Groundsmaster® 4500-D and 4700-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.

• If the operator or mechanic can not read the language of this manual, it is the owner's responsibility to explain this material to them.

• 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

  • Applying the brake does not regain control of a ride on machine that is sliding on a slope. The main reasons for loss of control are:

    • Insufficient wheel grip

    • Being driven too fast

    • Inadequate braking

    • The type of machine is unsuitable for the task

    • Lack of awareness of the effect of ground conditions, especially slopes

• The owner/user can prevent and is responsible for accidents or injuries occurring to people or damage to property.

• Use only an approved fuel container.

• Never refuel the machine indoors and do not smoke while refueling.

• Add fuel before starting the engine.

• Never remove the cap of the fuel tank or add fuel while the engine is running or when the engine is hot.

• If fuel is spilled, do not start the engine, move away from the spillage, and avoid creating any source of ignition until fuel vapors have dissipated.

• Replace all fuel tank and container caps securely.

• While mowing, always wear substantial, slip-resistant footwear, long trousers, safety glasses, and hearing 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.

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

• To ensure optimum performance and continued safety certification of the machine, use only genuine Toro replacement parts and accessories. Replacement parts and accessories made by other manufacturers could be dangerous, and such use could void the product warranty.

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

• Mow only in daylight or in good artificial light.

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

• Do not put hands or feet near or under rotating parts. Keep clear of the discharge opening at all times.

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

  • Never mow across the face of the slope, unless the mower is designed for this purpose.

  • Use counterweight(s) or wheel weights when suggested in the Operator's Manual.

• Watch out for traffic when crossing or near roadways.

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

• 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.

• Before leaving the operator's position:

  • Stop on level ground.

  • Disengage the power takeoff and lower the attachments.

  • Set the parking brake.

  • Turn the key in the ignition switch to the OFF position and remove the key.

    Important: Allow 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.

• Stop the engine at the following:

  • Before refuelling

  • Before making height adjustment

  • 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 engine speed setting during engine run-out.

• Keep hands and feet away from the cutting units.

• 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. Stop blades from rotating.

• Be aware of the mower discharge direction and do not point it at anyone.

• 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 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.

• Drain the fuel tank outdoors.

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

• On multi-spindle mowers, take care as rotating 1 blade can cause other blades to rotate.

• Disengage drives, lower the cutting units, set the parking brake, turn the key in the ignition switch to the OFF position, and remove the key. Wait for all movement to stop before adjusting, cleaning or repairing.

• Clean grass and debris from cutting units, 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.

• Use care when checking the blades. Wear gloves and use caution when servicing them.

• 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.

• Store the machine with the cutting units in the lowered position or secure the wing decks with the storage latches to prevent them from unintentionally lowering.

Pull out on the lever to slide the seat fore or aft (Figure 10).

Rotate the knob to adjust the seat arm rest angle.

Move the lever to adjust the seat back angle (Figure 10).

Indicates when the seat is adjusted to the weight of the operator (Figure 10). Height adjustment is made by positioning the suspension within the range of the green region.

Figure 10

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

Adjust for operator weight (Figure 10). Pull up on the lever to increase the air pressure and push down to decrease the air pressure. The proper adjustment is attained when the weight gauge is in the green region.

Fuel tank capacity: 83 L (22 US gallons)

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.

Fill the tank with diesel fuel until the level reaches the bottom of the filler neck.

1. Park the machine on a level surface.

2. Clean the are around the fuel-tank cap with a clean rag.

3. Remove the cap from the fuel tank (Figure 16).

   

   Figure 16

   1. Fuel-tank cap

4. Fill the tank with diesel fuel until the level reaches the bottom of the filler neck.

5. Install the fuel-tank cap tightly.

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

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 the traction pedal so that it is in NEUTRAL, and engage the parking brake.

2. Turn the key in the ignition switch to the RUN position. The glow indicator illuminates.

3. When the glow indicator dims, turn the key in the ignition switch to the START position. Release the key immediately when the engine starts and allow it to return to the RUN position. Adjust the engine speed.

