Groundsmaster® 4500-D and 4700-D Traction Unit

Check the tire pressure before use; refer to Checking the Tire Pressure.

Important: Maintain pressure in all tires to ensure a good quality-of-cut and proper machine performance. Do not underinflate the tires.

1. Check the rear-axle lubricant level before the engine is first started, refer to Checking the Rear-Axle Lubricant.

2. Check the engine-oil level before starting the engine; refer to Checking the Engine-Oil Level.

3. Check the hydraulic-fluid level before starting the engine; refer to Checking the Hydraulic-Fluid Level.

4. Check the cooling system before starting the engine; refer to Checking the Cooling System.

Grease the machine before use; refer to Greasing the Bearings and Bushings. Failure to properly grease the machine results in premature failure of critical parts.

Move the seat adjustment lever on the side of the seat outward, slide the seat to the desired position, and release the lever to lock the seat into position (Figure 12).

Figure 12

1. Weight gauge
2. Weight adjustment lever
3. Seat adjustment lever
4. Seat-back adjustment lever
5. Armrest adjustment knob

Rotate the knob to adjust the armrest angle (Figure 12).

Move the lever to adjust the seat-back angle (Figure 12).

The weight gauge indicates when the seat is adjusted to the weight of the operator (Figure 12). Adjust the height by positioning the suspension within the range of the green region.

Use this lever to adjust to the proper weight of the operator (Figure 12). Pull up the lever to increase the air pressure and push down to decrease the air pressure. The proper adjustment is correct when the weight gauge is in the green region.

1. From the Main Menu, scroll down to the Settings Menu and press the right button.

2. In the Settings Menu, scroll down to the Protected Menu and press the right button.

3. To enter the passcode, use the center button to set the first digit then press the right button to move on to the next digit.

4. Use the center button to set the second digit then press the right button to move on to the next digit.

5. Use the center button to set the third digit then press the right button to move on to the next digit.

6. Use the center button to set the fourth digit then press the right button.

7. Press the middle button to enter the code.

You can change the ability to view and change the settings in the Protected Menu. Go to the Protected Menu and scroll down to Protect Settings. Using the right button, changing Protect Settings to the OFF position allows you to view and change the settings in the Protected Menu without entering the passcode. Changing Protect Settings to the ON position hides the protected options and requires entering a passcode to change the setting in the Protected Menu. After you have set the passcode, you must turn the key to the OFF position and then to the ON position to enable and save this feature.

1. In the Protected Menu, scroll down to Protect Settings.

2. To view and change the settings without entering a passcode, use the right button to change the Protect Settings to OFF.

3. To view and change the settings with a passcode, use the left button to select ON, set the passcode, and turn the key to the OFF position and then to the ON position.

1. 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.

1. In the Settings Menu, scroll down to Mow Speed and press the right button.

2. Use the right button to increase the max full mow speed in 5% increments between 50% and 100%.

3. Use the center button to decrease the max full mow speed in 5% increments between 50% and 100%.

4. Press the left button to exit.

1. In the Settings Menu, scroll down to Transport Speed and press the right button.

2. Use the right button to increase the max transport speed in 5% increments between 50% and 100%.

3. Use the center button to decrease the max transport speed in 5% increments between 50% and 100%.

4. Press the left button to exit.

1. In the settings menu, scroll down to Smart Power.

2. Press the right button to switch between ON and OFF.

3. Press the left button to exit.

1. In the Settings Menu, scroll down to Counter Balance and press the right button.

2. Press the right button to switch between Low, Med, and High.

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.

You can view the average fuel consumption rate for the lifetime of the machine in the Service Menu.

If the Stationary Regeneration icon appears on the InfoCenter, refer to the Service Manual or contact your Toro Distributor for the maintenance procedure.

Before you start the engine and use the machine, check the oil level in the engine crankcase; refer to Checking the Engine-Oil Level.

Before you start the engine and use the machine, check the cooling system; refer to Checking the Cooling System.

Before you start the engine and use the machine, check the hydraulic system; refer to Checking the Hydraulic Lines and Hoses.

