Groundsmaster® 4300-D Traction Unit

• Read the operator's manual and other training material carefully. Be familiar with the controls, safety signs, and the proper use of the equipment.

• Never allow children or people unfamiliar with these instructions to use or service the mower. Local regulations may restrict the age of the operator.

• Never mow while people, especially children, or pets are nearby.

• Keep in mind that the operator or user is responsible for accidents or hazards occurring to other people or their property.

• Do not carry passengers.

• All drivers and mechanics should seek and obtain professional and practical instruction. The owner is responsible for training the users. Such instruction should emphasize:

  • the need for care and concentration when working with ride-on machines;

  • control of a ride-on machine sliding on a slope will not be regained by the application of the brake. The main reasons for loss of control are:

    • insufficient wheel grip;

    • being driven too fast;

    • inadequate braking;

    • the type of machine is unsuitable for its task;

    • lack of awareness of the effect of ground conditions, especially slopes;

    • incorrect hitching and load distribution.

• The owner/user can prevent and is responsible for accidents or injuries occurring to himself or herself, other people, or property.

• While mowing, always wear substantial, slip-resistant footwear, long trousers, hard hat, safety glasses, and ear protection. Long hair, loose clothing, or jewelry may get tangled in moving parts. Do not operate the equipment when barefoot or wearing open sandals.

• Thoroughly inspect the area where the equipment is to be used and remove all objects which may be thrown by the machine.

• Replace faulty silencers/mufflers.

• Evaluate the terrain to determine what accessories and attachments are needed to properly and safely perform the job. Only use accessories and attachments approved by the manufacturer.

• Check that the operator's presence controls, safety switches and shields are attached and functioning properly. Do not operate unless they are functioning properly.

• To avoid personal injury or property damage, use extreme care in handling gasoline. Gasoline is extremely flammable and the vapors are explosive.

• Extinguish all cigarettes, cigars, pipes, and other sources of ignition.

• Use only an approved fuel container.

• Never remove fuel cap or add fuel with the engine running.

• Allow engine to cool before refueling.

• Never refuel the machine indoors.

• Never store the machine or fuel container where there is an open flame, spark, or pilot light such as on a water heater or on other appliances.

• Never fill containers inside a vehicle or on a truck or trailer bed with a plastic liner. Always place containers on the ground away from your vehicle before filling.

• Remove equipment from the truck or trailer and refuel it on the ground. If this is not possible, then refuel such equipment with a portable container, rather than from a fuel dispenser nozzle.

• Keep the nozzle in contact with the rim of the fuel tank or container opening at all times until fueling is complete. Do not use a nozzle lock open device.

• If fuel is spilled on clothing, change clothing immediately.

• Never overfill fuel tank. Replace fuel cap and tighten securely.

• Do not operate the engine in a confined space where dangerous carbon monoxide and exhaust gases can collect.

• Mow only in daylight or in good artificial light.

• Before attempting to start the engine, disengage all blade attachment clutches, shift into neutral, and engage the parking brake.

• Remember there is no such thing as a safe slope. Travel on grass slopes requires particular care. To guard against overturning:

  • do not stop or start suddenly when going up or downhill;

  • machine speeds should be kept low on slopes and during tight turns;

  • stay alert for humps and hollows and other hidden hazards;

  • Do not turn sharply. Use care when reversing.

  • Use counterweight(s) or wheel weights as identified in the operator's manual.

• Stay alert for holes in the terrain and other hidden hazards.

• Watch out for traffic when crossing or near roadways.

• Stop the blades rotating before crossing surfaces other than grass.

• When using any attachments, never direct discharge of material toward bystanders nor allow anyone near the machine while in operation.

• Never operate the machine with damaged guards, shields, or without safety protective devices in place. Be sure all interlocks are attached, adjusted properly, and functioning properly.

• Do not change the engine governor settings or over-speed the engine. Operating the engine at excessive speed may increase the hazard of personal injury.

• Before leaving the operator's position:

  • stop on level ground;

  • disengage the power take-off and lower the attachments;

  • change into neutral and set the parking brake;

  • stop the engine and remove the key.

• Disengage drive to attachments when transporting or not in use.

