Groundsmaster® 4000 or 4010 Rotary Mower

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 6).

Figure 6

1. Weight gauge
2. Weight-adjustment lever
3. Seat-adjustment lever
4. Seat-back adjustment lever
5. Armrest-adjustment knob (not shown; located under arm rest)

Rotate the knob to adjust the armrest angle (Figure 6).

Move the lever to adjust the seat-back angle (Figure 6).

The weight gauge indicates when the seat is adjusted to the weight of the operator (Figure 6). 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 6). 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.

The air-recirculation control sets the cab to either recirculate the air in the cabin or to draw air into the cabin from outside (Figure 7).

• Set it to recirculate the air when using the air-conditioning.

• Set it to draw air in when using the heater or fan.

Rotate the fan control knob to regulate the speed of the fan (Figure 7).

Rotate the temperature control knob to regulate the air temperature in the cab (Figure 7).

Use this switch to turn the windshield wipers on or off (Figure 7).

Use this switch to turn the air conditioning on or off (Figure 7).

Lift up the latches to open the windshield (Figure 8). Press in the latch to lock the windshield open. Pull out and down on the latch to close and secure the windshield.

Figure 8

1. Windshield latch

Lift up the latches to open the rear window. Press in the latch to lock the window open. Pull out and down on the latch to close and secure the window (Figure 8).

Important: You must close the rear window before you open the hood; otherwise, damage may occur.

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 Fluid.

The correct air pressure in the tires is 172 to 207 kPa (25 to 30 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 14

Torque the wheel-lug nuts to 115 to 136 N∙m (85 to 100 ft-lb) in the order shown in Figure 15 and Figure 16.

Figure 15

Front Wheels

Figure 16

Rear Wheels

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

1. With machine on level surface, position the wheel so 1 check plug is at the 12 o'clock position and the other is at 3 o'clock position (Figure 17).

   

   Figure 17

   1. Check/drain plug (2)

2. Remove the plug at the 3 o’clock position (Figure 17).

   Note: 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.

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 18).

   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 18

   1. Check plug
   2. Fill 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 19).

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

   

   Figure 19

   1. Gear box
   2. Check/fill plug

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 20

Raising the Roll Bar

Figure 21

Mount the skids in the lower position when operating at heights of cut greater than 64 mm (2-1/2 inches) and in the higher position when operating at heights of cut lower than 64 mm (2-1/2 inches).

Note: When the skids become worn, you can switch them to the opposite sides of the mower by flipping them over. This allows you to use the skids longer before replacing them.

Adjust the skids (Figure 32).

Important: Torque the screw at the front of each skid to 9 to 11 N·m (80 to 100 in-lb).

Figure 32

The mower-deck rollers should be mounted in the lower position when operating at height of cuts greater than 64 mm (2-1/2 inches), and in the higher position when operating in height of cuts lower than 64 mm (2-1/2 inches).

Figure 33

Due to differences in grass conditions and the counterbalance setting of the traction unit, cut a sample area of grass and check the appearance before cutting the entire area.

1. Set all mower decks to the desired height of cut; refer to Adjusting the Height of Cut.

2. Check and adjust the front and rear tire pressures to 172 to 207 kPa (25 to 30 psi).

3. Check and adjust all of caster tire pressures to 345 kPa (50 psi).

4. Check the charge and counterbalance pressures with the engine at HIGH IDLE, using hydraulic-test ports.

   Note: Adjust the counterbalance to 2241 kPa (325 psi).

5. Check for bent blades; refer to Checking for a Bent Blade.

6. Cut grass in a test area to determine if all mower decks are cutting at the same height.

7. If mower-deck adjustments are still needed, find a flat surface using a 2 m (6 ft) or a longer straight edge.

8. To ease measuring the blade plane, raise the height of cut to 7.6 to 10.1 cm (3 to 4 inches); refer to Adjusting the Height of Cut.

9. Lower the mower decks onto a flat surface and remove the covers from the top of the mower decks.

10. Loosen the flange nut, securing the idler pulley, to release the belt tension on each mower deck.

Front Mower Deck Setup

Rotate the blade on each spindle until the ends face forward and backward. Measure from the floor to the front tip of the cutting edge. Adjust the shims on the front caster fork(s) to match the height-of-cut decal (Figure 34); refer to Measuring the Mower-Deck Pitch.

Figure 34

1. Tensioning cap
2. Spacers
3. Shims
4. Top axle-mounting hole
5. Caster wheel

Side Mower Deck Setup

Rotate the blade of each spindle until the ends face forward and backward. Measure from the floor to the front tip of the cutting edge. Adjust the shims on front caster arm(s) to match the height-of-cut decal (Figure 35). For the outside blade spindle only, refer to Adjusting the Front Mower-Deck Pitch.

Figure 35

1. Front caster arm
2. Shims
3. Front caster fork

The machine has interlock switches in the electrical system. These switches disengage either the traction or the PTO whenever you leave the seat. Although the engine continues to run if you disengage PTO switch, and the you release the traction pedal, shut off the engine before rising from the seat.

To check the operation of the interlock switches, perform the following procedure:

1. Drive the machine slowly to a large, relatively open area. Lower the mower deck, shut off the engine, and apply the parking brake.