Drain water or other contaminants from the water separator; refer to Servicing the Water Separator.

Check the rear axle and rear-axle gearbox for leaks; refer to Checking the Rear Axle and Gearbox for Leaks.

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.

Figure 16

Torque the wheel-lug nuts to 115 to 136 N∙m (85 to 100 ft-lb) in the order shown in Figure 17 and Figure 18.

Figure 17

Front Wheels

Figure 18

Rear Wheels

Important: Always use the seat belt when the roll bar is in the raised and locked position. Do 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.

Important: Ensure that the seat is secured with the seat latch.

Figure 19

Close section

Raising the Roll Bar

Figure 20

Close section

Important: The mower decks 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 mower deck’s bench 6 mm (1/4 inch) above that of reel cutting units cutting in the same area.

Important: Access to the rear mower decks is greatly improved by removing the mower deck from the machine.

1. Park the machine on a level surface, engage the parking brake, lower the mower deck to the ground, shut off the engine, and remove the key.

2. Loosen the bolt securing each height-of-cut bracket to the height-of-cut plate (front and each side) as shown inFigure 21.

3. Beginning with front adjustment, remove the bolt.

   

   Figure 21

   1. Height-of-cut bracket
   2. Height-of-cut plate
   3. Spacer

4. While supporting the chamber, remove the spacer (Figure 21).

5. Move the chamber to the desired height of cut and install a spacer into the designated height-of-cut hole and slot (Figure 22).

   

   Figure 22

6. Position the tapped plate in-line with the spacer.

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 3.8 cm (1-1/2 inches) may require temporary assembly to an intermediate height to prevent binding (e.g., changing from 3.1 to 7 cm (1.25 to 2.75 inches) height of cut).

The interlock switches are designed to shut off the machine when you rise from the seat when the traction pedal is pressed. However, you may rise from the seat while the engine is running and the traction pedal is in the NEUTRAL position. Although the engine continues to run when you disengage the PTO switch and release the traction pedal, shut off the engine before rising from the seat.

1. Park the machine on a level surface, engage the parking brake, lower the mower decks, and turn the key to the OFF position.

2. Press the traction pedal and turn the key to the ON position.

   Note: If the engine cranks, there is a malfunction in the interlock system. Correct this malfunction before operating the machine.

3. Turn the key to the ON position, rise from the seat, and move the PTO switch to ON.

   Note: The PTO should not engage. If the PTO engages, there is a malfunction in the interlock system. Correct this malfunction before operating the machine.

4. Engage the parking brake, turn the key to the ON position and move the traction pedal out of the NEUTRAL position.

   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.

Note: Lower the decks onto a clean section of turf or hard surface to avoid throwing dust and debris.

To verify this stopping time, have someone stand back from the decks at least 6 m (20 ft) and watch the blades on 1 of the mower decks. Disengage the mower decks and record the time it takes for the blades to come to a complete stop. If this time is greater than 7 seconds, adjust the braking valve. Call your Toro Distributor for assistance in making this adjustment.

Important: Bleed the fuel system if any of the following have occurred:

• The engine has shut off due to lack of fuel.

• Maintenance has been performed upon the fuel system components.

1. Remove your foot from the traction pedal and ensure that it is in NEUTRAL. Ensure that the parking brake is engaged.

2. Move the throttle control to the low idle position.

3. Turn the key to the RUN position. The glow indicator should light.

4. When the glow indicator dims, turn the key to the START position.

   Important: Do not run the starter motor more than 15 seconds at a time or premature 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.

5. Release the key immediately when the engine starts and allow it to return to the RUN position.

6. Move the throttle control to the desired position.

   When the temperature is less than -7°C (20°F), the starter motor can be run for 30 seconds on then 60 seconds off for 2 attempts.

   Important: Shut off the engine and allow the engine to cool before you check for oil leaks, loose parts, or other malfunctions.

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 turbocharger trouble.

Note: Lower the mower decks to the ground whenever machine is parked. This relieves the hydraulic load from the system, prevents wear on system parts, and also prevents accidental lowering of the mower decks.

