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 Gear Box 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.

Pull out on the lever to slide the seat forward or rearward (Figure 12).

Rotate the knob to adjust the seat arm rest angle.

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

Indicates when the seat is adjusted to the weight of the operator (Figure 12). Height adjustment is made by positioning the suspension within the range of the green region.

Figure 12

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

Adjust for your weight (Figure 12). Pull up the lever to increase the air pressure and push down to decrease the air pressure. You attain the proper adjustment 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.

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 17

Note: Front wheel nuts are 1/2-20 UNF. Rear wheel nuts are M12 x 1.6-6H (Metric).

Important: This cutting deck often cuts approximately 6 mm (1/4 inch) lower than a reel cutting unit with the same bench setting. It may be necessary to have these rotary cutting deck’s bench set 6 mm (1/4 inch) above that of reels cutting in the same area.

Important: Access to the rear cutting units is greatly improved by removing the cutting unit from the tractor.

1. Lower the cutting deck to the ground, shut off the engine, and remove the key from the ignition switch.

2. Loosen the bolt securing each height-of-cut bracket to the height-of-cut plate (front and each side); refer to Figure 18.

3. Beginning with front adjustment, remove the bolt.

   

   Figure 18

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

4. While supporting the chamber, remove the spacer (Figure 18).

5. Move the chamber to the desired height of cut and install a spacer into the designated height-of-cut hole and slot (Figure 19).

   

   Figure 19

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 stop the machine when the operator gets off the seat when the traction pedal is depressed. However, the operator may get off the seat while the engine is running and the traction pedal is in the NEUTRAL position. Although the engine continues to run if the PTO switch is disengaged and the traction pedal is released, it is strongly recommended that the engine be stopped before rising from the seat.

1. Park the machine on a level surface, lower the cutting unit, turn the key in the ignition switch to the OFF position, and engage the parking brake.

2. Press the traction pedal. Turn the key in the ignition switch 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 in the ignition switch to the ON position, rise from the seat, and move the PTO switch to ON.

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

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

   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.

The blades of the cutting deck should come to a complete stop in approximately 5 seconds after you shut down the cutting deck engagement switch.

Note: Make sure that the decks are lowered onto a clean section of turf or hard surface to avoid thrown dust and debris.

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

Important: Bleed the fuel system before starting the engine if the engine has stopped due to lack of fuel, or you have performed maintenance on the fuel system.

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 20 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 21 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 22 Advisory #179	None	100%	Notify your service department that advisory #179 displays in the InfoCenter.
Level 2: Engine Warning	Figure 23 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 24 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 25 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 26

Assist/reset-regeneration icon

• The assist/reset-regeneration icon displays in the InfoCenter (Figure 26).

• 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 27

Assist/reset-regeneration icon

• The assist/reset-regeneration icon displays in the InfoCenter (Figure 27).

• 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 28

Parked-regeneration request icon

• The parked-regeneration requested icon displays in the InfoCenter (Figure 28).

• If a parked regeneration is needed, the InfoCenter displays engine warning SPN 3719, FMI 16 (Figure 29) and the engine computer derates engine power to 85%.

  

  Figure 29

  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 30); refer to Accessing Protected Menus.

   

   Figure 30

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 31).

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

   

   Figure 31

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 32).

   

   Figure 32

4. When the “Initiate DPF Regen. Are you sure?” message displays, press the center button (Figure 33).

   

   Figure 33

5. If the coolant temperature is below 60°C (140°F) the “Insure is running and above 60C/140F” message displays. (Figure 34).

   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 34

6. Move the throttle control to LOW IDLE and press the center button (Figure 35).

   

   Figure 35

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

   1. The “Initiating DPF Regen.” message displays (Figure 36).

      

      Figure 36

   2. The “Waiting on ” message displays (Figure 37).

      

      Figure 37

   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 38).

        

        Figure 38

      • If the regeneration process is not allowed by the engine computer, the “DPF Regen Not Allowed” message displays in the InfoCenter (Figure 39). 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 39

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 40).

   

   Figure 40

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 traction unit and cutting units 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 cutting unit 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 stopping 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 in the ignition switch to the OFF position to shut off the engine.

The engine-cooling-fan switch has 2 positions for controlling the operation of the fan. The 2 positions are R and AUTO. The fan has the ability to reverse to blow debris off the rear screen. Under normal operating conditions, the switch should be in the AUTO position. In Auto, the fan speed will be controlled by the coolant or hydraulic-oil temperature and will automatically reverse to blow debris off the rear screen. A reverse cycle is automatically initiated when either the coolant or hydraulic-oil temperature reaches a certain point. By pressing the fan switch forward into the R position, the fan will complete a manually initiated reverse cycle. It is recommended to reverse the fan when the rear screen is clogged or prior to entering the shop or the storage area.

Note: Always use jack stands. Do not rely on a jack or hoist to hold the machine.

• Front— frame, on the inside of each drive tire.

• Rear— center of the axle.

• Use properly rated DOT approved straps in four corners to tie down machine.

