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 13).

Figure 13

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 13).

Move the lever to adjust the seat-back angle (Figure 13).

The weight gauge indicates when the seat is adjusted to the weight of the operator (Figure 13). 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 13). 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.

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 Draining 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 19

Torque the wheel-lug nuts to 115 to 136 N∙m (85 to 100 ft-lb) in the order shown in Figure 20 and Figure 21.

Figure 20

Front Wheels

Figure 21

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 22

Raising the Roll Bar

Figure 23

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 in Figure 24.

3. Beginning with front adjustment, remove the bolt.

   

   Figure 24

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

4. While supporting the chamber, remove the spacer (Figure 24).

5. Move the chamber to the desired height of cut and install a spacer into the designated height-of-cut hole and slot (Figure 25).

   

   Figure 25

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, start the engine and allow the glow plugs to heat, then 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 key to the OFF position.

5. Remove the key to prevent accidental starting.

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 26 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 27 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 28 Advisory #179	None	100%	Notify your service department that advisory #179 displays in the InfoCenter.
Level 2: Engine Warning	Figure 29 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 30 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 31 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 32

Assist/reset-regeneration icon

• The assist/reset-regeneration icon displays in the InfoCenter (Figure 32).

• 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 33

Assist/reset-regeneration icon

• The assist/reset-regeneration icon displays in the InfoCenter (Figure 33).

• 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 34

Parked-regeneration request icon

• The parked-regeneration requested icon displays in the InfoCenter (Figure 34).

• If a parked regeneration is needed, the InfoCenter displays engine warning SPN 3719, FMI 16 (Figure 35) and the engine computer derates engine power to 85%.

  

  Figure 35

  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 36); refer to Accessing Protected Menus.

   

   Figure 36

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 37).

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

   

   Figure 37

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 38).

   

   Figure 38

4. When the “Initiate DPF Regen. Are you sure?” message displays, press the center button (Figure 39).

   

   Figure 39

5. If the coolant temperature is below 60°C (140°F) the “Insure is running and above 60C/140F” message displays. (Figure 40).

   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 40

6. Move the throttle control to LOW IDLE and press the center button (Figure 41).

   

   Figure 41

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

   1. The “Initiating DPF Regen.” message displays (Figure 42).

      

      Figure 42

   2. The “Waiting on ” message displays (Figure 43).

      

      Figure 43

   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 44).

        

        Figure 44

      • If the regeneration process is not allowed by the engine computer, the “DPF Regen Not Allowed” message displays in the InfoCenter (Figure 45). 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 45

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 46).

   

   Figure 46

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 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 48

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 49

• 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 50) 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 50

   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 51

Figure 52

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 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 54)

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

Figure 54

Rear of the machine—at the center of the axle (Figure 55)

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 55

Tilt the hood to access the chassis as shown in Figure 56.

Figure 56

Tilt the seat to access the hydraulic lift compartment as shown in Figure 57.

Figure 57

Grease specification: No. 2 lithium grease

The grease fitting locations and quantities are as follows:

• Brake-shaft pivot bearings (5) as shown in Figure 58

  

  Figure 58

• Rear-axle-pivot bushings (2) as shown in Figure 59)

  

  Figure 59

• Steering-cylinder ball joints (2) as shown in Figure 60

  

  Figure 60

  1. Top fitting on kingpin

• Tie-rod ball joints (2) as shown in Figure 60

• Kingpin bushings (2) as shown in Figure 60

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

• Lift-arm bushings (1 per deck) as shown in Figure 61

  

  Figure 61

• Lift-cylinder bushings (2 per deck) as shown in Figure 61

• Cutting-unit spindle-shaft bearings (2 per mower deck) as shown in Figure 62

  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 62

• Cutting-unit carrier-arm bushings (1 per mower deck) as shown in Figure 62

• Rear roller bearings (2 per mower deck) as shown in Figure 63

  

  Figure 63

  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 64) 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 64

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 65).

   

   Figure 65

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

   Important: Never attempt to clean the safety filter (Figure 66). Replace the safety filter after every 3 primary filter services.

   

   Figure 66

   1. Air-cleaner safety filter

2. Reset the indicator (Figure 64) 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 69

• If engine faults , , or in the InfoCenter (Figure 70) display in the InfoCenter, clean the soot filter using the steps that follow:

  

  Figure 70

  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.

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 71.