1. Move the throttle control backward to the SLOW position.

2. Move the PTO switch to the OFF position.

3. Engage the parking brake.

4. Rotate the ignition key to the OFF position.

5. Remove the key to prevent accidental starting.

Practice driving the machine because it has a hydrostatic transmission and its characteristics are different than many turf maintenance machines. Some points to consider when operating the machine and mower decks are the transmission, engine speed, load on the cutting blades and the importance of the brakes.

With Toro Smart Power ™, the operator does not have to listen to the engine speed in heavy conditions. Smart Power prevents bogging down in heavy turf by automatically controlling the machine speed and optimizing cutting performance.

Another characteristic to consider is the operation of the pedals that are connected to the brakes. The brakes can be used to assist in turning the machine. However, use them carefully, especially on soft or wet grass because the turf may be torn accidentally. Another benefit of the brakes is to maintain traction. For example, in some slope conditions, the uphill wheel slips and loses traction. If this situation occurs, depress the uphill turn pedal gradually and intermittently until the uphill wheel stops slipping, thus, increasing traction on the downhill wheel.

Use extra care when operating the machine on slopes. Make sure that the seat latch is properly secured and the seat belt is buckled. Drive slowly and avoid sharp turns on slopes to prevent rollovers. For steering control, the mower decks must be lowered when going downhill.

Important: Allow the engine to idle for 5 minutes before shutting it off after a full load operation. This allows the turbo charger to cool down before shutting the engine off. Failure to do so may lead to turbo-charger trouble.

Before shutting off the engine, disengage all controls and set the engine speed to slow. Setting the engine speed to slow reduces high engine rpm, noise, and vibration. Turn the key to the OFF position to shut off the engine.

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. A reverse cycle is automatically initiated when either the coolant or hydraulic-fluid temperature reaches a specific temperature.

You can manually reverse the fan by pressing the 2 outer buttons of the InfoCenter for 2 seconds—the fan completes a manually initiated reverse cycle. Reverse the fan when the rear screen is clogged or prior to moving the machine into the shop or a storage area.

Figure 23

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.

Note: Pressing either the brake pedal or moving the traction pedal into the REVERSE position, for 1 second, also disengages the pedal position.

Use the 2 rear-transport latches for the No. 6 and 7 mower decks when moving the machine over long distances, rough terrain, when transporting, or storing the machine.

Figure 24

• Use care when loading or unloading the machine into a trailer or a truck.

• Use full-width ramps for loading the machine into a trailer or a truck.

• Tie the machine down securely.

In an emergency, the machine can be moved forward by actuating the bypass valve in the variable-displacement hydraulic pump and pushing or towing the machine.

Important: Do not push or tow the machine faster than 3 to 4.8 km/h (2 to 3 mph), because internal-transmission damage may occur. The bypass valves must be open whenever you push or tow the machine.

1. Open the hood and locate the bypass valves (Figure 25) on the top of pump, behind the battery/storage boxes.

2. Rotate each valve 3 turns counter-clockwise to open and allow oil to bypass internally.

   Note: Do not open more than 3 turns. Because fluid is bypassed, the machine can be slowly moved without damaging the transmission.

   

   Figure 25

   1. Bypass valve (2)

3. Close the bypass valves before starting the engine. Torque to 70 N∙m (52 ft-lb) to close the valve.

Important: If you must push or tow the machine in reverse, the check valve in the 4-wheel drive manifold must also be bypassed. To bypass the check valve, connect a hose assembly (Part No. 95-8843), 2 coupler fittings (Part No. 95-0985), and 2 hydraulic fittings (Part No. 340-77) to the reverse-traction, pressure test port, located on the hydrostat, and on the port located between ports M8 and P2 on the rear traction manifold, which is located to the inside of the front, rear tire.

Note: Use properly-rated DOT-approved straps in 4 corners to tie down the machine.