2. Sit on the seat and press the traction pedal. Try to start the engine. The engine should not start. If the engine starts, there is a malfunction in the interlock system that should be corrected before beginning operation.

3. Sit on the seat and start the engine. Rise from the seat and move the PTO switch to ON. The PTO should not engage. If the PTO engages, there is a malfunction in the interlock system that should be corrected before beginning operation.

4. Sit on the seat, engage the parking brake and start the engine. Move the traction pedal out of the NEUTRAL position. The InfoCenter should display “traction not allowed” and the machine should not move. If the engine does move, there is a malfunction in the interlock system that should be corrected before beginning operation.

1. Loosen the mounting nuts and position each headlight so it points straight ahead.

   Note: Tighten the mounting nut just enough to hold the headlight in position.

2. Place a flat piece of sheet metal over the face of the headlight.

3. Mount a magnetic protractor onto the plate.

4. While holding the assembly in place, carefully tilt the headlight downward 3 degrees, then tighten the nut.

5. Repeat the procedure on the other headlight.

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. The operator can simply set a maximum ground speed that is comfortable and mow without having to manually reduce the traction speed when mowing in heavy conditions.

The fan speed is controlled by the hydraulic-fluid temperature and engine-coolant temperature. A reverse cycle is automatically initiated when either the engine coolant or hydraulic-fluid temperature reaches a certain point. This reversal helps blow debris off the rear screen and lower the engine and hydraulic-fluid temperatures. By simultaneously pressing the right and left buttons on the InfoCenter, the fan completes a manually-initiated reverse cycle. Reverse the fan manually prior to leaving the work area, entering the shop, or storage area.

The machine is equipped with auto idle, which automatically idles the engine when all the following functions are not used, for a pre-determined time, previously set in the InfoCenter.

• The traction pedal is returned to the NEUTRAL position.

• The PTO is disengaged.

• None of the lift switches are activated.

  When any of the above functions are initiated, the machine automatically returns to the previous throttle position.

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.

Note: Cutting grass at a rate that loads the engine promotes DPF regeneration.

1. Move the machine to the job site.

2. Whenever possible, set the engine-speed switch to high idle.

3. Engage the PTO switch.

4. Gradually move the traction pedal forward and slowly drive the machine over the mowing area.

5. Once the front of the cutting units are over the mowing area, lower the cutting units.

6. Cut grass so that the blades can cut and discharge clippings at a high rate while producing a good quality of cut.

   Note: If the cutting rate is too high, the quality of cut may deteriorate. Reduce the ground speed of the machine or reduce the width of cut to regain high idle engine speed.

7. When the cutting units are over the far edge of the mowing area, lift the cutting units.

8. Perform a tear-shaped turn to quickly line up for your next pass.

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.

The DPF regeneration process uses heat from the engine exhaust to incinerate the soot accumulated on the soot filter, converting the soot to ash, and clears the channels of the soot filter so that filtered engine exhaust flows out the DPF.

The engine computer monitors the accumulation of soot by measuring the back pressure in the DPF. If the back pressure is too high, soot is not incinerating in the soot filter through normal engine operation. To keep the DPF clear of soot, remember the following:

• Passive regeneration occurs continuously while the engine is running—run the engine at full engine speed when possible to promote DPF regeneration.

• If the back pressure is too high, the engine computer signals you through the InfoCenter when additional processes (assist and reset regeneration) are running.

• Allow the assist and reset regeneration process to complete before shutting off the engine.

Operate and maintain your machine with the function of the DPF in mind. Engine load at high idle engine speed generally produce adequate exhaust temperature for DPF regeneration.

Important: Minimize the amount of time that you idle the engine or operate the engine at low-engine speed to help reduce the accumulation of soot in the soot filter.

DPF Soot Accumulation

• Over time, the DPF accumulates soot in the soot filter. The computer for the engine monitors the soot level in the DPF.

• When enough soot accumulates, the computer informs you that it is time to regenerate the diesel particulate filter.

• DPF regeneration is a process that heats the DPF to convert the soot to ash.

• In addition to the warning messages, the computer reduces the power produced by the engine at different soot-accumulation levels.

Engine Warning Messages—Soot Accumulation

Indication Level	Fault Code	Engine Power Rating	Recommended Action
Level 1: Engine Warning	Figure 37 Check EngineSPN 3719, FMI 16	The computer de-rates the engine power to 85%	Perform a parked regeneration as soon as possible; refer to Parked Regeneration.
Level 2: Engine Warning	Figure 38 Check EngineSPN 3719, FMI 0	The computer de-rates the engine power to 50%	Perform a recovery regeneration as soon as possible; refer to Recovery Regeneration.

DPF Ash Accumulation

• 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.

• When enough ash accumulates, the engine computer sends information to the InfoCenter in the form of a system advisory or an engine fault to indicate the accumulation of ash in the DPF.

• The advisory and faults are indications that it is time to service the DPF.

• In addition to the warnings, the computer reduces the power produced by the engine at different ash-accumulation levels.