• Stop the engine and disengage drive to attachment:

  • before refuelling;

  • before removing the grass catcher/catchers;

  • before making height adjustment unless adjustment can be made from the operator's position.

  • before clearing blockages;

  • before checking, cleaning or working on the mower;

  • after striking a foreign object or if an abnormal vibration occurs. Inspect the mower for damage and make repairs before restarting and operating the equipment.

• Reduce the throttle setting during engine run-out and, if the engine is provided with a shut-off valve, turn the fuel off at the conclusion of mowing.

• Keep hands and feet away from the cutting decks.

• Look behind and down before backing up to be sure of a clear path.

• Slow down and use caution when making turns and crossing roads and sidewalks.

• Do not operate the mower under the influence of alcohol or drugs.

• Lightning can cause severe injury or death. If lightning is seen or thunder is heard in the area, do not operate the machine; seek shelter.

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

• Use care when approaching blind corners, shrubs, trees, or other objects that may obscure vision.

• Keep all nuts, bolts and screws tight to be sure the equipment is in safe working condition.

• Never store the equipment with fuel in the tank inside a building where fumes may reach an open flame or spark.

• Allow the engine to cool before storing in any enclosure.

• To reduce the fire hazard, keep the engine, silencer/muffler, battery compartment and fuel storage area free of grass, leaves, or excessive grease.

• Keep all parts in good working condition and all hardware and hydraulic fittings tightened. Replace all worn or damaged parts and decals.

• If the fuel tank has to be drained, do this outdoors.

• Be careful during adjustment of the machine to prevent entrapment of the fingers between moving blades and fixed parts of the machine.

• Disengage drives, lower the cutting decks, set parking brake, stop engine and remove key from ignition. Wait for all movement to stop before adjusting, cleaning or repairing.

• Clean grass and debris from cutting decks, drives, silencers/mufflers, and engine to help prevent fires. Clean up oil or fuel spillage.

• Use jack stands to support components when required.

• Carefully release pressure from components with stored energy.

• Disconnect battery before making any repairs. Disconnect the negative terminal first and the positive last. Reconnect positive first and negative last.

• Keep hands and feet away from moving parts. If possible, do not make adjustments with the engine running.

• Charge batteries in an open well ventilated area, away from spark and flames. Unplug charger before connecting or disconnecting from battery. Wear protective clothing and use insulated tools.

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

• Use full width ramps for loading machine into trailer or 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

Important: Use only ultra-low sulphur diesel fuel. Fuel with higher rates of sulfur degrades the diesel oxidation catalyst (DOC), which causes operational problems and shortens the service life of engine components.Failure to observe the following cautions may damage the engine.

• Never use kerosene or gasoline instead of diesel fuel.

• Never mix kerosene or used engine oil with the diesel fuel.

• Never keep fuel in containers with zinc plating on the inside.

• Do not use fuel additives.

Fuel tank capacity: 53 L (14 US gallons)

1. Park the machine on a level surface.

2. Using a clean rag, clean area around fuel tank cap.

3. Remove the cap from the fuel tank (Figure 17).

   

   Figure 17

   1. Fuel tank cap

4. Fill the tank until the level is 6 to 13 mm (1/4 to 1/2 inch) below the bottom of the filler neck.

5. Install fuel tank cap tightly after filling tank.

   Note: If possible, fill the fuel tank after each use. This will minimize possible buildup of condensation inside the fuel tank.

Fill the tank to about 6 to 13 mm (1/4 to 1/2 inch) below the top of the tank, not the filler neck, with Number 2-D diesel fuel.

Note: If possible, fill the fuel tank after each use; this will minimize possible buildup of condensation inside the fuel tank.

1. Sit on the seat, keep your foot off of the traction pedal so that it is in Neutral, engage the parking brake, set the engine speed switch to the Mid position, and ensure that the Enable/Disable switch is in the Disable position.

2. Turn the ignition key to the Run position.

3. When the glow indicator dims, turn the ignition key to the Start position. Release the key immediately when the engine starts and allow it to return to the Run position. Allow engine to warm up (without load), then move the throttle control to the desired position.

1. Move all controls to Neutral, set the parking brake, move the engine speed switch to the low idle position and allow the engine to reach low idle speed.

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

2. Turn the key to the Off position and remove it from the switch.

• 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 19 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 20 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.