• On each side of the frame by the operator’s platform

• On the rear bumper

Figure 26

Figure 27

1. Ensure that the PTO is disengaged.

2. Park the machine on a level surface.

3. Engage the parking brake.

4. Lower the cutting unit(s) if necessary.

5. Shut off the engine and wait for all moving parts to stop.

6. Turn the ignition key to the STOP position and remove it.

7. Allow machine components to cool before performing maintenance.

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 29)

Important: Do not support the machine at the wheel-drive motors. Keep the lifting equipment clear of hydraulic tubing and hoses.

Figure 29

Rear of the machine—at the center of the axle (Figure 30)

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.

Figure 30

Tilt the hood to access the chassis as shown in Figure 31.

Figure 31

Tilt the seat to access the hydraulic lift compartment as shown in Figure 32.

Figure 32

Grease specification: No. 2 lithium grease

The grease fitting locations and quantities are as follows:

• Brake-shaft pivot bearings (5) as shown in Figure 33

  

  Figure 33

• Rear-axle-pivot bushings (2) as shown in Figure 34)

  

  Figure 34

• Steering-cylinder ball joints (2) as shown in Figure 35

  

  Figure 35

  1. Top fitting on kingpin

• Tie-rod ball joints (2) as shown in Figure 35

• Kingpin bushings (2) as shown in Figure 35

  Important: The top fitting on the kingpin should only be lubricated annually (2 pumps).

• Lift-arm bushings (1 per deck) as shown in Figure 36

  

  Figure 36

• Lift-cylinder bushings (2 per deck) as shown in Figure 36

• Cutting-unit spindle-shaft bearings (2 per mower deck) as shown in Figure 37

  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 deck).

  

  Figure 37

• Cutting-unit carrier-arm bushings (1 per mower deck) as shown in Figure 37

• Rear roller bearings (2 per mower deck) as shown in Figure 38

  

  Figure 38

  Important: Make sure that the grease groove in each roller mount aligns with the grease hole in each end of the roller shaft. To help align the groove and the hole, there is also an alignment mark on 1 end of the roller shaft.

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.

Service the air-cleaner filter only when the service indicator (Figure 39) requires it. Changing the air filter before it is necessary only increases the chance of dirt entering the engine when you remove the filter.

Figure 39

1. Air-cleaner indicator

Important: Be sure that the cover is seated correctly and seals with the air-cleaner body.

1. Replace the air cleaner (Figure 40).

   

   Figure 40

   Note: Do not clean a used element because cleaning it can damage the filter media.

   Important: Never attempt to clean the safety filter (Figure 41). Replace the safety filter after every 3 primary filter services.

   

   Figure 41

   1. Air-cleaner safety filter

2. Reset the indicator (Figure 39) if it shows red.

Drain and clean the tank also if the fuel system becomes contaminated or if you are storing the machine for an extended period of time. Use clean fuel to flush out the tank.

Inspect the fuel lines and connections for deterioration, damage, or loose connections.

Service the water separator as shown in Figure 44.

Figure 44

1. Clean the area around the fuel-filter head (Figure 45).

   

   Figure 45

   1. Fuel-filter head
   2. Fuel filter

2. Remove the filter and clean the filter head mounting surface (Figure 45).

3. Lubricate the filter gasket with clean lubricating engine oil; refer to the engine owner's manual for additional information.

4. Install the dry filter canister, by hand, until the gasket contacts the filter head, then rotate it an additional 1/2 turn.

5. Start the engine and check for fuel leaks around the filter head.

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. Remove the hose clamp that secures the fuel supply hose to the fitting of the fuel-pickup tube (Figure 46).

   

   Figure 46

   1. Fitting (fuel-pickup tube)
   2. Hose clamp
   3. Fuel supply hose
   4. Rubber bushing
   5. Screen

2. Separate the hose from the fitting (Figure 46).

3. Lift the fuel-pickup tube from the fuel tank (Figure 46).

   Note: Lift the tube straight from the busing in the tank.

4. Clean any debris from the screen at the end of the fuel-pickup tube (Figure 46).

5. Insert the fuel-pickup tube through the rubber bushing and into the tank (Figure 46).

   Note: Ensure that the fuel-pickup tube is fully seated into the rubber bushing.