InfoCenter Advisory and Engine Warning Messages—Ash Accumulation

Indication Level	Advisory or Fault Code	Engine Speed Reduction	Engine Power Rating	Recommended Action
Level 1: System Advisory	Figure 39 Advisory #179	None	100%	Notify your service department that advisory #179 displays in the InfoCenter.
Level 2: Engine Warning	Figure 40 Check EngineSPN 3720, FMI 16	None	The computer de-rates the engine power to 85%	Service the DPF; refer to Servicing the Diesel-Oxidation Catalyst (DOC) and the Soot Filter
Level 3: Engine Warning	Figure 41 Check EngineSPN 3720, FMI 0	None	The computer de-rates the engine power to 50%	Service the DPF; refer to Servicing the Diesel-Oxidation Catalyst (DOC) and the Soot Filter
Level 4: Engine Warning	Figure 42 Check EngineSPN 3251, FMI 0	Engine speed at max torque + 200 rpm	The computer de-rates the engine power to 50%	Service the DPF; refer to Servicing the Diesel-Oxidation Catalyst (DOC) and the Soot Filter

Types of Diesel Particulate Filter Regeneration

Types of diesel particulate filter regeneration that are performed while the machine is operating:

Type of Regeneration	Conditions for DPF regeneration	DPF description of operation
Passive	Occurs during normal operation of the machine at high-engine speed or high-engine load	The InfoCenter does not display an icon indicating passive regeneration.
		During passive regeneration, the DPF processes high-heat exhaust gasses; oxidizing harmful emissions and burning soot to ash.
		Refer to Passive DPF Regeneration.
Assist	Occurs as a result of low-engine speed, low-engine load, or after the computer detects back pressure in the DPF	When the assist/reset-regeneration icon is displayed in the InfoCenter, an assist regeneration is in progress.
		During assist regeneration, the computer controls the intake throttle to increase the exhaust temperature, enabling assist regeneration to occur.
		Refer to Assist DPF Regeneration.
Reset	Occurs after assist regeneration only if the computer detects that assist regeneration did not sufficiently reduce the soot level	When the assist/reset-regeneration icon is displayed in the InfoCenter, a regeneration is in progress.
	Also occurs every 100 hours to reset baseline sensor readings
		During reset regeneration, the computer controls the intake throttle and fuel injectors to increase the exhaust temperature during regeneration.
		Refer to Reset Regeneration.

Types of diesel particulate filter regeneration that require you to park the machine:

Type of Regeneration	Conditions for DPF regeneration	DPF description of operation
Parked	Soot buildup occurs as a result of prolonged operation at low-engine speed or low-engine load. May also occur as a result of using incorrect fuel or oil	When the parked-regeneration icon is displayed in the InfoCenter, a regeneration is requested.
	The computer detects back pressure due to soot buildup and requests a parked regeneration
		• Perform the parked regeneration as soon as possible to avoid needing a recovery regeneration.
		• A parked regeneration requires 30 to 60 minutes to complete.
		• You must have at least a 1/4 tank of fuel in the tank.
		• You must park the machine to perform a recovery regeneration.
		Refer to Parked Regeneration.
Recovery	Occurs as a result of ignoring parked regeneration requests and continuing operation, adding more soot when the DPF is already in need of a parked regeneration	When the recovery-regeneration icon is displayed in the InfoCenter, a recovery regeneration is requested.
		Contact your Authorized Toro Distributor to have a service technician perform the recovery regeneration.
		• A recovery regeneration requires up to 4 hours to complete.
		• You must have at least a 1/2 tank of fuel in the machine.
		• You must park the machine to perform a recovery regeneration.
		Refer to Recovery Regeneration.

Assist DPF Regeneration

Figure 43

Assist/reset-regeneration icon

• The assist/reset-regeneration icon displays in the InfoCenter (Figure 43).

• The computer takes control of the intake throttle to increase the temperature of the engine exhaust.

• While operating the machine, run the engine at full engine speed when possible to promote DPF regeneration.

• The icon displays in the InfoCenter while the assist regeneration is processing.

• Whenever possible, do not shut off the engine or reduce engine speed while the assist regeneration is processing.

  Important: Allow the machine to complete the assist regeneration process before shutting off the engine.

  Note: The assist regeneration is finished processing when the icon disappears from the InfoCenter.

Reset Regeneration

Figure 44

Assist/reset-regeneration icon

• The assist/reset-regeneration icon displays in the InfoCenter (Figure 44).

• The computer takes control of the intake throttle and changes the fuel injection operation to increase the temperature of the engine exhaust.

  Important: The assist/reset-regeneration icon indicates that the exhaust temperature discharged from of your machine may be hotter than during regular operation.

• While operating the machine, run the engine at full engine speed when possible to promote DPF regeneration.

• 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.

  Important: Allow the machine to complete the reset regeneration process before shutting off the engine.

  Note: The reset regeneration is finished processing when the icon disappears from the InfoCenter.

Parked Regeneration

Figure 45

Parked-regeneration request icon

• The parked-regeneration requested icon displays in the InfoCenter (Figure 45).

• If a parked regeneration is needed, the InfoCenter displays engine warning SPN 3719, FMI 16 (Figure 46) and the engine computer derates engine power to 85%.

  

  Figure 46

  Important: If you do not complete a parked regeneration within 2 hours, the engine computer derates engine power to 50%.

• A parked regeneration requires 30 to 60 minutes to complete.

• If you are authorized by your company, you need the PIN code to perform the parked-regeneration process.

