Groundsmaster® 4300-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 engine-oil level before starting the engine; refer to Checking the Engine-Oil Level.

2. Check the hydraulic-fluid level before starting the engine; refer to Checking the Hydraulic System.

3. 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.

Before you start the engine and use the machine, check the oil level in the engine crankcase; refer to Checking the Engine-Oil Level.

Before you start the engine and use the machine, check the cooling system; refer to Checking the Cooling System.

Before you start the engine and use the machine, check the hydraulic system; refer to Checking the Hydraulic Lines and Hoses.

Drain water or other contaminants from the water separator; refer to Servicing the Water Separator.

The correct air pressure in the front and rear tires is 83 to 103 kPa (12 to 15 psi).

Important: Maintain 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 15

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 the bench of the rotary cutting deck 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. If the unit is equipped with a Sidewinder®, sidewind the cutting units to the right, remove the rear cutting unit, and slide it out to the right side.

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) as shown in Figure 16.

3. Beginning with the front adjustment, remove the bolt.

   

   Figure 16

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

4. While supporting the chamber, remove the spacer (Figure 16).

5. Move the chamber to the desired height of cut and install a spacer into the designated height-of-cut hole and slot (Figure 17).

   

   Figure 17

6. Position the tapped plate in-line with the spacer.

7. Install the bolt finger-tight.

8. Repeat steps through 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 (1-1/4 to 2-3/4 inches) height of cut).

The interlock switches stop the machine when you raise from the seat while the traction pedal is pressed. 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, shut off the before rising from the seat.

1. Park the machine on a level surface, lower the cutting unit, shut off the engine, 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, start the engine, rise from the seat, and move the PTO switch to the ON position.

   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, start the engine, and move the traction pedal out of the NEUTRAL position.

   Note: The InfoCenter displays "traction denied" and the machine should not move. If the machine does move, there is a malfunction in the interlock system. Correct this malfunction before operating the machine.

5. Start the engine with the PTO engaged.

   Note: If the engine cranks, there is a malfunction in the interlock system. Correct this malfunction before operating the machine.

To ensure optimum performance of the parking-brake system, burnish (break in) the brakes before use. Set the forward traction speed to 6.4 km/h (4 mph) to match the reverse traction speed (all 8 spacers moved to the top of the mow-speed control). With the engine at high idle, proceed forward with the mow-speed-control stop engaged and ride the brake for 15 seconds. Proceed backward at full reverse speed and ride the brake for 15 seconds. Repeat this 5 times, waiting 1 minute between each forward and reverse cycle to avoid overheating the brakes; refer to Adjusting the Parking Brakes.

The machine is equipped with a diagnostic, light which indicates if the machine detects a malfunction. The diagnostic light is located on the InfoCenter, above the display screen (Figure 18). When the machine functions properly and the key switch is moved to the ON/RUN position, the diagnostic light turns on briefly to indicate that the light is working properly. When a machine advisory message displays, the light illuminates when the message is present. When a fault message is displayed, the light blinks until the fault is resolved.

Figure 18

1. Diagnostic light

During different times of the mowing season or when turf conditions vary, the amount of counterbalance (upward lift) required on the cutting decks can be changed to meet the conditions.

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

2. In the InfoCenter Settings Menu, scroll down to Counterbalance.

3. Press the right button to select counterbalance and change between the low, medium, and high settings.

   Note: Once the adjustment has been completed, move the machine to a test area and operate the machine with the new setting. The new counterbalanced setting may change the effective height of cut.

Important: The fuel system automatically bleeds itself before starting the engine if you are starting the engine for the first time, the engine has shut off 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 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.

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 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

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 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.

Reset 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 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 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.

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 29); refer to Accessing Protected Menus.

   

   Figure 29

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 30).

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

   

   Figure 30

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 31).

   

   Figure 31

4. When the “Initiate DPF Regen. Are you sure?” message displays, press the center button (Figure 32).

   

   Figure 32

5. If the coolant temperature is below 60°C (140°F), the “Insure is running and above 60C/140F” message displays. (Figure 33).

   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 33

6. Move the throttle control to LOW IDLE and press the center button (Figure 34).

   

   Figure 34

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

   1. The “Initiating DPF Regen.” message displays (Figure 35).

      

      Figure 35

   2. The “Waiting on ” message displays (Figure 36).

      

      Figure 36

   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 37).

        

        Figure 37

      • If the regeneration process is not allowed by the engine computer, the “DPF Regen Not Allowed” message displays in the InfoCenter (Figure 38). 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 38

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 39).

   

   Figure 39

• Front of the machine—the hole in the rectangular pad, under the axle tube, inside each front tire (Figure 41).

  

  Figure 41

  1. Front tie-down

• Rear of the machine—each side of the machine on the rear frame(Figure 42).

  

  Figure 42

  1. Rear tie-down

In an emergency, the machine can be moved 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 the machine is pushed or towed.

1. The bypass valve is located on the left side of the hydrostat (Figure 43). Rotate the bolt 1-1/2 turns to open and allow the oil to bypass internally. Because fluid is bypassed, the machine can be moved slowly without damaging the transmission.

