Groundsmaster® 4500-D or 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;

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

    • insufficient wheel grip;

    • being driven too fast;

    • inadequate braking;

    • the type of machine is unsuitable for 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 himself or herself, other people, or property.

• While mowing, always wear substantial footwear, long trousers, hard hat, 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.

• Warning-Fuel is highly flammable. Take the following precautions:

  • Store fuel in containers specifically designed for this purpose.

  • Refuel outdoors only 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 attempt to start the engine but move the machine away from the area of spillage and avoid creating any source of ignition until fuel vapors have dissipated.

  • Replace all fuel tank and container caps securely.

• Replace faulty silencers/mufflers.

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

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

• 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, shift into neutral, 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 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.

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

• 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.

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

• Before leaving the operator's position:

  • stop on level ground;

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

  • set the parking brake;

  • stop the engine 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

  • 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 throttle 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 loading or unloading the machine into a trailer or truck

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

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

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

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

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

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

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

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

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

• Disengage drives, lower the cutting units, set parking brake, stop engine and remove ignition 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.

• Make sure all hydraulic line connectors are tight and all hydraulic hoses and lines are in good condition before applying pressure to the system.

• Keep your body and hands away from pin hole leaks or nozzles that eject hydraulic fluid under high pressure. Use paper or cardboard, not your hands, to search for leaks. Hydraulic fluid escaping under pressure can have sufficient force to penetrate the skin and cause serious injury. Seek immediate medical attention if fluid is injected into skin.

• Before disconnecting or performing any work on the hydraulic system, all pressure in the system must be relieved by stopping the engine and lowering the cutting units and attachments to the ground.

• Check all fuel lines for tightness and wear on a regular basis. Tighten or repair them as needed.

• If the engine must be running to perform a maintenance adjustment, keep hands, feet, clothing, and any parts of the body away from the cutting units, attachments, and any moving parts.

• To ensure safety and accuracy, have an Authorized Toro Distributor check the maximum engine speed with a tachometer.

• If major repairs are ever needed or if assistance is desired, contact an Authorized Toro Distributor.

• Use only Toro-approved attachments and replacement parts. The warranty may be voided if used with unapproved attachments.

Pull out on the lever to slide the seat fore or aft (Figure 13).

Rotate the knob to adjust the seat arm rest angle (Figure 13).

Move the lever to adjust the seat back angle (Figure 13).

Indicates when the seat is adjusted to the weight of the operator (Figure 13). Height adjustment is made by positioning the suspension within the range of the green region.

Figure 13

1. Weight gauge
2. Weight adjusting lever
3. Fore and Aft adjusting lever
4. Seat back adjusting lever
5. Arm rest adjusting knob

Adjust for operator weight (Figure 13). 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.

Important: The fuel system must be bled if any of the following situations have occurred:

• The engine has ceased running due to lack of fuel.

• Maintenance has been performed upon the fuel system components.

1. Remove your foot from the traction pedal and ensure that it is in neutral. Ensure that the parking brake is set.

2. Move the throttle control to the low idle position.

3. Turn the ignition key to the Run position. The glow indicator will light.

4. When the glow indicator dims, turn the ignition key to the Start position. Release the key immediately when the engine starts and allow it to return to the Run position. Move the throttle control to the desired position.

   Important: Do not run the starter motor more than 15 seconds at a time or premature starter failure may result. If the engine fails to start after 15 seconds, turn the key to the Off position, recheck the controls and procedures, wait 15 additional seconds, and repeat the starting procedure.

   When the temperature is less than 20°F (-7°C), 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 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 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 throttle control backward to the Slow position.

2. Move the PTO switch to the Off position.

3. Set the parking brake.

4. Rotate the ignition key to Off.

5. Remove the key from the switch to prevent accidental starting.

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 1 in. (25 mm) 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 will need to mow approximately every 4-5 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 2-3 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 one direction.

The counterbalance system maintains hydraulic back pressure on the deck lift cylinders. This counterbalance pressure transfers cutting deck weight to the mower's drive wheels to improve traction. The counterbalance pressure has been factory set to an optimal balance of aftercut appearance and traction capability in most turf conditions. Decreasing the counterbalance setting can produce a more stable cutting deck, but can decrease the traction capability. Increasing the counterbalance setting can increase the traction capability, but may result in aftercut appearance issues. Reference the service manual for your traction unit for instructions to adjust counterbalance pressure.

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

Use the two rear transport latches for the outer cutting units when transporting over long distances, rough terrain, or when trailering.