Preparing to Perform a Parked or Recovery Regeneration

1. Ensure that the machine has at least 1/4 tank of fuel.

2. 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, lower the cutting units and shut them off.

6. Engage the parking brake.

7. Set the throttle to the low IDLE position.

Performing a Parked Regeneration

Note: For instructions on unlocking protected menus, refer to Accessing Protected Menus.

1. Access the protected menu and unlock the protected settings submenu (Figure 47); refer to Accessing Protected Menus.

   

   Figure 47

2. Navigate to the MAIN MENU, press the center button to scroll down to the SERVICE MENU, and press the right button to select the SERVICE option (Figure 48).

   Note: The InfoCenter should display the PIN indicator in the upper right corner of the display.

   

   Figure 48

3. In the SERVICE MENU, press the middle button until the DPF REGENERATION options displays, and press the right button to select the DPF REGENERATION option (Figure 49).

   

   Figure 49

4. When the “Initiate DPF Regen. Are you sure?” message displays, press the center button (Figure 50).

   

   Figure 50

5. If the coolant temperature is below 60°C (140°F) the “Insure is running and above 60C/140F” message displays. (Figure 51).

   Observe the temperature in the display, and run the machine at full throttle until the temperature reaches 60°C (140°F), then press the center button.

   Note: If the coolant temperature is above 60°C (140°F) this screen is skipped.

   

   Figure 51

6. Move the throttle control to LOW IDLE and press the center button (Figure 52).

   

   Figure 52

7. The following messages display as the parked regeneration process begins:

   1. The “Initiating DPF Regen.” message displays (Figure 53).

      

      Figure 53

   2. The “Waiting on ” message displays (Figure 54).

      

      Figure 54

   3. The computer determines whether the regeneration runs. One of the following messages displays in the InfoCenter:

      • If the regeneration is allowed, the “Regen Initiated. Allow up to 30 minutes for completion” message displays in the InfoCenter, wait for the machine to complete the parked regeneration process (Figure 55).

        

        Figure 55

      • If the regeneration process is not allowed by the engine computer, the “DPF Regen Not Allowed” message displays in the InfoCenter (Figure 56). Press the left button to exit to the home screen

        Important: If you did not meet all the requirements for regeneration or if less than 50 hours have passed since the last regeneration, the “DPF Regen Not Allowed” message appears.

        

        Figure 56

8. While the regeneration is running, the InfoCenter returns to the home screen and shows the following icons:

   		The engine is cold—wait.
   		The engine is warm—wait.
   		The engine hot—regeneration in progress (percent complete).

9. The parked regeneration is complete when the “Regen Complete” message displays in the InfoCenter. Press the left button to exit to the home screen (Figure 57).

   

   Figure 57

The engine-speed switch has 2 modes to change the engine speed. By momentarily tapping the switch, the engine speed increases or decreases in 100-rpm increments. By holding the switch down, the engine automatically moves to HIGH or LOW IDLE, depending on which part of the switch you pressed.

Supervisor (Protected Menu)

This feature allows the supervisor to set the maximum mowing speed in increments of 50%, 75% or 100%, at which the operator can mow (low range).

Refer to Setting the Maximum Allowed Mow Speed for the procedure to set the mow speed.

Operator

This feature allows the operator to adjust the maximum mowing speed (low range), within the supervisors pre-adjusted settings. When in the InfoCenter splash or main screen, press the middle button ( icon) to adjust the speed.

Note: When switching between low and high ranges, the settings will transfer based on the previous setting. The settings are reset when the machine is turned off.

Note: This feature may also be used in conjunction with cruise control.

Supervisor (Protected Menu)

This feature allows the supervisor to set the maximum transport speed in increments of 50%, 75% or 100%, at which the operator can transport (high range).

Refer to Setting the Maximum Allowed Transport Speed for the procedure to set the transport speed.

Operator

This feature allows the operator to adjust the maximum transport speed (high range) within the supervisors pre-adjusted settings. When in the InfoCenter splash or main screen, press the middle button ( icon) to adjust the speed.

Note: When switching between low and high ranges, the settings transfer based on the previous setting. The settings are reset when the machine is turned off.

Note: You can also use this feature in conjunction with cruise control.

Practice driving the machine because it has a hydrostatic transmission and its characteristics are different than many turf-maintenance machines.

With Toro Smart Power™, you do not need 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.

You can use the brakes to assist in turning the machine, but use them carefully, especially on soft or wet grass because they can damage the turf. You can also use the brakes to maintain traction. For example, in some slope conditions, the uphill wheel slips and loses traction. If this situation occurs, press the uphill turn pedal gradually and intermittently until the uphill wheel stops slipping, thus, increasing traction on the downhill wheel.

Traction Assist is now automatic and requires no operator input. When a wheel starts to slip, flow is automatically split between the front and rear wheels to minimize wheel slip and loss of traction.

Use extra care when operating the machine on slopes. Ensure that the seat latch is properly secured and that you buckle the seat belt. Drive slowly and avoid sharp turns on slopes to prevent roll overs. For steering control, the mower deck must be lowered when going downhill.

Before stopping the engine, disengage all controls and change the throttle to the SLOW position. Changing the throttle to the SLOW position reduces high engine speed, noise, and vibration. Turn the key to the OFF position to shut off the engine.