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

• Passive regeneration occurs as part of normal engine operation.

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

Figure 25

Assist/reset-regeneration icon

• The assist/reset-regeneration icon displays in the InfoCenter (Figure 25).

• 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.

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 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.

Figure 27

Parked-regeneration request icon

• The parked-regeneration requested icon displays in the InfoCenter (Figure 27).

• If a parked regeneration is needed, the InfoCenter displays engine warning SPN 3719, FMI 16 (Figure 28) and the engine computer derates engine power to 85%.

  

  Figure 28

  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.

• If you ignore the request for a parked regeneration (displayed in the InfoCenter) and continue to operate the machine, a critical amount of soot builds up in the DPF.

• If a recovery regeneration is needed, the InfoCenter displays engine warning SPN 3719, FMI 16 (Figure 40) and the engine computer derates engine power to 85%.

  

  Figure 40

  Important: If you do not complete a recovery regeneration within 15 minutes, the engine computer derates engine power to 50%.

• Perform a recovery-regeneration whenever there is a loss of engine power and a parked regeneration cannot effectively clean the DPF of soot.

• A recovery regeneration requires up to 4 hours to complete.

• You need a distributor technician to perform the recovery regeneration process; contact your Authorized Toro Distributor.

1. Park the machine on a level surface, lower the cutting units, stop the engine, and engage the parking brake.

2. Turn the key switch to the On position, but do not start the machine.

3. Locate the appropriate switch function in the diagnostics menu on the InfoCenter.

4. Individually, change each of the switches from open to closed (i.e., sit on seat, engage traction pedal, etc.), and note that the appropriate state of the switch changes. Repeat this for all switches that you can change by hand.

5. If a switch is closed and the appropriate indicator does not change, check all wiring and connections to the switch and/or check the switches with an ohm meter. Replace any defective switches and repair any defective wiring.

Note: The InfoCenter display also has the ability to detect which output solenoids or relays are turned on. This is a quick way to determine if a machine malfunction is electrical or hydraulic.

1. Park the machine on a level surface, lower the cutting units, stop the engine, and engage the parking brake.

2. Turn the key switch to the On position and start the machine.

3. Locate the appropriate output function in the diagnostics menu on the InfoCenter.

4. Sit on the seat and attempt to operate the desired function of the machine. The appropriate outputs should change state to indicate that the ECM is turning on that function.

Note: If the correct outputs do not illuminate, verify that the required input switches are in the necessary positions to allow that function to occur. Verify correct switch function.If the output displays are on as specified, but the machine does not function properly, this indicates a non-electrical problem. Repair as necessary.

This blade was designed to provide excellent lift and dispersion in almost any condition. If more or less lift and discharge velocity is required, consider a different blade.

Attributes: Excellent lift and dispersion in most conditions.

The blade generally performs best in lower heights of cut - 1.9 to 6.4 cm (3/4 to 2–1/2 inch).

Attributes:

• Discharge remains more even at lower heights of cut.

• Discharge has less tendency to throw left and thus a cleaner look around bunkers and fairways.

• Lower power requirement at lower heights and dense turf.

The blade generally performs better in the higher heights of cut - 7 to 10 cm (2 to 4 inch).

Attributes:

• More lift and higher discharge velocity.

• Sparse or limp turf is picked up significantly at higher heights of cut.

• Wet or sticky clippings are discharged more efficiently reducing congestion in the deck.

• Requires more horsepower to run.

• Tends to discharge further left and can tend to windrow at lower heights of cut.

This blade was designed to provide excellent leaf mulching.

Attributes: Excellent leaf mulching

Before mowing grass, practice operating the machine in an open area. Start and stop the engine. Operate in forward and reverse. Lower and raise the cutting decks and engage and disengage the mowers. When you feel familiar with the machine, practice operating up and down slopes at different speeds.

If a warning light comes on during operation, stop the machine immediately and correct the problem before continuing operation. Serious damage could occur if you operate the machine with a malfunction.

Start the engine and move the throttle to the Fast position. Move the Enable/Disable switch to the Enable position and use the Lower Mow/Raise lever to control the cutting decks. To move forward and cut grass, press the traction pedal forward.