• On each side of the frame by the operator’s seat.

• On the rear bumper.

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 valve must be open whenever you push or tow the machine.

Important: If you must push or tow the machine in reverse, the check valve in the four-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 in-between ports M8 and P2 on the rear traction manifold which is located to the inside of the front rear tire.

1. Open the hood and locate the bypass valves (Figure 43) 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. Do not open more than 3 turns. Because fluid is bypassed, the machine can be slowly moved without damaging the transmission.

   

   Figure 43

   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.

• 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.

1. Release the hood latches (Figure 45) and pivot open the hood.

   

   Figure 45

   1. Hood latch (2)

2. Remove the cotter pins securing the rear hood brackets to the frame pins and lift off the hood.

The machine has grease fittings that must be lubricated regularly with No. 2 lithium grease.

The grease fitting locations and quantities are as follows:

• Brake-shaft pivot bearings (5) (Figure 46)

  

  Figure 46

• Rear axle pivot bushings (2) (Figure 47)

  

  Figure 47

• Steering cylinder ball joints (2) (Figure 48)

  

  Figure 48

  1. Top fitting on king pin

• Tie-rod ball joints (2) (Figure 48)

• King-pin bushings (2) (Figure 48). The top fitting on the king pin should only be lubricated annually (2 pumps).

• Lift-arm bushings (1 per deck) (Figure 49)

  

  Figure 49

• Lift-cylinder bushings (2 per deck) (Figure 49)

• Cutting unit spindle-shaft bearings (2 per cutting unit) (Figure 50)

  Note: You can use either fitting, whichever is more accessible. Pump grease into the fitting until a small amount appears at bottom of the spindle housing (under the deck).

  

  Figure 50

• Cutting unit carrier-arm bushings (1 per cutting unit) (Figure 50)

• Rear roller bearings (2 per cutting unit) (Figure 51)

  

  Figure 51

  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 hole, there is also an alignment mark on 1 end of the roller shaft.

Check the air-cleaner body for damage that 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 52) 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 52

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 53).

   

   Figure 53

   Note: Cleaning the used element is not recommended due to the possibility of damage to the filter media.

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

2. Reset the indicator (Figure 52) 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 56

• If engine faults , , or in the InfoCenter (Figure 57) display in the InfoCenter, clean the soot filter using the steps that follow:

  

  Figure 57

  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 if fuel system becomes contaminated or if the machine will be stored 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.

1. Clean the area around the fuel filter head (Figure 59).

   

   Figure 59

   1. Fuel-filter head
   2. Fuel Filter

2. Remove the filter and clean the filter-head mounting surface (Figure 59).

3. Lubricate the filter gasket with clean lubricating engine oil; refer to the Engine Operator's Manual.

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 fuel pick-up tube and clean the screen as required.

1. Unlatch and raise the operator's console panel (Figure 60).

   

   Figure 60

   1. Operator's console panel
   2. Latch

   Danger

   Battery electrolyte contains sulfuric acid which is a deadly poison 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. 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.

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

   Warning

   Charging the battery produces gasses that can explode.

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

4. Install the positive cable (red) to the positive (+) terminal and the negative cable (black) to the negative (-) terminal of the battery (Figure 61).

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

   Note: Make sure that the positive (+) terminal is all of the way onto the post and the cable is positioned snug to the battery. The cable must not contact the battery cover.

6. Slide the rubber boot over the positive terminal to prevent a possible short from occurring.

   

   Figure 61

   1. Positive battery cable
   2. Negative battery cable

   Warning

   Battery posts, terminals, and related accessories contain lead and lead compounds, chemicals known to the State of California to cause cancer and reproductive harm. Wash hands after handling.

7. Coat both battery connections with Grafo 112X (skin-over) grease, Part No. 505-47, petroleum jelly, or light grease to prevent corrosion. Slide the rubber boot over the positive terminal.

8. Close the console panel and secure the latch.

   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.

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

Note: Keep the terminals and the entire battery case clean to avoid slow discharge. To clean the battery, remove it from the machine and 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 (Part No. 505-47) or petroleum jelly to prevent corrosion.

Figure 62

Unhook the latch and raise operator's console panel (Figure 63) to expose the fuses (Figure 64).

Figure 63

1. Latch
2. Operator's console panel

Figure 64

1. Fuses

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, lower the cuting units, shut off the engine, and remove the key from the ignition switch.

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 of the jack, injuring anyone beneath it.

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

   • Always remove the key from the ignition before getting off of 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 65

   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 wt. gear lube as a replacement.

1. With machine on level surface, position the wheel so one check plug (Figure 66) is at the 12 o'clock position and the other is at 3 o'clock position.

   

   Figure 66

   1. Check/drain plug (2)

2. Remove the plug at the 3 o’clock position (Figure 66).

   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 the hole at the 3 o’clock position.

   Install both plugs.

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

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

1. Position the machine on a level surface and position a wheel so that 1 of the check plugs is at the lowest (6 o'clock) position (Figure 67).