Before transporting the machine, raise the mower decks and secure the transport latches (Figure 59).

Figure 59

1. Transport latch (side mower decks)

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 toe the machine.

1. Raise the seat and locate the bypass valves, which are located below the front of the fuel tank (Figure 60).

   

   Figure 60

   1. Bypass valve (2)

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.

3. Close the bypass valves before starting the engine.

4. Torque to 70 N∙m (52 ft-lb) to close the valve.

Important: To push or tow the machine in reverse, you must bypass the check valve in the 4-wheel drive manifold. To bypass the check valve, connect a hose assembly 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 behind the front tire. The hose assembly includes 1 hose (Part No. 95-8843), 2 coupler fittings (Part No. 95-0985), and 2 hydraulic fittings (Part No. 340-77).

There are jacking points located at the front and rear of the machine.

• On the frame at the inside of each front drive tire

• At the center of the rear axle

• 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 using straps, chains, cable, or ropes. Both front and rear straps should be directed down and outward from the machine.

There are tie downs located at the front and rear sides of the machine (Figure 61).

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

• 2 on the front of the operator's platform

• Rear bumper

Figure 61

1. Rear tie-down point
2. Front tie-down points

1. Ensure that the PTO is disengaged.

2. Park the machine on a level surface.

3. Engage the parking brake.

4. Lower the mower deck(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.

1. Unlatch and raise the hood.

2. Remove the hairpin cotter securing the hood pivot to the mounting brackets (Figure 64).

   

   Figure 64

   1. Hairpin cotter

3. Slide the hood to the right side, lift the other side, and pull it out of the brackets.

Note: Reverse this procedure to install the hood.

The machine has grease fittings that you must lubricate regularly with No. 2 lithium grease. Also, lubricate the machine immediately after every washing.

The grease-fitting locations and quantities are:

Traction Unit

• 2 front and rear-axle-pivot bushings (Figure 65)

• 2 steering-cylinder-ball joints (Figure 66)

• 2 tie-rod-ball joints (Figure 66)

• 2 king-pin bushings (Figure 66).The top fitting on the king pin should only be lubricated annually (2 pumps).

Figure 65

Figure 66

Front Mower Deck

• 2 caster-fork-shaft bushings (Figure 67)

• 3 spindle-shaft bearings—located under the pulley (Figure 68)

• 2 idler-arm-pivot bushings (Figure 68)

Figure 67

Figure 68

Front Lift Assemblies

• 2 (each side) lift-arm-cylinder bushings (Figure 69)

• 2 lift-arm-ball joints (Figure 70)

Figure 69

Figure 70

Side Mower Decks

• 1 caster-fork-shaft bushing (Figure 71)

• 2 (each side) spindle-shaft bearings—located under the pulley

• 1 idler-arm-pivot bushings—located on the idler arm

Figure 71

Side Lift Assemblies

• 6 main lift-arm bushings (Figure 72 and Figure 73)

• 2 bell-crank-pivot bushings (Figure 74)

• 4 rear arm bushings (Figure 74)

• 4 lift-cylinder bushings (Figure 75)

Figure 72

Figure 73

Figure 74

Figure 75

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 78) 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 78

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 79).

   

   Figure 79

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

   Important: Never attempt to clean the safety filter (Figure 80). Replace the safety filter after every 3 primary filter services.

   

   Figure 80

   1. Air-cleaner safety filter

2. Reset the indicator (Figure 78) if it shows red.

• If advisory message displays in the InfoCenter, the DPF is nearing the recommended point for servicing the diesel-oxidation catalyst and the soot filter.

  

  Figure 81

• If engine faults , , or in the InfoCenter (Figure 82) display in the InfoCenter, clean the soot filter using the steps that follow:

  

  Figure 82

  1. Refer to the Engine section in the Service Manual for information on disassembling and assembling the diesel-oxidation catalyst and the soot filter of the DPF.

  2. Refer to your Authorized Toro Distributor for diesel-oxidation catalyst and the soot filter replacement parts or service.

  3. Contact your Authorized Toro Distributor to have them reset the engine ECU after you install a clean DPF.

Service the water separator as shown in Figure 83.

Figure 83

1. Clean the area around the fuel-filter head (Figure 84).

   

   Figure 84

   1. Fuel-filter head
   2. Fuel filter

2. Remove the filter and clean the filter head mounting surface (Figure 84).

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.

Important: Before welding on the machine, disconnect the negative cable from the battery to prevent damage to the electrical system.

Note: Check the battery condition weekly or after every 50 hours of operation. Keep the terminals and the entire battery case clean because a dirty battery will discharge 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. Open the battery cover on the side of the shroud (Figure 85).

   Note: Press down on the flat surface above the battery cover to ease the removal of the cover (Figure 85).

   

   Figure 85

   1. Battery cover
   2. Press down here.
   

   Figure 86

   1. Battery

   Warning

   Charging the battery produces gasses that can explode.

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

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

   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.

   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.

3. Coat both battery connections with Grafo 112X (skin-over) grease, Toro Part No. 505-47, petroleum jelly, or light grease to prevent corrosion.

4. Slide the rubber boot over the positive terminal.

5. Close the battery cover.

The traction-unit fuses are located under the power-center cover (Figure 87, Figure 88, and Figure 89).