6. Install the supply hose onto the fitting of the fuel-pickup tube, and secure the hose with the hose clamp that you removed in step 1.

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). To prime the fuel system, make sure that the fuel tank has fuel in it. Then, turn the ignition key to the ON position for 10 to 15 seconds which allows the fuel pump to prime the fuel system.

Important: Do not use the engine starter motor to crank the engine in order to prime the fuel system.

Note: Use this procedure only if the fuel system has been purged of air through normal priming procedures and the engine does not start.

1. Loosen the tube nut for the cylinder #1 fuel-injector at the injection pump (Figure 47).

   

   Figure 47

   1. Tube nut (cylinder #1 fuel injector)

2. Move the throttle to the FAST position.

3. Turn the key in the ignition switch to the START position and watch the fuel flow around the connector.

4. Turn the key to the OFF position when you observe solid flow.

5. Tighten the pipe connector securely.

6. Clean all residual fuel from the engine.

7. Repeat the procedure for the remaining fuel-injector tubes.

Important: Before welding on the machine, disconnect the negative cable from the battery to prevent damage to the electrical system. Also, you must disconnect the engine, InfoCenter, and machine controllers before welding on the machine.

Note: Keep the terminals and the entire battery case clean, because a dirty battery discharges slowly. To clean the battery, wash the entire case with a solution of baking soda and water. Rinse with clear water. Coat the battery posts and cable connectors with Grafo 112X (skin-over) grease (Toro Part No. 505-47) or petroleum jelly to prevent corrosion.

1. Unlatch and raise the operator's console panel (Figure 48).

   

   Figure 48

   1. Operator's console panel
   2. Latch

   Danger

   Battery electrolyte contains sulfuric acid, which is fatal if consumed and causes severe burns.

   • Do not drink electrolyte and avoid contact with skin, eyes, or clothing. Wear safety glasses to shield your eyes and rubber gloves to protect your hands.

   • Fill the battery where clean water is always available for flushing the skin.

2. Remove the rubber boot from the positive terminal and inspect the battery.

3. Remove the negative cable (black) from the negative (-) terminal and the positive cable (red) from the positive (+) terminal of the battery (Figure 49).

   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.

   • 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.

   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.

   

   Figure 49

   1. Positive battery cable
   2. Negative battery cable

4. Connect a 3 to 4 A battery charger to the battery posts. Charge the battery at a rate of 3 to 4 A for 4 to 8 hours.

   Warning

   Charging the battery produces gasses that can explode.

   Never smoke near the battery and keep sparks and flames away from battery.

5. When the battery is charged, disconnect the charger from the power outlet and battery posts.

6. Install the positive cable (red) to the positive (+) terminal and the negative cable (black) to the negative (-) terminal of the battery (Figure 49).

7. Secure the cables to the posts with bolts and nuts.

   Note: Make sure that the positive (+) terminal is all the way on the post and the cable is 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.

The fuse block for the machine is located in the right storage box

Figure 50

1. Loosen the latch for the cover of the right storage box and raise the cover (Figure 51) to expose the fuse block (Figure 52).

   

   Figure 51

   1. Latch
   2. Right storage box

2. Replace the open fuse(s) as needed (Figure 52).

   

   Figure 52

   1. Fuses

3. Close the cover of the right storage box and secure the cover with the latch (Figure 51).

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. Park the machine on a level surface, engage the parking brake, lower the mower decks, shut off the engine, and remove the key.

2. Chock the rear wheels and raise the front of machine, supporting the front axle/frame on jack stands.

   Danger

   A machine on a jack may be unstable and slip off the jack, injuring anyone beneath it.

   • Do not start the engine while the machine is on a jack.

   • Always remove the key from the switch before getting off the machine.

   • Block the tires when you are raising the machine with a jack.

   • Support the machine with jack stands.

3. Grasp 1 of the front drive wheels and push/pull it toward and away from the machine, noting any movement.

   

   Figure 53

   1. Front drive wheels

4. Repeat step 3 for the other drive wheel.

5. If either wheel moves, contact your Toro Distributor to have the planetary drive rebuilt.

Use high quality SAE 85W-140 gear lube as a replacement.