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

Mow either in the late morning to avoid the dew, which causes grass clumping, or in late afternoon to avoid the damage that can be caused by direct sunlight on the sensitive, freshly mowed grass.

Remove approximately one inch or no more than 1/3 of the grass blade when cutting. In exceptionally lush and dense grass you may have to raise the height–of–cut setting.

A sharp blade cuts cleanly and without tearing or shredding the grass blades like a dull blade. Tearing and shredding causes the grass to turn brown at the edges which impairs growth and increases susceptibility to diseases. Make sure blade is in good condition and a full sail is present.

Make sure that the cutting chambers are in good condition. Straighten any bends in the chamber components to ensure the correct blade tip/chamber clearance.

To ensure optimum performance, clean the underside of mower housing. If you allow residue to build up in mower housing, cutting performance will decrease.

Move the Enable/Disable switch to the Disable position and raise the cutting decks to the transport position. Move the Mow/Transport lever to the transport position. Be careful when driving between objects so you do not accidentally damage the machine or cutting decks. Use extra care when operating the machine on slopes. Drive slowly and avoid sharp turns on slopes to prevent roll overs. Lower the cutting decks when going downhill for steering control.

If you operate the machine under normal conditions, lubricate all grease fittings for the bearings and bushings after every 50 hours of operation with No. 2 General Purpose Lithium Base Grease. Lubricate bearings and bushings immediately after every washing, regardless of the interval listed.

The grease fitting locations and quantities are as follows:

• Pump drive shaft U-joint (3) (Figure 47)

  

  Figure 47

• Cutting unit lift arm cylinders (2 each) (Figure 48)

  

  Figure 48

• Lift arm pivots (1 each) (Figure 48)

• Cutting unit carrier frame pivot (1 each) (Figure 49)

  

  Figure 49

• Lift arm pivot shaft (1 each) (Figure 50)

  

  Figure 50

• Rear axle tie rod (2) (Figure 51)

  

  Figure 51

• Axle steering pivot (1) (Figure 52)

  

  Figure 52

• Steering cylinder ball joints (2) and rear axle (1) (Figure 53)

  

  Figure 53

• Brake pedal (1) (Figure 54)

  

  Figure 54

• Cutting unit spindle shaft bearings (2 per cutting unit) (Figure 55)

  Note: Either fitting can be used, which ever is more accessible. Pump grease into the fitting until a small amount appears at bottom of the spindle housing (under the deck).

  

  Figure 55

• Rear roller bearings (2 per cutting unit) (Figure 56)

  

  Figure 56

  Note: Make sure 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 one end of the roller shaft.

Check the air cleaner body for damage which could cause an air leak. Replace if damaged. Check the whole intake system for leaks, damage or loose hose clamps.

Service the air cleaner filter only when the service indicator (Figure 57) requires it. Changing the air filter before it is necessary only increases the chance of dirt entering the engine when the filter is removed.

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

1. Release the latches securing the air cleaner cover to the air cleaner body (Figure 57).

   

   Figure 57

   1. Air cleaner cover
   2. Air cleaner cover latch
   3. Air cleaner service indicator

2. Remove the cover from the air cleaner body. Before removing the filter, use low pressure air (40 psi, clean and dry) to help remove large accumulations of debris packed between outside of the filter and the canister. Avoid using high pressure air which could force dirt through the filter into the intake tract.

   This cleaning process prevents debris from migrating into the intake when the filter is removed.

3. Remove and replace the filter (Figure 58).

   Cleaning of the used element is not recommended due to the possibility of damage to the filter media. Inspect the new filter for shipping damage, checking the sealing end of the filter and the body. Do not use a damaged element. Insert the new filter by applying pressure to the outer rim of the element to seat it in the canister. Do not apply pressure to the flexible center of the filter.

   

   Figure 58

   1. Air cleaner cover
   2. Air cleaner filter
   3. Air cleaner indicator

4. Clean the dirt ejection port located in the removable cover. Remove the rubber outlet valve from the cover, clean the cavity and replace the outlet valve.

5. Install the cover orienting the rubber outlet valve in a downward position—between approximately 5:00 to 7:00 when viewed from the end.

