at the wheel-drive motors. Keep the lifting equipment clear of hydraulic tubing and hoses.
Accessing the Hydraulic Lift Compartment Opening the Hood Tilt the hood to access the chassis as shown in Figure 79. Tilt the seat to access the hydraulic lift compartment as shown in Figure 80.
Lubrication • Steering-cylinder ball joints (2) as shown in Figure 83 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 81 g009706 Figure 83 g009704 1.
Engine Maintenance • Cutting-unit spindle-shaft bearings (2 per cutting unit) as shown in Figure 85 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 and remove the key before checking the oil or adding oil to the crankcase. • Do not change the governor speed or overspeed the engine.
g198631 g009712 Figure 89 1. Air-cleaner safety filter 2. Reset the indicator (Figure 87) 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 3,000 hours or clean the soot filter if engine faults P242F or P1420 display in the InfoCenter. Contact your authorized Toro distributor. 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 95. g198661 Figure 93 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 94).
Servicing the Fuel Filter Service Interval: Every 400 hours 1. Clean the area around the fuel-filter head (Figure 96). g036687 Figure 97 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 97). 3. Lift the fuel-pickup tube from the fuel tank (Figure 97). Figure 96 1. Fuel-filter head Note: Lift the tube straight from the bushing in the tank. 2. Fuel filter 2.
Priming the Fuel System Electrical System Maintenance Prime the fuel system before starting the engine for the first time, after running out of fuel, or after fuel system maintenance (e.g., draining the filter/water separator, replacing a fuel hose). Electrical System Safety To prime the fuel system, perform the following steps: 1. Ensure that fuel is in the fuel tank. 2. Perform the following steps to prime the filter and the lines to the high pressure pump to prevent wear or damage to the pump: A.
Charging and Connecting the Battery 1. WARNING Battery terminals or metal tools could short against metal components, causing sparks. Sparks can cause the battery gasses to explode, resulting in personal injury. • When removing or installing the battery, do not allow the battery terminals to touch any metal parts of the machine. • Do not allow metal tools to short between the battery terminals and metal parts of the machine.
positioned snug to the battery. The cable must not contact the battery cover. 8. Coat both battery connections with Grafo 112X (skin-over) grease, Part No. 505-47, petroleum jelly, or light grease to prevent corrosion. 9. Slide the rubber boot over the positive terminal. 10. Close the console panel and secure the latch. Locating the Fuses The fuse block for the machine is located in the right storage box g009985 Figure 100 1. Latch 2. 2.
Drive System Maintenance g028798 Figure 103 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. g225611 Figure 102 Checking the Planetary Gear-Drive Lubricant Checking for End-Play in the Planetary Drives Service Interval: Every 400 hours (check if you notice external leakage).
The oil level should be at the bottom of the check-plug hole. g225609 Figure 106 g225606 Figure 105 1. Check-plug hole 2. Check plug 1. Drain-plug hole 3. Check plug 2. Fill plug 4. Drain plug 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. 3. Place a drain pan under the planetary hub, remove the drain plug at the 6 o’clock position, and allow the oil to fully drain (Figure 106). 4.
Filling the Planetary-Gear-Drive with Lubricant 1. Checking the Rear Axle and Gearbox for Leaks 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. Service Interval: Before each use or daily Visually inspect the rear axle and rear-axle gearbox for leaks. Important: If the planetary fills before the 0.
lube or until the lubricant is up to the bottom of the hole. 7. Install the check plug. Checking the Rear-Axle-Gearbox Lubricant Service Interval: Every 400 hours g009716 Figure 111 The gear box is filled with SAE 85W-140 gear lube. The capacity is 0.5 L (16 fl oz). Visually inspect for leaks daily. 2. Fill plug 1. Check plug Changing the Rear-Axle Lubricant Service Interval: After the first 200 hours Every 800 hours 1.
Checking the Rear Wheel Toe-In 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. Service Interval: Every 800 hours/Yearly (whichever comes first) 1. 2.
Cooling System Maintenance Cooling System Safety • Swallowing engine coolant can cause poisoning; keep out of reach from children and pets. • Discharge of hot, pressurized coolant or touching a hot radiator and surrounding parts can cause severe burns. – Always allow the engine to cool at least 15 minutes before removing the radiator cap. – Use a rag when opening the radiator cap, and open the cap slowly to allow steam to escape. • Do not operate the machine without the covers in place.
3. Unlatch and swing open the rear screen (Figure 117). Note: To remove the screen, lift it off the hinge pins. 4. Clean the screen thoroughly of all debris. g020509 Figure 118 1. Oil cooler/radiator g198662 Figure 117 Important: Cleaning the oil cooler/radiator 1. Rear-screen latch 5. with water promotes premature corrosion damage to components and compacts debris. Thoroughly clean both sides of the oil cooler and the radiator with compressed air (Figure 118). 6.
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 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.
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 123). 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 122 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 124). 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 125).
Blade Maintenance Assembling the Front Roller 1. Press the first bearing into the roller housing (Figure 126). Press on the outer race only or equally on the inner and outer race. 2. Insert the spacer (Figure 126). 3. Press the second bearing into the roller housing (Figure 126). 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 86).
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 86). Storage Safety • Shut off the engine, remove the key, 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.
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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).