Remove the 2 screws securing the power-center cover to the frame and remove the cover (Figure 87).

Figure 87

1. Power-center cover
2. Screws

Figure 88

1. Fuses

Figure 89

The cab fuses are located in the fuse box in the cab headliner (Figure 90 and Figure 91).

Note: Cab model only

Figure 90

1. Cab fuse box
2. Fuses

Figure 91

1. Loosen the 2 nuts and bolts securing the left side of the traction pedal to the bracket (Figure 92).

   

   Figure 92

   1. Traction pedal
   2. Mounting nuts and bolts

2. Pivot the pedal to the desired operating angle and tighten the nuts (Figure 92).

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

1. With the machine on a level surface, position a wheel so a check plug is at the lowest (6 o'clock) position (Figure 93).

   

   Figure 93

   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 94).

   

   Figure 94

   1. Drain plug
   2. Brake housing

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 one 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.

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 95).

3. Remove the check plugs to make draining the oil easier.

4. Remove the drain plugs and allow the oil to drain into the pans.

   

   Figure 95

   1. Drain-plug location

5. Clean the area around the drain plug at the bottom of the gear box (Figure 96).

6. Remove the drain plug from the gearbox and allow the oil to drain into a pan.

   Note: Remove the fill plug to make draining the oil easier.

   

   Figure 96

   1. Drain plug

7. Add enough oil to bring the level up to the bottom of the check plug holes; refer to Changing the Planetary-Gear-Drive Oil.

8. Install the plugs.

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

   Note: The front measurement must be 6 mm (1/4 inch) less than the rear measurement.

2. To adjust, loosen the clamps at both ends of the tie rods.

3. Rotate the tie-rod end to move the front of the tire inward or outward.

4. Tighten the tie-rod clamps when the adjustment is correct.

Check the coolant level at the beginning of each day. The capacity of the system is 8.5 L (9 US qt).

1. Carefully remove the radiator cap and expansion-tank cap (Figure 97).

2. Check the coolant level in the radiator.

   Note: The radiator should be filled to the top of the filler neck and the expansion tank filled to the Full mark.

   

   Figure 97

   1. Expansion tank

3. If the coolant is low, add a 50/50 mixture of water and ethylene glycol anti-freeze.

   Important: Do not use water only or alcohol/methanol base coolants, as this may cause damage.

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

Remove debris from the oil radiator/oil cooler daily. 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 the radiator/oil cooler and screen debris buildup. While this feature can help reduce the time required to clean radiator/oil cooler, it does not eliminate the need for routine cleaning. Periodic cleaning and inspection of the radiator/oil cooler is still required.

1. Shut off the engine and raise the hood.

2. Clean the engine area thoroughly of all debris.

3. Clean both sides of the radiator/oil cooler area thoroughly with compressed air (Figure 98).

   Note: Start from the fan side and blow the debris out toward the back. Then, clean from the back side and blow toward the front. Repeat this procedure several times until all chaff and debris is removed.

   Important: Cleaning the radiator/oil cooler with water can promote premature corrosion and damage to components.

   

   Figure 98

   1. Radiator/oil cooler

4. Close the hood.

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 99).

      

      Figure 99

      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 44 N∙m (10 ft-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 100).

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 100

1. Alternator
2. Mounting bolt
3. Compressor
4. Idler pulley

1. Proper tension of the belt allows 10 mm (3/8 inch) of deflection when a force of 44 N∙m (10 ft-lb) is applied on the belt midway between the pulleys.

2. If the deflection is not 10 mm (3/8 inch), loosen the idler pulley mounting bolt (Figure 100).

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

When properly tensioned, the inside measurement of the extension spring (hook to hook) should be approximately 8.3 to 9.5 cm (3-1/4 to 3-3/4 inches). Once the correct spring tension is attained, adjust the stop bolt (carriage bolt) until there is approximately 2 to 5 mm (0.065 to 0.185 inch) clearance between the head of the bolt and the idler arm (Figure 101).

Note: Ensure that the belt is positioned on the spring side of the belt guide (Figure 101).

Figure 101

1. Belt
2. Eye bolt
3. Extension spring
4. Belt guide
5. Flange nut
6. Stop bolt

The blade-drive belt, tensioned by the spring-loaded idler pulley, is very durable. However, after many hours of use, the belt will show signs of wear. Signs of a worn belt are: squealing when the belt is rotating, blades slipping when cutting grass, frayed edges, burn marks, and cracks. Replace the belt if any of these conditions are evident.

1. Lower the mower deck to the shop floor, remove the belt covers from the top of the mower deck, and set the covers aside.

2. Loosen the eye bolt allowing the removal of the extension spring (Figure 101).

3. Loosen the flange nut securing the stop bolt to the mounting tab and move the idler pulley away from the belt to release the belt tension (Figure 101).

   Note: Loosen the nut enough to allow the idler arm to pass the stop bolt.

   Note: If the stop bolt is ever removed from the mounting tab, make sure that it is installed again in the hole that aligns the stop-bolt head with the idler arm.