1. With machine on level surface, position the wheel so that 1 check plug is at the 12 o'clock position and the other is at 3 o'clock position (Figure 54).

   

   Figure 54

   1. Check/drain plug (2)

2. Remove the plug at the 3 o’clock position (Figure 54).

   The oil level should be at the bottom of the check-plug hole.

3. If the oil level is low, remove the plug at the 12 o’clock position and add oil until it begins to flow out of the hole at the 3 o’clock position.

4. Install both plugs.

5. Repeat steps 1 through 4 on the opposite planetary gear assembly.

Use a high-quality, SAE 85W-140 gear lube.

1. With the machine on a level surface, position a wheel so that a check plug is at the lowest (6 o'clock) position (Figure 55).

   

   Figure 55

   1. Check/drain plug

2. Place a drain pan under the planetary hub, remove the plug, and allow the oil to drain.

3. Place a drain pan under the brake housing, remove the drain plug, and allow the oil to drain (Figure 56).

   

   Figure 56

   1. Brake housing
   2. Drain plug

4. When all of the oil has drained from both locations, install the plug in the brake housing.

5. Rotate the wheel until the open plug hole in the planetary is at the 12 o'clock position.

6. Through the open 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.

7. Install the plug.

8. Repeat the procedure on the opposite planetary/brake assembly.

Visually inspect the rear axle and rear-axle gearbox for leaks.

Figure 57

The rear axle is filled with SAE 85W-140 gear lube. The capacity is 2.4 L (80 fl oz). Visually inspect for leaks daily.

1. Position the machine on a level surface.

2. Remove a check plug from 1 end of the axle and ensure that the lubricant is up to the bottom of the hole (Figure 58).

   Note: If the level is low, remove the fill plug and add enough lubricant to bring the level up to the bottom of the check-plug holes.

   

   Figure 58

   1. Check plug
   2. Fill plug

Lubricant specification: high-quality SAE 85W-140 gear lubricant

Axle capacity: 2.4 L (80 fl oz)

1. Position the machine on a level surface.

2. Clean the area around the 3 drain plugs—1 on each end and 1 in the center (Figure 59).

   

   Figure 59

   1. Drain-plug location

3. Remove the oil-level check plugs and the main-axle-vent cap to ease draining the gear lubricant.

4. Remove the drain plugs and allow the gear lubricant to drain into the pans.

5. Install the plugs.

6. Remove a check plug and fill the axle with approximately 2.4 L (80 fl oz) of 85W-140 gear lube or until the lubricant is up to the bottom of the hole.

7. Install the check plug.

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.

1. Position the machine on a level surface.

2. Remove the check/fill plug from the left side of the gear box and ensure that lubricant is up to the bottom of the hole (Figure 60).

   Note: If the level is low, add enough lubricant to bring the level up to the bottom of the hole.

   

   Figure 60

   1. Gearbox
   2. Check/fill plug

1. Measure the center-to-center distance (at axle height) at the front and rear of the steering tires (Figure 61).

   Note: The front measurement must be 3 mm (1/8 inch) less than the rear measurement.

   

   Figure 61

   1. Front of the machine
   2. 3 mm (1/8 inch) less than the rear measurement
   3. Center to center distance

2. To adjust, remove the cotter pin and nut from either tie rod ball joint (Figure 62). Remove the tie-rod ball joint from the axle-case support.

   

   Figure 62

   1. Tie-rod clamp
   2. Tie-rod ball joint

3. Loosen the clamps at both ends of the tie rods (Figure 62).

4. Rotate the detached ball joint inward or outward 1 complete revolution and tighten the clamp at the loose end of the tie rod.

5. Rotate the entire tie-rod assembly the same direction (inward or outward) 1 complete revolution and tighten the clamp at the connected end of the tie rod.

6. Install the ball joint in the axle-case support, tighten the nut finger-tight, and measure the toe-in.

7. Repeat procedure if necessary.

8. Tighten the nut and install a new cotter pin when the adjustment is correct.

Coolant specification: 50/50 mixture of water and ethylene glycol antifreeze

Cooling system capacity: 8.5 L (9 US qt).