   

   Figure 67

   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 68).

   

   Figure 68

   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 twelve o'clock position.

6. Through the open hole, slowly fill the planetary with 0.65 L (22 oz) of high quality SAE 85W-140 wt. gear lube.

   Important: If the planetary fills before the 0.65 L (22 oz) of oil is added, wait 1 hour or install the plug and move the machine approximately 3 m (10 ft) to distribute the oil through the brake system. Then, remove the plug and add the remaining oil.

   Install the plug.

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

The rear axle is shipped from the factory filled with SAE 85W-140 wt. gear lube. The capacity is 2.4 L (80 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 (Figure 69) and make sure that the lubricant is up to the bottom of the hole.

3. If the level is low, remove the fill plug (Figure 69) and add enough lubricant to bring the level up to the bottom of the check plug holes.

   

   Figure 69

   1. Check plug
   2. Fill plug

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 70).

   

   Figure 70

   1. Drain-plug location

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

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

5. Install the plugs.

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

7. Install the check plug.

The gear box is filled with SAE 85W-140 gear lube. Check the oil level before the engine is first started and every 400 hours thereafter. The capacity is 0.5 L (16 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 (Figure 71) and make sure that lubricant is up to the bottom of the hole. If the level is low, add enough lubricant to bring the level up to the bottom of the hole.

   

   Figure 71

   1. Gear box
   2. Check/fill plug

1. Measure the center-to-center distance (at axle height) at the front and rear of the steering tires. The front measurement must be 3 mm (1/8 inch) less than the rear measurement (Figure 72).

   

   Figure 72

   1. Front of traction unit
   2. 1/8 inch less than rear of tire
   3. Center to center distance

2. To adjust, remove the cotter pin and nut from either tie rod ball joint (Figure 73). Remove the tie-rod ball joint from the axle-case support.

   

   Figure 73

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

3. Loosen the clamps at both ends of the tie rods (Figure 73).

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.

Check level of coolant at the beginning of each day. The capacity of the system is 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 74

   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 74).

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 build-up. 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 75).

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

2. Clean the screen thoroughly of all debris.

   

   Figure 75

   1. Rear-screen latch

3. Thoroughly clean both sides of the oil cooler and the radiator (Figure 76) with compressed air. 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 76

   1. Oil cooler/radiator

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

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

Adjust the service brakes when there is more than 25 mm (1 inch) of free travel of the brake pedal or when the brakes do not work effectively. Free travel is the distance the brake pedal moves before braking resistance is felt.

1. Disengage 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:

   1. Loosen the front nut on the threaded end of the brake cable (Figure 77).

      

      Figure 77

      1. Brake cable

   2. Tighten the rear nut to move the cable backward 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.

1. Check the tension of the alternator belt by depressing it midway between the alternator and the crankshaft pulleys with 4.5 kg (10 lb) of force.

   Note: The belt should deflect 10mm (3/8 inch). If the deflection is incorrect, proceed to step 2. If correct, continue operation.

2. Loosen the alternator-mounting bolts (Figure 78).

3. 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 78

   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 79).

   

   Figure 79

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. Turn the key in the ignition switch to the OFF position and raise the hood.

2. Disconnect the case return line from the bottom of the reservoir and let the hydraulic fluid flow into a large drain pan.

3. Install the hose when the hydraulic fluid stops draining.

4. Fill the reservoir with approximately 28.4 L (7.50 US gallons) of hydraulic fluid; refer to Checking the Hydraulic-Fluid Level.

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

5. Install the reservoir cap.

6. Turn the key in the ignition switch to the ON position to start the engine, use all of the hydraulic controls to distribute hydraulic fluid throughout the system, and check for leaks.

7. Turn the key in the ignition switch to the OFF position.

8. 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 (cutting unit) 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. Position the machine on a level surface, lower the cutting units, shut off the engine, engage the parking brakes, and remove the ignition key.

2. Replace the hydraulic filters (Figure 80).

   

   Figure 80

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

1. Position the machine on a level surface, lower the cutting decks to the floor, turn the key in the ignition switch to the OFF position, and engage the parking brake.

2. Disconnect and remove the hydraulic motor from the deck (Figure 81). Cover the top of the spindle to prevent contamination.

   

   Figure 81

   1. Motor-mounting screws

3. Remove the lynch pin or retaining nut (Groundsmater 4700 only) securing the deck-carrier frame to the lift-arm pivot pin (Figure 82).

   

   Figure 82

   1. Lynch pin
   2. Lift-arm pivot pin

4. Roll the cutting deck away from the traction unit.

1. Position the machine on a level surface and turn the key in the ignition switch to the OFF position.

2. Move cutting deck into position in front of traction unit.

3. Slide deck carrier frame onto lift-arm pivot pin. Secure with lynch pin or retaining nut (Groundsmaster 4700 only) (Figure 82).

4. Install the hydraulic motor to the deck (Figure 81). Make sure that the O-ring is in position and not damaged.

5. Grease the spindle.

The rotary 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 cutting 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.

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