4. Remove the bolts securing the hydraulic motor to the mower deck (Figure 102).

   

   Figure 102

   1. Hydraulic motor
   2. Mounting bolts

5. Lift the motor off the mower deck and lay it on top of the mower deck.

6. Remove the old belt from around the spindle pulleys and idler pulley.

7. Route the new belt around the spindle pulleys and idler-pulley assembly.

8. Position the hydraulic motor on the mower deck after routing the belt around the pulleys. Mount the motor to the mower deck with the bolts previously removed.

   Note: Ensure that the belt is positioned on the spring side of the belt guide (Figure 101).

9. Connect the extension spring (Figure 101) to the eye bolt and tension the belt as follows:

   • When properly tensioned, the inside measurement of the extension spring (hook to hook) should be approximately 8.27 to 9.53 cm (3.25 to 3.75 inches).

   • When you attain the correct spring tension, adjust the stop bolt (carriage bolt) until there is approximately 0.17 to 0.47 cm (0.065 to 0.185 inches) clearance between the head of the bolt and the idler arm.

Note: Although not needed for normal maintenance procedures, you can pivot (tilt) the front mower deck to an upright position. To tilt the mower deck, do the following.

1. Raise the front mower deck slightly off the floor, engage the parking brake, shut off the engine, and remove the key from the ignition switch.

2. Remove the hairpin cotter and clevis pin securing the deck-transport latch to the latch plate and pivot the latch toward the rear of the deck.

3. Remove the hairpin cotter and clevis pin securing the height-of-cut chains to the rear of the mower deck.

4. Start the engine, slowly raise the front mower deck, shut off the engine, and remove the key from the ignition.

5. Grasp the front of the mower deck and lift it to an upright position.

6. Hold the mower deck upright, fit the cable end over the pin on the mower deck lift arm, and secure it with the hairpin cotter (Figure 107).

   

   Figure 107

   1. Cable
   2. Pin

1. With the help of another person, hold the mower deck upright, remove the hairpin cotter securing the cable end, and remove the cable from the pin.

2. Pivot (tilt) the mower deck downward.

3. Store the cable under the operator's platform.

4. Sit on the seat, start the engine, and lower the mower deck until it is slightly off the floor.

5. Secure the height-of-cut chains to the rear of the mower deck.

6. Pivot the transport latch upward into position and secure it with the clevis pin and cotter pin.

The caster arms have bushings pressed into the top and bottom of the tube and after many hours of operation, the bushings develop wear. To check the bushings, move the caster fork back and forth and from side to side. If the caster spindle is loose inside the bushings, the bushings are worn and must be replaced.

1. Raise the mower deck so the wheels are off the floor and block the mower deck so it cannot fall.

2. Remove the tensioning cap, spacer(s), and thrust washer from the top of the caster spindle.

3. Pull the caster spindle out of the mounting tube.

   Note: Keep the thrust washer and spacer(s) on the bottom of the spindle.

4. Insert a pin punch into the top or bottom of the mounting tube and drive the bushing out of the tube (Figure 110).

   Note: Also drive the other bushing out of the tube. Clean the inside of the tubes to remove dirt.

   

   Figure 110

   1. Caster-arm tube
   2. Bushings

5. Apply grease to the inside and outside of the new bushings.

6. Using a hammer and flat plate, drive the bushings into the mounting tube.

7. Inspect the caster spindle for wear and replace it if it is damaged.

8. Push the caster spindle through the bushings and mounting tube.

9. Slide the thrust washer and spacer(s) onto the spindle and install the tensioning cap on the caster spindle to retain all parts in place.

1. Remove the locknut from the bolt holding the caster-wheel assembly between the caster fork (Figure 111) or the caster-pivot arm (Figure 112).

   Note: Grasp the caster wheel and slide the bolt out of the fork or pivot arm.

   

   Figure 111

   1. Caster bolt
   2. Caster fork
   3. Bearing
   4. Bearing spacer
   

   Figure 112

   1. Caster wheel
   2. Caster-pivot arm
   3. Bearing
   4. Bearing spacer

2. Remove the bearing from the wheel hub and allow the bearing spacer to fall out (Figure 111 and Figure 112).

3. Remove the bearing from the opposite side of the wheel hub.

4. Check the bearings, spacer, and inside of the wheel hub for wear and replace any damaged parts.

5. To assemble the caster wheel, push the bearing into the wheel hub.

   Note: When installing the bearings, press on the outer race of the bearing.

6. Slide the bearing spacer into the wheel hub and push the other bearing into the open end of the wheel hub to captivate the bearing spacer inside the wheel hub.

7. Install the caster-wheel assembly between the caster fork and secure it in place with the bolt and locknut.

After striking a foreign object, inspect the machine for damage and make repairs before starting and operating the equipment. Torque all of the spindle-pulley nuts to 176 to 203 N∙m (130 to 150 ft-lb).

1. Position the machine on a level surface, raise the mower deck, engage the parking brake, put the traction pedal in NEUTRAL, put the PTO lever in the OFF position, shut off the engine, and remove the key from the ignition.

   Note: Block the mower deck to prevent it from accidentally falling.

2. Rotate the blade until the ends face forward and backward and measure from the inside of the mower deck to the cutting edge at the front of the blade (Figure 113).

   Note: Remember this dimension.

   

   Figure 113

3. Rotate the opposite end of the blade forward and measure between the mower deck and cutting edge of the blade at the same position as in step 2.