   

   Figure 43

   1. Bypass valve

2. Close the bypass valve before starting the engine. However, do not exceed 7 to 11 N∙m (5 to 8 ft-lb) torque to close the valve.

   Important: Running the engine with the bypass valve open will cause the transmission to overheat.

• 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.

Use the following as points to jack up the machine:

• Front of the machine—rectangular pad, under the axle tube, inside each front tire (Figure 45).

  

  Figure 45

  1. Front jacking point

• Rear of the machine—rectangular axle tube on the rear axle.

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 lithium grease. Lubricate bearings and bushings immediately after every washing, regardless of the interval listed.

The grease fitting locations and quantities are as follows:

• Pump driveshaft U-joint (3)—Figure 46

  

  Figure 46

• Cutting unit lift-arm cylinders (2 each)—Figure 47

  

  Figure 47

• Lift-arm pivots (1 each)—Figure 47

• Cutting unit carrier-frame pivot (1 each)—Figure 48

  

  Figure 48

• Lift-arm pivot shaft (1 each)—Figure 49

  

  Figure 49

• Rear axle tie rod (2)—Figure 50

  

  Figure 50

• Axle-steering pivot (1)—Figure 51

  

  Figure 51

• Steering-cylinder ball joints (2) and rear axle (1)—Figure 52

  

  Figure 52

• Brake pedal (1)—Figure 53

  

  Figure 53

• Cutting unit spindle-shaft bearings (2 per cutting unit)—Figure 54

  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 54

• Rear-roller bearings (2 per cutting unit)—Figure 55

  

  Figure 55

  Note: 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 whole intake system for leaks, damage, or loose hose clamps. Do not use a damaged air filter.

Service the air-cleaner filter only when the service indicator requires it. Changing the air filter before it is necessary only increases the chance of dirt entering the engine when you remove the filter.

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

Figure 56

• 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 59

• If engine faults , , or in the InfoCenter (Figure 60) display in the InfoCenter, clean the soot filter using the steps that follow:

  

  Figure 60

  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.

1. Clean the area around the fuel-filter head (Figure 61).

   

   Figure 61

   1. Fuel-filter head
   2. Fuel filter

2. Remove the filter and clean the filter head mounting surface (Figure 61).

3. Lubricate the filter gasket with clean lubricating engine oil. Refer to the Engine Operator's Manual for additional information.

4. Install the dry filter canister by hand, until the gasket contacts the filter head, then rotate it an additional 1/2 turn.

5. Start the engine and check for fuel leaks around the filter head.

The fuel-pickup tube, located inside the fuel tank, is equipped with a screen to help prevent debris from entering the fuel system. Remove the fuel-pickup tube and clean screen as required.

There are 8 fuses in the Electrical System. The fuse block (Figure 63) is located behind the control-arm-access panel.

Figure 63

1. Fuse block

Figure 64

Important: Before welding on the machine, disconnect the negative cable from the battery to prevent damage to the electrical system. Also, you must disconnect the engine, InfoCenter, and machine controllers before welding on the machine.

Note: Keep the terminals and the entire battery case clean, because a dirty battery discharges slowly. To clean the battery, wash the entire case with a solution of baking soda and water. Rinse with clear water. Coat the battery posts and cable connectors with Grafo 112X (skin-over) grease (Toro Part No. 505-47) or petroleum jelly to prevent corrosion.

Important: Keep the battery fully charged. This is especially important to prevent battery damage when the temperature is below 0°C (32°F).

1. Clean the exterior of the battery case and the battery posts.

   Note: Connect the leads of the battery charger to battery posts before connecting the charger to the electrical source.

2. Look at the battery and identify the positive and negative battery posts.

3. Connect the positive lead of the battery charger to the positive battery post (Figure 65).

   

   Figure 65

   1. Positive battery post
   2. Negative battery post
   3. Red (+) charger lead
   4. Black (-) charger lead

4. Connect the negative lead of the battery charger to the negative-battery post (Figure 65).

5. Connect the battery charger to the electrical source, and charge the battery.

   Important: Do not overcharge the battery.

6. When the battery is fully charged, unplug the charger from the electrical source, then disconnect the charger leads from the battery posts (Figure 65).

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, turn the key in the ignition switch to the OFF position, 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 66).

   

   Figure 66

   1. Locknut
   2. Traction-adjustment cam

   Warning

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

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

4. Turn the key in the ignition switch to the ON position, 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. Turn the key in the ignition switch to the OFF position, remove the jack stands, and lower the machine to the shop floor.

7. Test drive the machine to make sure that 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 67).

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

   

   Figure 67

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

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.

   Note: 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.

The cooling system is filled with a 50/50 solution of water and permanent ethylene glycol antifreeze. The capacity of the cooling system is 9.5 L (10 US qt).

1. Check the level of coolant in the expansion tank (Figure 68).

   Note: The coolant level should be between the marks on the side of the tank.

   

   Figure 68

   1. Expansion tank

2. If the coolant level is low, remove the expansion-tank cap and replenish the system. Do not overfill.

3. Install the expansion-tank cap.

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

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

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 radiator and 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 0.63 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. Brake detent
   3. Parking brake pawl
   4. Screws (2)

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 disengage the parking brake.