1. Carefully remove the radiator cap.

   Caution

   If the engine has been running, the pressurized, hot coolant can escape and cause burns.

   • Do not open the radiator cap when the engine is running.

   • Use a rag when opening the radiator cap, and open the cap slowly to allow steam to escape.

   

   Figure 63

   1. Expansion tank

2. 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 63).

3. 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 base coolants.

4. Install the radiator cap and expansion-tank cap.

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. Periodic cleaning and inspection of the radiator/cooler is still required.

1. Unlatch and swing open the rear screen (Figure 64).

   Note: To remove the screen, lift it off the hinge pins.

2. Clean the screen thoroughly of all debris.

   

   Figure 64

   1. Rear-screen latch

3. Thoroughly clean both sides of the oil cooler and the radiator with compressed air (Figure 65).

   Note: Start from the front and blow the debris out toward the back. Then clean from the back side and blow toward the front. Repeat procedure several times until you remove all chaff and debris.

   

   Figure 65

   1. Oil cooler/radiator

   Important: Cleaning the oil cooler/radiator with water promotes premature corrosion damage to components and compacts debris.

4. Close the rear screen and secure it with the latch.

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. Release the locking latch from the brake pedals so that both pedals work independently of each other.

2. To reduce free travel of the brake pedals, tighten the brakes as follows:

   1. Loosen the front nut on the threaded end of the brake cable (Figure 66).

      

      Figure 66

      1. Brake cable

   2. Tighten the rear nut to move the cable rearward until the brake pedals have 13 to 25 mm (1/2 to 1 inch) of free travel.

   3. Tighten the front nuts after the brakes are adjusted correctly.

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.

If the deflection is not 10 mm (3/8 inch), loosen the alternator-mounting bolts (Figure 67).

Note: Increase or decrease the alternator-belt tension and tighten the bolts. Check the deflection of the belt again to ensure that the tension is correct.

Figure 67

1. Mounting bolt
2. Alternator

The reservoir is filled at the factory with approximately 28.4 L (7.50 US gallons) of high-quality hydraulic fluid. Check the level of the hydraulic fluid before the engine is first started and daily thereafter. The recommended replacement fluid is as follows:

Toro Premium All Season Hydraulic Fluid (Available in 19 L (5 US gallons) pails or 208 L (55 US gallons) drums. See the Parts Catalog or your Toro Distributor for part numbers).

Alternative fluids: If the Toro fluid is not available, other conventional, petroleum-based fluids may be used, provided they meet all of the following material properties and industry specifications. Check with your oil supplier to see whether the oil meets these specifications.

Note: Toro does not assume responsibility for damage caused by improper substitutions, so use only products from reputable manufacturers who will stand behind their recommendation.

Important: The ISO VG 46 Multigrade fluid has been found to offer optimal performance in a wide range of temperature conditions. For operation in consistently high ambient temperatures, 65°F (18°C) to 120°F (49°C), ISO VG 68 hydraulic fluid may offer improved performance.

Premium Biodegradable Hydraulic Fluid-Mobil EAL EnviroSyn 46H

Important: Mobil EAL EnviroSyn 46H is the only synthetic biodegradable fluid approved by Toro. This fluid is compatible with the elastomers used in Toro hydraulic systems and is suitable for a wide-range of temperature conditions. This fluid is compatible with conventional mineral oils, but for maximum biodegradability and performance the hydraulic system should be thoroughly flushed of conventional fluid. The fluid is available in 19 L (5 US gallon) containers or 208 L (55 US gallon) drums from your Mobil Distributor.

Important: Many hydraulic fluids are almost colorless, making it difficult to spot leaks. A red dye additive for the hydraulic system fluid is available in 20 ml (2/3 oz) bottles. 1 bottle is sufficient for 15 to 22 L (4 to 6 US gallons) of hydraulic fluid. Order part no. 44-2500 from your Toro Distributor.

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. Check the hydraulic-fluid level (Figure 68).