6. Secure the latches.

• 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 61

• If engine faults , , or in the InfoCenter (Figure 62) display in the InfoCenter, clean the soot filter using the steps that follow:

  

  Figure 62

  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 fuel tank if the fuel system becomes contaminated or if the machine is to be stored for an extended period. Use clean fuel to flush out the tank.

Check the fuel lines and connections every 400 hours or yearly, whichever comes first. Inspect them for deterioration, damage, or loose connections.

Drain water or other contaminants from water separator (Figure 63) daily. Replace filter canister after every 400 hours of operation.

1. Place a clean container under the fuel filter.

2. Loosen the drain plug on the bottom of the filter canister and open the vent on the top of the canister mount.

   

   Figure 63

   1. Water separator filter canister

3. Clean the area where the filter canister mounts.

4. Remove the filter canister and clean the mounting surface.

5. Lubricate the gasket on the filter canister with clean oil.

6. Install the filter canister by hand until the gasket contacts mounting surface, then rotate it an additional 1/2 turn.

7. Tighten the drain plug on the bottom of the filter canister and close the vent on the top of the canister mount.

The engine fuel filter should be replaced after every 400 hours of operation.

1. Clean the area around the fuel filter head (Figure 64).

   

   Figure 64

   1. Fuel Filter head
   2. Fuel Filter

2. Remove the filter and clean the filter head mounting surface (Figure 64).

3. Lubricate the filter gasket with clean lubricating engine oil. Refer to the Engine Operator's Manual, included with the machine, 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 pick-up tube, located inside the fuel tank, is equipped with a screen to help prevent debris from entering the fuel system. Remove the fuel pick-up tube and clean screen as required.

Check the battery condition weekly or after every 50 hours of operation. Keep the terminals and the entire battery case clean because a dirty battery will discharge slowly. To clean the battery, wash the entire case with a solution of baking soda and water. Rinse it with clear water.

There are 8 fuses in the electrical system. The fuse block (Figure 65) is located behind the control arm access panel.

Figure 65

1. Fuse block

Figure 66

The machine must not creep when the traction pedal is released. If it does creep, adjust as follows:

1. Park the machine on a level surface, stop the engine, and lower the cutting decks to the floor.

2. Jack up the machine until all the tires are off the shop floor. Support the machine with jack stands to prevent it from falling accidentally.

3. On the right side of the hydrostat, loosen the locknut on the traction adjustment cam (Figure 67).

   

   Figure 67

   1. Locknut
   2. Traction adjustment cam

   Warning

   The engine must be running so the final adjustment of the traction adjustment cam can be performed. This could cause personal injury.

   Keep hands, feet, face, and other body parts away from the muffler, other hot parts of the engine, and any rotating parts.

4. Start the engine and rotate the cam hex in either direction until the wheels cease rotation.

5. Tighten the locknut to secure the adjustment.

6. Stop the engine. Remove the jack stands and lower the machine to the shop floor.

7. Test drive the machine to make sure it does not creep.

1. Rotate the steering wheel so that the rear wheels are straight ahead.

2. Loosen the jam nut on each end of the tie rod (Figure 68).

   Note: The end of the tie rod with the external groove is a left hand thread.

   

   Figure 68

   1. Jam nut
   2. Tie rod
   3. Wrench slot

3. Using the wrench slot, rotate the tie rod

4. Measure the distance at the front and rear of the rear wheels at axle height. The distance at the front of the rear wheels should be less than 6 mm (1/4 inch) of the distance measured at the rear of the wheels.

5. Repeat procedure as required.

Remove debris from the screen and radiator/oil cooler daily (clean more frequently in dirty conditions).

1. Turn the engine off and remove the key from the ignition switch.

2. Thoroughly clean all debris out of the engine area.

3. Unlatch the clamp and pivot open the rear screen (Figure 69).

   

   Figure 69

   1. Rear screen latch
   2. Rear screen

4. Thoroughly clean both sides of the and the radiator/oil cooler (Figure 70) with compressed air.

   

   Figure 70

   1. Radiator/oil cooler

5. Close the screen and secure the latch.

Adjust the brakes when there is more than 2.5 cm (1 inch) of free travel (Figure 71) of the brake pedal, or when more holding force is required. Free travel is the distance the brake pedal moves before you feel braking resistance.

Figure 71

1. Free travel

Note: Use the wheel motor backlash to rock the drums back and forth to ensure that the drums are free prior to and after adjustment.