5. Check the adjustment and adjust as required.

1. Proper tension allows 10 mm (3/8 inch) deflection when a force of 4.5 kg (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

The machines reservoir is filled at the factory with approximately 37.8 L (10 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:

Alternate fluids: If the Toro fluid is not available, other fluids may be used provided they meet all the following material properties and industry specifications. We do not recommend the use of synthetic fluid. Consult with your lubricant distributor to identify a satisfactory product.

Note: Toro will 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, 18°C (65°F) to 49°C (120°F), 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 oil is available in 19 L (5 US gallons) containers or 55 gallon drums from your Mobil Distributor.

Note: 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. Position the machine on a level surface, lower the cutting decks, and turn the key in the ignition switch to the OFF position.

2. Check the hydraulic-fluid level (Figure 75).

   

   Figure 75

If fluid becomes contaminated, contact your authorized Toro distributor; the system must be flushed. Contaminated fluid looks milky or black when compared to clean fluid.

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

2. Place a large drain pan under the fitting secured to the bottom of the hydraulic-fluid reservoir (Figure 76).

   

   Figure 76

   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 L (12 US gallons) of hydraulic fluid; refer to Changing the Hydraulic Fluid.

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

6. Install the reservoir cap.

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

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

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

   Important: Do not overfill.

The hydraulic system is equipped with a service interval indicator (Figure 77). 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 77

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, turn the key in the ignition switch to the OFF position, engage the parking brake, and remove the key.

2. Replace both of the hydraulic filters (Figure 78).

   

   Figure 78

3. Turn the key in the ignition switch to the ON position, start the engine, and let it run for about 2 minutes to purge air from the system.

4. Turn the key in the ignition switch to the OFF position and check for leaks.

Make all necessary repairs before operating.

The test ports are used to test the pressure in the hydraulic circuits. Contact your authorized Toro distributor for assistance.

Use the list below to identify and describe the different functions of the solenoids in the hydraulic manifold. Each solenoid must be energized to allow function to occur.

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

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

3. Slide the deck carrier frame onto the lift-arm pivot pin and secure it with the 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.

• Use care when checking the blades. Wrap the blades or wear gloves, and use caution when servicing the blades. Only replace the blades; never straighten or weld them.

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

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.

Replace the blade if a solid object is hit, the blade is out of balance, or if the blade is bent. Always use genuine Toro replacement blades to be sure of safety and optimum performance. Never use replacement blades made by other manufacturers because they could be dangerous.

1. Raise the cutting deck to the highest position, turn the key in the ignition switch to the OFF position, and engage the parking brake. Block the cutting deck to prevent it from falling accidentally.

2. Grasp the end of the blade using a rag or thickly padded glove. Remove the blade bolt, anti-scalp cup, and blade from the spindle shaft (Figure 83).

   

   Figure 83

   1. Blade bolt
   2. Anti-scalp cup

3. Install the blade, sail facing toward the cutting deck, with the anti-scalp cup and blade bolt (Figure 83). Tighten the blade bolt to 115 to 149 N∙m (85 to 110 ft-lb).

1. Raise the cutting deck to the highest position, turn the key in the ignition switch to the OFF position, and engage the parking brake.

2. Block the cutting deck to prevent it from falling accidentally.

3. Examine the cutting ends of the blade carefully, especially where the flat and curved parts of the blade meet (Figure 84).

   Note: Since sand and abrasive material can wear away the metal that connects the flat and curved parts of the blade, check the blade before using the machine.

4. If wear is noticed (Figure 84), replace the blade; refer to Removing and Installing a Blade.

   Danger

   If the blade is allowed to wear, a slot will form between the sail and flat part of the blade (Figure 83). Eventually a piece of the blade may break off and be thrown from under the housing, possibly resulting in serious injury to yourself or bystanders.

   • Inspect the blade periodically for wear or damage.

   • Always replace a worn or damaged blade.

   

   Figure 84

   1. Cutting edge
   2. Sail
   3. Wear/slot/crack

5. Inspect the cutting edges of all blades. Sharpen the cutting edges if they are dull or nicked. Sharpen only the top of the cutting edge and maintain the original cutting angle to make sure that it is sharp (Figure 85).

6. If dull or nicked, sharpen only the top cutting edge while maintaining the original cutting angle (Figure 85).

   Note: The blade will remain balanced if the same amount of metal is removed from both cutting edges.

   

   Figure 85

   1. Sharpen at this angle only

7. To check the blade for being straight and parallel, lay the blade on a level surface and check its ends.

   Note: Position the ends of the blade slightly lower than the center, and the cutting edge lower than the heel of the blade. This blade produces a good quality of cut and requires minimal power from the engine. By contrast a blade that is higher at the ends than the center, or if cutting edge is higher than the heel, the blade is bent or warped and must be replaced.

8. Install the blade, sail facing toward cutting deck, with the anti-scalp cup and blade bolt. Torque the blade bolt to 115 to 149 N∙m (85 to 110 ft-lb).

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