To ensure optimum performance, clean the underside of the mower housings after each use. If residue is allowed to build up in the mower housing, cutting performance will decline.

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 hood latches (Figure 21) and pivot open the hood.

   

   Figure 21

   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 General Purpose Lithium Base Grease. If the machine is operated under normal conditions, lubricate all bearings and bushings after every 50 hours of operation or immediately after every washing.

The grease fitting locations and quantities are as follows:

• Brake shaft pivot bearings (5) (Figure 22)

  

  Figure 22

• Rear axle pivot bushings (2) (Figure 23)

  

  Figure 23

• Steering cylinder ball joints (2) (Figure 24)

  

  Figure 24

  1. Top fitting on king pin

• Tie rod ball joints (2) (Figure 24)

• King pin bushings (2) (Figure 24). The top fitting on the king pin should only be lubricated annually (2 pumps).

• Lift arm bushings (1 per deck) (Figure 25)

  

  Figure 25

• Lift cylinder bushings (2 per deck) (Figure 25)

• Cutting unit spindle shaft bearings (1 per cutting unit) (Figure 26)

  

  Figure 26

• Cutting unit carrier arm bushings (1 per cutting unit) (Figure 26)

• Rear roller bearings (2 per cutting unit) (Figure 27 )

  

  Figure 27

  Important: Make sure the grease groove in each roller mount aligns with the grease hole in each end of the roller shaft. To help align the groove and hole, there is also an alignment mark on one end of the roller shaft.

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

Service the air cleaner filter only when the service indicator (Figure 28) requires it. Changing the air filter before it is necessary only increases the chance of dirt entering the engine when the filter is removed.

Figure 28

1. Air cleaner indicator

Important: Be sure 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 29).

   

   Figure 29

   1. Air cleaner latch
   2. Air cleaner cover

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

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

3. Remove and replace the primary filter (Figure 30).

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

   

   Figure 30

   1. Air cleaner primary filter

   Important: Never attempt to clean the safety filter (Figure 31). Replace the safety filter with a new one after every three primary filter services.

   

   Figure 31

   1. Air cleaner safety filter

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

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

6. Reset the indicator (Figure 28) if it shows red.

Change the oil and filter initially after the first 50 hours of operation; thereafter change the oil and filter every 150 hours.

1. Remove the rear drain plug (Figure 32) and let the oil flow into a drain pan. When the oil stops, install the drain plug.

   

   Figure 32

   1. Engine oil drain plug

2. Remove the oil filter (Figure 33). Apply a light coat of clean oil to the new filter seal before screwing it on. Do not overtighten.

   

   Figure 33

   1. Engine oil filter

3. Add oil to the crankcase; refer to Checking the Engine Oil in Operation.

Adjust the throttle cable (Figure 34) so that the governor lever on the engine contacts the high speed set bolt at the same point that the throttle cable contacts the end of the slot in the control arm.

Figure 34

1. Throttle cable

Drain and clean the fuel tank every 800 hours. Also, 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.

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

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

1. Place a clean container under the fuel filter(Figure 35).

2. Loosen the drain plug on the bottom of the filter canister.

   

   Figure 35

   1. Water separator filter canister

3. Clean the area where the filter canister mounts.

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

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

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

7. Tighten the drain plug on the bottom of the filter canister.

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.

Note: This procedure should be used only if the fuel system has been purged of air through normal priming procedures and the engine will not start.

1. Loosen the pipe connection to the No. 1 injector nozzle and holder assembly at the injection pump (Figure 36).

   

   Figure 36

   1. No. 1 injector nozzle

2. Move the throttle to the Fast position.

3. Turn the key in the ignition switch to the Start position and watch the fuel flow around the connector. Turn the key to the Off position when solid flow is observed.

4. Tighten the pipe connector securely.

5. Repeat the procedure on the remaining nozzles.

1. Unlatch and raise the operator's console panel (Figure 37).

   

   Figure 37

   1. Operator's console panel
   2. Latch

   Danger

   Battery electrolyte contains sulfuric acid which is a deadly poison and causes severe burns.

   • Do not drink electrolyte and avoid contact with skin, eyes or clothing. Wear safety glasses to shield your eyes and rubber gloves to protect your hands.

   • Fill the battery where clean water is always available for flushing the skin.

2. Connect a 3 to 4 amp. battery charger to the battery posts. Charge the battery at a rate of 3 to 4 amperes 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 38). Secure cables to posts with capscrews and nuts. 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. Slide the rubber boot over the positive terminal to prevent a possible short from occurring.

