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-Fluid Level.

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 14

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 15.

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

   

   Figure 15

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

4. While supporting the chamber, remove the spacer (Figure 15).

5. Move the chamber to the desired height of cut and install a spacer into the designated height-of-cut hole and slot (Figure 16).

   

   Figure 16

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 machine has interlock switches in the electrical system. These switches disengage either the traction or the PTO whenever you leave the seat. Although the engine continues to run if you disengage the PTO switch, and you release the traction pedal, shut off the engine 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 17). 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 17

1. Diagnostic light

You can change the amount of required cutting-unit counterbalance (upward lift) to meet your current mowing conditions.

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

2. Turn the key in the switch to the RUN position.

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

4. 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.

1. Sit on the seat, keep your foot off 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 key in the switch to the RUN position.

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

4. Run the engine at low idle speed until it warms up.

1. Move all controls to NEUTRAL, engage 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 in the switch to the OFF position and remove the key.

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 in the DPF is too high or a reset regeneration has not occurred for 100 hours, the engine computer signals you through the InfoCenter when reset regeneration is running.

• Allow the 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 (full throttle) engine speed generally produces 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 diesel particulate filter 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 DPF.

• 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 or Recovery 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 Parked or 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 an engine fault to indicate the accumulation of ash in the DPF.

• The fault messages indicate 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	Fault Code	Engine Speed Reduction	Engine Power Rating	Recommended Action
Level 1: Engine Warning	Figure 20 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 2: Engine Warning	Figure 21 Check EngineSPN 3720, FMI 16	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 3: Engine Warning	Figure 22 Check EngineSPN 3251, FMI 0	Engine speed at maximum 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 that cause 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 because of low-engine speed, low-engine load, or after the computer detects the DPF is becoming obstructed with soot	• The InfoCenter does not display an icon indicating assist regeneration.
		• During assist regeneration, the engine computer adjusts the engine settings to raise the exhaust temperature.
		Refer to Assist DPF Regeneration.
Reset	Occurs every 100 hours	• When the high exhaust-temperature icon is displayed in the InfoCenter, a regeneration is in progress.
	Also occurs after assist regeneration only if the computer detects that assist regeneration did not sufficiently reduce the soot level
		• During reset regeneration, the engine computer adjusts the engine settings to raise the exhaust temperature.
		Refer to Reset Regeneration.

Types of diesel particulate filter regeneration that require you to park the machine:

Type of Regeneration	Conditions that cause DPF regeneration	DPF description of operation
Parked	Occurs because the computer detects back pressure in the DPF due to soot buildup	• When the reset-standby/parked or recovery regeneration icon or ADVISORY #188 displays in the InfoCenter, a regeneration is requested.
	Also occurs because the operator initiates a parked regeneration
	May occur because you set the InfoCenter to inhibit reset regeneration and continued operating the machine, adding more soot when the DPF already needs a reset regeneration	• Perform the parked regeneration as soon as possible to avoid needing a recovery regeneration.
	May result from using the incorrect fuel or engine oil	• 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 parked regeneration.
		Refer to Parked or Recovery Regeneration.
Recovery	Occurs because the operator ignored requests for a parked regeneration and continued operating the machine, adding more soot to the DPF	• When the reset-standby/parked or recovery regeneration icon or ADVISORY #190 displays in the InfoCenter, a recovery regeneration is requested.
		• A recovery regeneration requires up to 3 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 Parked or Recovery Regeneration.

Accessing the DPF Regeneration Menus

Accessing the DPF Regeneration Menus

1. Access the Service menu, press the center button to scroll down to the DPF REGENERATION option (Figure 23).

   

   Figure 23

2. Press the right button to select the DPF Regeneration entry (Figure 23).

Time Since Last Regeneration

Access the DPF Regeneration menu, press the center button to scroll down to the LAST REGEN field (Figure 24).

Use the LAST REGEN field to determine how many hours you have run the engine since the last reset, parked, or recovery regeneration.

Figure 24

Technician Menu

Important: For operating convenience, you may decide to perform a parked regeneration before the soot load reaches 100%, provided the engine has run more than 50 hours since the last successful reset, parked, or recovery regeneration.

Use the technician menu to view the current state of engine regeneration control and view the reported soot level.

Access the DPF Regeneration menu, press the center button to scroll down to the TECHNICIAN option, and press the right button to select the Technician entry (Figure 25).

Figure 25

• Use the DPF operation table to understand the current state of DPF operation (Figure 26).

  

  Figure 26

  .

  DPF Operation Table

  State	Description
  Normal	The DPF is in normal-operating mode—passive regeneration.
  Assist Regen	The engine computer is performing an assist regeneration.
  Reset Stby	The engine computer is trying to run a reset regeneration, but 1 of the following conditions prevents regeneration:	The regen inhibit setting is set to ON.
  		The exhaust temperature is too low for regeneration.
  Reset Regen	The engine computer is running a reset regeneration.
  Parked Stby	The engine computer is requesting that you run a parked regeneration.
  Parked Regen	You initiated a parked regeneration request and the engine computer is processing the regeneration.
  Recov. Stby	The engine computer is requesting that you run a recovery regeneration.
  Recov. Regen	You initiated a recovery regeneration request and the engine computer is processing the regeneration.