   

   Figure 68

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. Park the machine on a level surface, engage the parking brake, lower the mower decks, 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. Install the hose when the hydraulic fluid stops draining.

5. Fill the reservoir with hydraulic fluid; refer to Checking the Hydraulic-Fluid Level.

   Important: Use only the hydraulic fluids specified. Other fluids could cause system damage.

6. Install the reservoir cap.

7. Turn the key in the key switch to the ON position to start the engine. Use all the hydraulic controls to distribute hydraulic fluid throughout the system, and check for leaks.

8. Turn the key in the key switch to the OFF position.

9. Check the fluid level and add enough to raise level the level to the FULL mark on the dipstick. Do not overfill.

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.

Important: Use of any other filter may void the warranty on some components.

1. Tilt the operators seat to access the mower pressure filter; refer to Accessing the Hydraulic Lift Compartment

   

   Figure 69

2. Replace the charge hydraulic filter at the hydraulic lift compartment as shown in Figure 70.

   

   Figure 70

3. Lower and secure the operator’s seat.

4. Replace the return filter at the right side of the machine (Figure 70).

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.

Inspect the hydraulic lines and hoses daily for leaks, kinked lines, loose mounting supports, wear, loose fittings, weather deterioration, and chemical deterioration. Make all necessary repairs before operating the machine.

1. Remove the roller-mounting bolt (Figure 73).

2. Insert a punch through the end of the roller housing and drive the opposite bearing out by alternating taps to the opposite side of inner bearing race. There should be a 1.5 mm (0.060 inch) lip of inner race exposed.

   

   Figure 73

   1. Front roller
   2. Mounting bolt
   3. Bearing
   4. Bearing spacer

3. Push the second bearing out in press.

4. Inspect the roller housing, bearings, and bearing spacer for damage (Figure 73). Replace damaged components and assemble.

1. Press the first bearing into the roller housing (Figure 73). Press on the outer race only or equally on the inner and outer race.

2. Insert the spacer (Figure 73).

3. Press the second bearing into the roller housing (Figure 73). Pressing equally on the inner and outer race until the inner race comes in contact with the spacer.

4. Install the roller assembly into the deck frame.

5. Verify that there is no more than a 1.5 mm (0.060 inch) gap between roller assembly and the roller mount brackets of the deck frame. If there is a gap over 1.5 mm (0.060 inch), install enough 5/8-inch diameter washers to take up the slop.

   Important: Securing the roller assembly with a gap larger than 1.5 mm (0.060 inch) creates a side load on the bearing and can lead to premature bearing failure

6. Torque the mounting bolt to 108 N∙m (80 ft-lb).

1. Remove the hydraulic motor from the mower deck and remove the mower deck from the machine.

2. Use a hoist (or minimum of 2 people) and place the mower deck on a flat table

3. Mark 1 end of the blade with a paint pen or marker. Use this end of the blade to check all heights.

4. Position the cutting edge of the marked end of the blade at 12 o’clock (straight ahead in the direction of mowing) (Figure 74) and measure height from table to cutting edge of blade.

   

   Figure 74

5. Rotate the marked end of the blade to the 3 and 9 o’clock positions (Figure 74) and measure the heights.

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.

If any of these measurements are not within specification, proceed to Adjusting the Blade Plane.

Start with the front adjustment (change 1 bracket at a time).

1. Remove the height-of-cut bracket, (front, left, or right) from the deck frame (Figure 75).

2. Adjust 1.5 mm (0.060 inch) shims and/or 0.7 mm (0.030 inch) shims between the deck frame and bracket to achieve the desired height setting (Figure 75).

   

   Figure 75

   1. Height-of-cut bracket
   2. Shims

3. Install the height-of-cut bracket to the deck frame with the remaining shims assembled below the height-of-cut bracket.

4. Secure the socket-head bolt/spacer and flange nut.

   Note: Socket-head bolt/spacer are held together with thread-locking adhesive to prevent the spacer from falling inside the deck frame.

5. Verify the 12 o’clock height and adjust if needed.

6. Determine if only 1 or both (right and left) height-of-cut brackets need to be adjusted.

   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.