1. To reduce free travel of the brake pedals, tighten the brakes by loosening the front nut on the threaded end of the brake cable (Figure 72).

   

   Figure 72

   1. Brake cables
   2. Front nuts

2. Tighten the rear nut to move the cable backward until brake pedals have .63 to 1.27 cm (1/4 to 1/2 inch) of free travel (Figure 71), before wheel lock up is achieved.

3. Tighten the front nuts, ensuring that both cables actuate the brakes simultaneously. Ensure that the cable conduit does not rotate during tightening procedure.

If the parking brake fails to engage and latch, an adjustment to the brake pawl is required.

1. Loosen the 2 screws securing the parking brake pawl to the frame (Figure 73).

   

   Figure 73

   1. Brake cables
   2. Screws (2)
   3. Parking brake pawl
   4. Brake detent

2. Press the parking brake pedal forward until the brake detent completely engages on the brake pawl (Figure 73).

3. Tighten the 2 screws locking the adjustment.

4. Press the brake pedal to release the parking brake.

5. Check the adjustment and readjust as required.

Check the condition and tension of the belt (Figure 74) after every 100 operating hours.

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

2. If the deflection is not 10 mm (3/8 inch), loosen the alternator mounting bolts (Figure 74). 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 74

   1. Mounting bolt
   2. Alternator

Change hydraulic fluid after every 800 operating hours, in normal conditions. If fluid becomes contaminated, contact your local Toro distributor because the system must be flushed. Contaminated fluid looks milky or black when compared to clean oil.

1. Stop the engine and raise the hood.

2. Place a large drain pan under the fitting secured to the bottom of the hydraulic fluid reservoir (Figure 75).

   

   Figure 75

   1. Hose

3. Disconnect the hose from the bottom of the fitting and let the hydraulic fluid flow into the drain pan.

4. Install the hose when hydraulic fluid stops draining.

5. Fill the reservoir with approximately 45 liters (12 U.S. gallons) of hydraulic fluid; refer to Checking the Hydraulic Fluid.

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

6. Install the reservoir cap.

7. Start the engine and use all of the hydraulic controls to distribute hydraulic fluid throughout the system. Also check for leaks.

8. Stop the engine.

9. Check the level of the hydraulic fluid and add enough to raise level to the Full mark on the dipstick.

   Important: Do not over-fill.

The hydraulic system is equipped with a service interval indicator (Figure 76). With the engine running, view the indicator, it should be in the Green zone. When the indicator is in the Red zone, change the hydraulic filters.

Figure 76

1. Hydraulic filter restriction indicator

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

1. Position the machine on a level surface, lower the cutting decks, stop the engine, engage the parking brake, and remove the key from the ignition switch.

2. Clean the area around the filter mounting area and place a drain pan under filter (Figure 77) and (Figure 78).

   

   Figure 77

   1. Hydraulic filter
   

   Figure 78

   1. Hydraulic filter

3. Remove the filter.

4. Lubricate the gasket on the new filter with hydraulic oil.

5. Ensure that the filter mounting area is clean.

6. Install the filter by hand until the gasket contacts the mounting surface, then rotate it an additional 1/2 turn.

7. Repeat the procedure on the other filter.

8. Start the engine and let it run for about two minutes to purge air from the system.

9. Stop the engine and check for leaks.

Daily, check 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.

Use the hydraulic system test ports to test the pressure in the hydraulic circuits. Contact your local Toro distributor for assistance.

1. Position the machine on a level surface, lower the cutting decks to the floor, shut the engine off, and engage the parking brake.

2. Disconnect and remove the hydraulic motor from the deck (Figure 79). Cover the top of the spindle to prevent contamination.

   

   Figure 79

   1. Motor mounting screws

3. Remove the lynch pin securing the deck carrier frame to the lift arm pivot pin (Figure 80).

   

   Figure 80

   1. Lynch pin
   2. Lift arm pivot pin

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

1. Position machine on a level surface and shut engine off.

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 (Figure 80).

4. Install the hydraulic motor to the deck (Figure 79). 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 (2.00 inch) height-of-cut and blade rake of 7.9 mm ( 0.310 inch). The left-hand and right-hand 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.