• View the soot load which is measured as the percentage of soot in the DPF(Figure 27); refer to the soot-load table.

  Note: The soot load value varies as the machine is operated and DPF regeneration occurs.

  

  Figure 27

  Soot-Load Table

  Important Soot Load Values	Regeneration State
  0% to 5%	Minimum soot load range
  78%	The engine computer performs an assist regeneration.
  100%	The engine computer automatically requests a parked regeneration.
  122%	The engine computer automatically requests a recovery regeneration.

Reset Regeneration

Caution

The exhaust temperature is hot (approximately 600°C (1,112°F) during DPF regeneration. Hot exhaust gas can harm you or other people.

• Never operate the engine in an enclosed area.

• Make sure that there are no flammable materials around the exhaust system.

• Never touch a hot exhaust system component.

• Never stand near or around the exhaust pipe of the machine.

Figure 28

• The high exhaust-temperature icon displays in the InfoCenter (Figure 28).

• The engine computer adjusts engine settings to raise the exhaust temperature.

  Important: The high exhaust-temperature 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 and high load 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: Whenever possible, allow the machine to complete the reset regeneration process before shutting off the engine.

Periodic Reset Regeneration

If the engine has not completed a successful Reset, Parked, or Recovery regeneration in the previous 100 hours of engine operation, the engine computer will attempt to perform a reset regeneration.

Setting the Inhibit Regen

Reset Regeneration Only

Note: If you set the InfoCenter to inhibit regeneration, the InfoCenter displays ADVISORY #185 (Figure 29) every 15 minutes while the engine requests a reset regeneration.

Figure 29

A reset regeneration produces the elevated engine exhaust. If you are operating the machine around trees, brush, tall grass, or other temperature-sensitive plants or materials, you can use the Inhibit Regen setting to prevent the engine computer from performing a reset regeneration.

Important: When you shut off the engine and start it again, the inhibit regen setting defaults to OFF.

1. Access the DPF Regeneration menu, press the center button to scroll down to the INHIBIT REGEN option, and press the right button to select the Inhibit Regen entry (Figure 30).

   

   Figure 30

2. Press the right button to change the inhibit regeneration setting from On to Off (Figure 30) or from Off to On (Figure 31).

   

   Figure 31

Allowing a Reset Regeneration

The InfoCenter displays the high exhaust-temperature icon when the reset regeneration is in process.

Note: If INHIBIT REGEN is set to ON, the InfoCenter displays ADVISORY #185 (Figure 32). Press button 3 to set inhibit regeneration setting to OFF and continue with the reset regeneration.

Figure 32

Note: If the engine exhaust temperature is too low, the InfoCenter displays ADVISORY #186 (Figure 33) to inform you to set the engine to full throttle (high idle).

Figure 33

Note: When the reset regeneration completes, the high exhaust-temperature disappears from the InfoCenter screen.

• Front of the machine—the hole in the rectangular pad, under the axle tube, inside each front tire (Figure 54).

  

  Figure 54

  1. Front tie-down

• Rear of the machine—each side of the machine on the rear frame(Figure 55).

  

  Figure 55

  1. Rear tie-down

• Remove the key and shut off the fuel (if equipped) before storing or transporting the machine.

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

• Use full-width ramps for loading the machine into a trailer or a truck.

• Tie the machine down securely.

In an emergency, you can move the machine forward by actuating the bypass valve in the variable-displacement hydraulic pump and pushing or towing the machine.

Important: Do not push or tow the machine faster than 3 to 4.8 km/h (2 to 3 mph). If you push or tow at a faster speed, internal transmission damage may occur.The bypass valves must be open whenever you push or tow the machine.

1. Locate the bypass valve on the left side of the hydrostat (Figure 56).

   

   Figure 56

   1. Bypass valve

2. Loosen the bolt 1-1/2 turns to allow the oil to bypass internally.

   Note: Because the fluid is bypassed, the machine can be moved slowly without damaging the transmission.

3. Push or tow the machine.

4. Finish pushing or towing the machine and close the bypass valve . Torque the valve to 11 N∙m (5 to 8 ft-lb).

   Important: Ensure that the bypass valve is closed before you start the engine. Running the engine with an open bypass valve causes the transmission to overheat.

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 57).

  

  Figure 57

  1. Front jacking point

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

If you operate the machine under normal conditions, use No. 2 lithium grease to lubricate all bearings and bushings at the specified maintenance interval. 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 58

  

  Figure 58

• Cutting unit lift-arm cylinders (2 each)—Figure 59

  

  Figure 59

• Lift-arm pivots (1 each)—Figure 59

• Cutting unit carrier-frame pivot (1 each)—Figure 60

  

  Figure 60

• Lift-arm pivot shaft (1 each)—Figure 61

  

  Figure 61

• Rear axle tie rod (2)—Figure 62

  

  Figure 62

• Axle-steering pivot (1)—Figure 63

  

  Figure 63

• Steering-cylinder ball joints (2) and rear axle (1)—Figure 64

  

  Figure 64

• Brake pedal (1)—Figure 65

  

  Figure 65

• Cutting unit spindle-shaft bearings (2 per cutting unit)—Figure 66

  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 cutting unit).