Figure 71

1. Clean the area around the fuel-filter head (Figure 72).

   

   Figure 72

   1. Fuel-filter head
   2. Fuel filter

2. Remove the filter and clean the filter head mounting surface (Figure 72).

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 73).

   

   Figure 73

   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 73).

3. Lift the fuel-pickup tube from the fuel tank (Figure 73).

   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 73).

5. Insert the fuel-pickup tube through the rubber bushing and into the tank (Figure 73).

   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 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 74).

   

   Figure 74

   1. Tube nut (cylinder #1 fuel injector)

2. Move the throttle to the FAST position.

3. Turn the key in the 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 75).

   

   Figure 75

   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 76).

   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 76

   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 76).

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 77

1. Loosen the latch for the cover of the right storage box and raise the cover (Figure 78) to expose the fuse block (Figure 79).

   

   Figure 78

   1. Latch
   2. Right storage box

2. Replace the open fuse(s) as needed (Figure 79).

   

   Figure 79

   1. Fuses

3. Close the cover of the right storage box and secure the cover with the latch (Figure 78).

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 80

   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 81).

   

   Figure 81

   1. Check/drain plug (2)

2. Remove the plug at the 3 o’clock position (Figure 81).

   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 82).

   

   Figure 82

   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 83).

   

   Figure 83

   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 84

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 85).

   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 85

   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 86).

   

   Figure 86

   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 87).

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

   

   Figure 87

   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 88).

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

   

   Figure 88

   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 89). Remove the tie-rod ball joint from the axle-case support.

   

   Figure 89

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

3. Loosen the clamps at both ends of the tie rods (Figure 89).

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 90

   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 90).

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 91).

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

2. Clean the screen thoroughly of all debris.

   

   Figure 91

   1. Rear-screen latch

3. Thoroughly clean both sides of the oil cooler and the radiator with compressed air (Figure 92).

   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 92

   1. Oil cooler/radiator

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

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 93).

      

      Figure 93

      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 94).

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 94

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.

High Viscosity Index/Low Pour Point Anti-wear Hydraulic Fluid, ISO VG 46

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 95).

   

   Figure 95

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 96

2. Replace the charge hydraulic filter at the hydraulic lift compartment as shown in Figure 97.

   

   Figure 97

3. Lower and secure the operator’s seat.

4. Replace the return filter at the right side of the machine (Figure 97).

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

2. Disconnect and remove the hydraulic motor from the deck (Figure 98). Cover the top of the spindle to prevent contamination.

   

   Figure 98

   1. Motor-mounting screws

3. Remove the lynch pin (for Groundsmaster 4500 machines) or retaining nut (for Groundsmaster 4700 machines) securing the deck-carrier frame to the lift-arm pivot pin (Figure 99).

   

   Figure 99

   1. Lynch pin
   2. Lift-arm pivot pin

4. Roll the cutting deck away from the machine.

1. Move the mower deck into position in front of the machine.

2. Slide the deck carrier frame onto the lift-arm-pivot pin (Figure 99). Secure the deck to the pin with the lynch pin (for Groundsmaster 4500 machines) or retaining nut (for Groundsmaster 4700 machines).

3. Install the hydraulic motor to the deck (Figure 98). Make sure that the O-ring is in position and not damaged.

4. Grease the spindle.

Inspect the front roller for wear, excess wobble, or binding. Service or replace the roller or components if any of these conditions exist.

The mower deck comes from the factory preset at 5 cm (2 inches) height of cut and blade rake of 7.9 mm (0.310 inch). The left and right heights are also preset to within ± 0.7 mm (0.030 inch) of the other.

The mower deck is designed to withstand blade impacts without deformation of the chamber. If a solid object is struck, inspect the blade for damage and the blade plane for accuracy.

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. Park the machine on a level surface, raise the mower deck to the highest position, engage the parking brake, shut off the engine, and remove the 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 103).

   

   Figure 103

   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. Park the machine on a level surface, raise the mower decks, 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.

2. Examine the cutting ends of the blade carefully, especially where the flat and curved parts of the blade meet (Figure 104).

   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 104), replace the blade.

   

   Figure 104

   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 105).

   Note: Sharpen only the top of the cutting edge and maintain the original cutting angle to ensure sharpness (Figure 105). The blade remains balanced if the same amount of metal is removed from both cutting edges.

   

   Figure 105

   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).