   Important: Do not run the starter motor more than 30 seconds at a time or premature starter failure may result. If the engine fails to start after 30 seconds, turn the key to the Off position, recheck the controls and procedures, wait 30 additional seconds, and repeat the starting procedure.

   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.

   Caution

   Shut the engine off and wait for all moving parts to stop before checking for oil leaks, loose parts, and other malfunctions.

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

Note: Lower the cutting units 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 cutting units.

1. Move the PTO switch to the OFF position.

2. Set the parking brake.

3. Return the engine low idle.

4. Turn the key in the ignition switch to the OFF position and remove the key.

• 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 18 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 19 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 20 Advisory #179	None	100%	Notify your service department that advisory #179 displays in the InfoCenter.
Level 2: Engine Warning	Figure 21 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 22 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 23 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 24

Assist/reset-regeneration icon

• The assist/reset-regeneration icon displays in the InfoCenter (Figure 24).

• 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 25

Assist/reset-regeneration icon

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

• 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 26

Parked-regeneration request icon

• The parked-regeneration requested icon displays in the InfoCenter (Figure 26).

• If a parked regeneration is needed, the InfoCenter displays engine warning SPN 3719, FMI 16 (Figure 27) and the engine computer derates engine power to 85%.

  

  Figure 27

  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 39) and the engine computer derates engine power to 85%.

  

  Figure 39

  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.

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 25 mm (1 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 to the next setting.

Under most normal conditions you need to mow approximately every 4 to 5 days. But remember, grass grows at different rates at different times. This means that in order to maintain the same height-of-cut, which is a good practice, you will need to cut more frequently in early spring; as the grass growth rate slows in mid summer, cut only every 8-10 days. If you are unable to mow for an extended period due to weather conditions or other reasons, mow first with the height-of-cut at a high level; then mow again 2 to 3 days later with a lower height 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.

Change mowing patterns often to minimize aftercut appearance issues induced by repetitive operation in only 1 direction.

Reference Aftercut Appearance Troubleshooting Guide available at www.Toro.com.

To ensure that optimum performance is met, clean the underside of the mower housings after each use. If residue is allowed to buildup in the mower housing, cutting performance declines.

Note: Lower cutting units 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 cutting units.

1. Release the hood latches (Figure 42) and pivot the hood open.

   

   Figure 42

   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 43)

  

  Figure 43

• Rear axle pivot bushings (2) (Figure 44)

  

  Figure 44

• Steering cylinder ball joints (2) (Figure 45)

  

  Figure 45

  1. Top fitting on king pin

• Tie-rod ball joints (2) (Figure 45)

• King-pin bushings (2) (Figure 45). The top fitting on the king pin should only be lubricated annually (2 pumps).

• Lift-arm bushings (1 per deck) (Figure 46)

  

  Figure 46

• Lift-cylinder bushings (2 per deck) (Figure 46)

• Cutting unit spindle-shaft bearings (1 per cutting unit) (Figure 47)

  

  Figure 47

• Cutting unit carrier-arm bushings (1 per cutting unit) (Figure 47)

• Rear-roller bearings (2 per cutting unit) (Figure 48 )

  

  Figure 48

  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 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 49) 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 49

1. Air-cleaner indicator

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

1. Pull the latch outward and rotate the air-cleaner cover counterclockwise (Figure 50).

   

   Figure 50

   1. Air-cleaner latch
   2. Air-cleaner cover

2. Remove the cover from the air-cleaner body.

3. Use low pressure air (40 psi, clean and dry) to help remove large accumulations of debris packed between outside of primary filter and the canister. Avoid using high pressure air which could force dirt through the filter into the intake tract.

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

4. Remove and replace the primary filter (Figure 51).

   Note: It is not recommended to clean the used filter due to possibly damaging the filter media.