  

  Figure 66

• Rear-roller bearings (2 per cutting unit)—Figure 67

  

  Figure 67

  Note: Ensure 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 the filter is removed.

Important: Make sure that the cover is seated correctly, seals with the air-cleaner body, and the rubber outlet valve is in a downward position—between the 5 o’clock and 7 o’clock positions when viewed from the end.

Figure 68

If engine faults , , or display in the InfoCenter (Figure 71), clean the soot filter using the steps that follow:

Figure 71

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 reset the engine ECU after you install a clean DPF.

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

   

   Figure 72

   1. Fuel-filter head
   2. Fuel filter

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

3. Lubricate the filter gasket with clean lubricating engine oil. Refer to the Engine 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.

After every 50 hours of operation, perform the following tasks to service the battery:

• Check the battery condition

• Clean the battery (if necessary)

  Note: To clean the battery, wash the entire case with a solution of baking soda and water. Rinse it with clear water.

• Check the battery-cable connections

There are 8 fuses in the electrical system. The fuse block (Figure 74) is located behind the control-arm-access panel. Refer to Figure 75 for a description of each fuse.

Figure 74

1. Fuse block

Figure 75

1. Read the Operator's Manual.
2. Power point (10 A)
3. Head lights (10 A)
4. Power (10 A)
5. Engine start (15 A)
6. Optional air ride seat suspension (20 A)
7. Engine computer management C (7.5 A)
8. Engine computer management B (7.5 A)
9. Engine computer management A (7.5 A)

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, shut off the engine, and lower the cutting units to the ground.

2. Jack up the machine until all the tires are off the ground; refer to Raising the Machine. 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 76).

   

   Figure 76

   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 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 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 switch to the OFF position, remove the jack stands, and lower the machine to the ground.

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 77).

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

   

   Figure 77

   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 78).

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

   

   Figure 78

   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.

1. Turn the key in the 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 79).

   

   Figure 79

   1. Rear-screen latch
   2. Rear screen

4. Clean the screen thoroughly with compressed air.

5. Pivot the latches inward to release the oil cooler (Figure 80).

   

   Figure 80

   1. Oil-cooler latches
   2. Oil cooler

6. Thoroughly clean both sides of the oil cooler and the radiator (Figure 81) with compressed air.

   

   Figure 81

   1. Radiator

7. Pivot the oil cooler back into position and secure the latches.

8. Close the screen and secure the latch.

Adjust the brakes when there is more than 2.5 cm (1 inch) of free travel (Figure 82) 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 82

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 83).

   

   Figure 83

   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 82), 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 84).

   

   Figure 84

   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 84).

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.

Proper tension of the belt allows 10 mm (3/8 inch) of deflection when a force of 4.5 kg (10 lb) is applied on the belt midway between the pulleys.

If the deflection is not 10 mm (3/8 inch), loosen the alternator-mounting bolts (Figure 85).

Note: Increase or decrease the alternator-belt tension and tighten the bolts. Check the deflection of the belt again to ensure that the tension is correct.

Figure 85

1. Mounting bolt
2. Alternator

The machines reservoir is filled at the factory with approximately 56.7 L (15 US gallons) of high quality hydraulic fluid. 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: Use products only from reputable manufactures. Toro does not take responsibility for damage caused by improper substitutions.

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 208 L (55 US gallons) 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 oil is available in 20 ml (2/3 oz) bottles. 1 bottle is sufficient for 15 to 23 L (4 to 6 US gallons) of hydraulic oil. 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 switch to the OFF position.

2. Check the hydraulic-fluid level (Figure 86).

   

   Figure 86

If 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 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 87).

   

   Figure 87

   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 56.7 L (15 US gallons) of hydraulic fluid; refer to Checking the Hydraulic-Fluid Level.

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

6. Install the reservoir cap.

7. Turn the key in the 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 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 88). 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 88

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

2. Replace both of the hydraulic filters (Figure 89).

   

   Figure 89

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

Make all necessary repairs before operating.

Use the hydraulic system test ports 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 units to the floor, turn the key in the switch to the OFF position, and engage the parking brake.

2. Disconnect and remove the hydraulic motor from the cutting unit (Figure 90). Cover the top of the spindle to prevent contamination.

   

   Figure 90

   1. Motor-mounting screws

3. Remove the lynch pin securing the deck-carrier frame to the lift-arm pivot pin (Figure 91).

   

   Figure 91

   1. Lynch pin
   2. Lift-arm pivot pin

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

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

2. Move the cutting unit 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 91).

4. Install the hydraulic motor to the deck (Figure 90). Make sure that the O-ring is in position and not damaged.

5. Grease the spindle.

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

The 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 95).

   

   Figure 95

   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 95). 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 96).

   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 96), 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 95). 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 96

   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 97).

6. If dull or nicked, sharpen only the top cutting edge while maintaining the original cutting angle (Figure 97).

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

   

   Figure 97

   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).