   Note: The difference between the dimensions obtained in steps 2 and 3 must not exceed 3 mm (1/8 inch). If the dimension exceeds 3 mm (1/8 inch), the blade is bent and must be replaced; refer to Removing and Installing the Mower Blade(s).

Replace the blade if it hits a solid object, is out of balance, or if it is bent. Always use genuine Toro replacement blades to ensure safety and optimum performance.

1. Raise the mower deck to the highest position, engage the parking brake, shut off the engine, and remove the ignition key.

   Note: Block the mower deck to prevent it from accidentally falling.

2. Grasp the end of the blade using a rag or thickly-padded glove.

3. Remove the blade bolt, anti-scalp cup, and blade from the spindle shaft (Figure 114).

   

   Figure 114

   1. Blade bolt
   2. Anti-scalp cup

4. Install the blade, anti-scalp cup, and blade bolt and tighten the blade bolt to 115 to 149 N∙m (85 to 110 ft-lb).

   Important: The curved part of the blade must be pointing toward the inside of the mower deck to ensure proper cutting.

   Note: After striking a foreign object, torque all of the spindle-pulley nuts to 115 to 149 N∙m (85 to 110 ft-lb).

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. As the sail wears down, the quality of cut degrades, although the cutting edges are sharp. The cutting edge of the blade must be sharp so that the grass is cut rather than torn. A dull cutting edge is evident when the tips of the grass appear brown and shredded. Sharpen the cutting edges to correct this condition.

1. Position the machine on a level surface, raise the mower deck, engage the parking brake, put the traction pedal in NEUTRAL, put the PTO lever in the OFF position, shut off the engine, and remove the key from the ignition.

2. Examine the cutting ends of the blade carefully, especially where the flat and curved parts of the blade meet (Figure 115).

   Note: Because sand and abrasive material can wear away the metal that connects the flat and curved parts of the blade, check the blade before using the mower. If wear is noticed (Figure 115), replace the blade.

   

   Figure 115

   1. Cutting edge
   2. Curved area
   3. Wear/slot forming
   4. Crack

3. Examine the cutting edges of all of the blades and sharpen the cutting edges if they are dull or nicked (Figure 116).

   Note: Sharpen only the top of the cutting edge and maintain the original cutting angle to ensure sharpness (Figure 116). The blade remains balanced if the same amount of metal is removed from both cutting edges.

   

   Figure 116

   1. Sharpen at the original angle.

   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 Mower Blade(s).

If there is mismatch between the blades, on a single mower deck, the grass will appear streaked when it is cut. This problem can be corrected by ensuring that the blades are straight and all of the blades are cutting on the same plane.

1. Park the machine on a level surface of the shop floor.

2. Raise the height of cut to the highest position; refer to Adjusting the Height of Cut.

3. Lower the mower deck onto the flat surface and remove the covers from the top of the mower deck.

4. Loosen the flange nut securing the idler pulley to release the belt tension.

5. Rotate the blades until the ends face forward and rearward and measure from the floor to the front tip of the cutting edge.

   Note: Remember this dimension. Then rotate the same blade so that the opposite end is forward, and measure again. The difference between the dimensions must not exceed 3 mm (1/8 inch). If the dimension exceeds 3 mm (1/8 inch), replace the blade because it is bent. Measure all the blades.

6. Compare the measurements of the outer blades with the center blade.

   Note: The center blade must not be more than 10 mm (3/8 inch) lower than the outer blades. If the center blade is more than 10 mm (3/8 inch) lower than the outer blades, proceed to step 7 and add shims between the spindle housing and the bottom of the mower deck.

7. Remove the bolts, flat washers, lock washers, and nuts from the outer spindle in the area where the shims must be added.

   Note: To raise or lower the blade, add a shim (Part No. 3256-24) between the spindle housing and the bottom of the mower deck. Continue to check the alignment of the blades and add shims until the tips of the blades are within the required dimension.

   Important: Do not use more than 3 shims at any 1 hole location. Use decreasing numbers of shims in adjacent holes if more than 1 shim is added to any 1 hole location.

8. Adjust the idler pulley and install the belt covers.

1. Remove the screws and grates from both the in-cab and rear cab air filters (Figure 117 and Figure 118).

   

   Figure 117

   In-Cab Air Filter

   1. Filter
   2. Grate
   3. Screw
   

   Figure 118

   Rear Cab Air Filter

   1. Filter
   2. Grate
   3. Screw

2. Clean the filters by blowing clean, oil-free, compressed air through them.

   Important: If either filter has a hole, tear, or other damage, replace the filter.

3. Install the filters and the grate with the thumbscrews.

1. Perform the pre-maintenance procedure; refer to Preparing the Machine for Maintenance.

2. Disconnect the wire for each fan.

   

   Figure 119

   Right fan shown

   1. Fan
   2. Wire
   3. Knob

3. Remove the 2 knobs and remove the fan assembly.

4. Open the 4 latches on the air-conditioning assembly and remove the screen.

   

   Figure 120

   1. Air-conditioning coil
   2. Latch
   3. Air-conditioning screen

5. Remove the air filters (see Figure 118).

6. Clean the air-conditioning assembly.

7. Install the air filters, screen, and fan assembly (Figure 118, Figure 119, and Figure 120).

8. Connect the wire for each fan (Figure 119).