5. Inspect the sealing end and body of the filter for shipping damage. Do not use a damaged element.

6. Insert a new filter and apply pressure to the outer rim to seat it in the canister. Do not apply pressure to the flexible center of the filter.

7. 

   Figure 51

   1. Air-cleaner primary filter

   Important: Never attempt to clean the safety filter (Figure 52). Replace the safety filter after every 3 primary filter services.

   

   Figure 52

   1. Air-cleaner safety filter

8. Clean the dirt ejection port located in the removable cover. To clean the cavity, remove, clean, and replace the rubber outlet valve.

9. Install the cover orienting the rubber outlet valve in a downward position—between approximately 5 o’clock to 7 o’clock when viewed from the end.

10. Reset the indicator (Figure 49) 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 them for deterioration, damage, or loose connections.

1. Place a clean container under the fuel filter (Figure 58).

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

   

   Figure 58

   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, and 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.

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 pick-up 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 screen as required.

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

   

   Figure 60

   1. 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 electrical 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).

   

   Figure 61

   1. Positive battery cable
   2. Negative battery cable

5. Secure cables to posts with capscrews 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.

   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 the console panel (Figure 63) to expose the fuses (Figure 64).

Figure 63

1. Latch
2. Console panel

Figure 64

1. Fuses

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

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

1. Position the machine on a level surface and position the wheel so 1 check plug (Figure 65) is at the 12 o'clock position and the other is at 3 o'clock position.

   

   Figure 65

   1. Check/drain plug (2)

2. Remove the plug at the 3 o’clock position (Figure 65).

   Note: 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.

4. Install both plugs.

5. 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 66).

   

   Figure 66

   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 67).

   

   Figure 67

   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 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 10 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.

The rear axle is shipped from the factory filled with SAE 85W-140 gear lube. The capacity is 2.4L (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 68) 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 68) and add enough lubricant to bring the level up to the bottom of the check plug holes.

   

   Figure 68

   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 69).

   

   Figure 69

   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 2.4L (80 oz) of 85W-140 gear lube or until lubricant reaches the bottom of the hole.

7. Install check 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 70).

   

   Figure 70

   1. Front of traction unit
   2. 3 mm (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 71) and remove the tie-rod ball joint from axle case support.

   

   Figure 71

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

3. Loosen the clamps at both ends of the tie rods (Figure 71).

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

5. Rotate the entire tie-rod assembly in 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 and 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.

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 72).

2. Clean the screen thoroughly of all debris.

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

   

   Figure 72

   1. Rear screen latch

3. Thoroughly clean both sides of the oil cooler and the radiator (Figure 73) with compressed air. Start from the front and blow the debris out towards the back. Then clean from the back side and blow towards the front. Repeat procedure several times until all chaff and debris is removed.

   

   Figure 73

   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 74).

      

      Figure 74

      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.

Check the condition and tension of the belts (Figure 75) after every 100 operating hours.

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

1. Loosen the alternator mounting bolts (Figure 75).

   

   Figure 75

   1. Mounting bolt
   2. Alternator

2. Increase or decrease the alternator belt tension, tighten the bolts, and check the deflection of the belt again to ensure that the tension is correct.

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 the drain pan.

3. Install the hose when hydraulic fluid stop draining.

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

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

5. Install the reservoir cap.

6. 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: The use of any other filter may void the warranty on some components.

1. Position the machine on a level surface, lower the cutting units, turn the key in the ignition switch to the OFF position, engage the parking brakes, and remove the key.

2. Clean the area around the filter mounting area. Place a drain pan under the filter and remove the filter (Figure 76 and Figure 77).

3. Lubricate the gasket on the new filter and fill the filter with hydraulic fluid.

   

   Figure 76

   1. Hydraulic filter
   

   Figure 77

   1. Hydraulic filter

4. Ensure that the filter mounting area is clean.

5. Screw the filter by hand until the gasket contacts the mounting surface and then tighten the filter an additional 1/2 turn.

6. Start the engine and let it run for about 2 minutes to purge air from the system.

7. Stop 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.