   

   Figure 38

   1. Positive battery cable
   2. Negative battery cable

   Warning

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

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

6. 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 cable from the battery to prevent damage to the electrical system.

Note: Check the battery condition weekly or after every 50 hours of operation. Keep the terminals and the entire battery case clean because a dirty battery will discharge slowly. To clean the battery, remove it from the machine, 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.

The fuses are located under the operators control panel.

Figure 39

Unhook latch and raise operator's console panel (Figure 40) to expose the fuses (Figure 41).

Figure 40

1. Latch
2. Operator's console panel

Figure 41

1. Fuses

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

There should be no end play in the planetary drives/drive wheels (i.e., the wheels should not move when you pull or push them in a direction parallel to the axle).

1. Park the machine on a level surface, engage the parking brake, lower the cutting units, shut off the engine, and remove the key.

2. Chock the rear wheels and raise the front of machine, supporting the front axle/frame on jack stands.

   Danger

   A machine on a jack may be unstable and slip off the jack, injuring anyone beneath it.

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

   • Always remove the key from the switch before getting off the machine.

   • Block the tires when you are raising the machine with a jack.

   • Support the machine with jack stands.

3. Grasp 1 of the front drive wheels and push/pull it toward and away from the machine, noting any movement.

   

   Figure 42

   1. Front drive wheels

4. Repeat step 3 for the other drive wheel.

5. If either wheel moves, contact your authorized Toro distributor to have the planetary drive rebuilt.

Check the oil level after every 400 hours of operation or if external leakage is noted. Use high quality SAE 85W-140 wt. gear lube as a replacement.

The capacity of the system is approximately 16 oz. (0.5l).

1. With the machine on a level surface, position the wheel so that the check/drain plug (Figure 43) is at either the 3 or 9 o'clock position.

   

   Figure 43

   1. Check/drain plug (3 or 9 o'clock position)

2. Remove the plug on the planetary (Figure 43). Oil should be at the bottom of the check plug hole on the back side of the brake.

3. Add gear oil to the hole in the planetary, if necessary, to bring the oil up to the proper level. Install the plug.

4. Repeat steps 1–3 on the opposite gear assembly.

Change the oil initially after first 200 hours of operation. Thereafter change the oil every 800 hours, or yearly, whichever occurs first. Use a high quality SAE 85W-140 wt. gear lube.

1. With the machine on a level surface, position the wheel so that the check/drain plug (Figure 44) is at the 6 o'clock position.

   

   Figure 44

   1. Check/drain plug (6 o'clock position)

2. Place a drain pan under the hub, remove the plug, and allow the oil to drain.

3. Place another drain pan under the brake housing on the other side of the wheel (Figure 45).

   

   Figure 45

   1. Brake housing
   2. Drain plug
   3. Check plug

4. Remove check/drain plugs from the brake housing and allow the oil to drain.

5. When all of the oil has drained, install the bottom plug in the brake housing.

6. Position the wheel so that the plug hole is at the 3 or 9 o'clock position on the planetary.

7. Slowly add approximately 16 oz. (0.5l) of high quality SAE 85W-140 wt. gear lube to the planetary fill hole (at the ten or two o'clock position) until the level is up to the bottom of the brake housing check hole. 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 wt. gear lube. Check the oil level before the engine is first started and every 400 hours thereafter. The capacity is 80 oz. (2.4l). Visually inspect for leaks daily.

1. Position the machine on a level surface.

2. Remove a check plug from one end of the axle (Figure 46) and make sure that the lubricant is up to the bottom of the hole. If the level is low, remove the fill plug (Figure 46) and add enough lubricant to bring the level up to the bottom of the check plug holes.

   

   Figure 46

   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 47).

   

   Figure 47

   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 80 oz. of 85W-140 gear lube or until lubricant is up to bottom of hole.

7. Install check plug.

The machine must not creep when traction pedal is released. If it does creep, an adjustment is required.

1. Park machine on a level surface, shut engine off, position speed control into LOW range and lower cutting units to the floor. Depress only the right brake pedal and engage the parking brake.

2. Jack up left side of machine until left front tire is off the shop floor. Support machine with jack stands to prevent it from falling accidentally.

3. Start engine and allow run at low idle.

4. Adjust jam nuts on pump rod end to move pump control tube forward to eliminate forward creep or rearward to eliminate rearward creep (Figure 48).

   

   Figure 48

   1. Pump rod jam nuts
   2. Pump control tube

5. After wheel rotation ceases, tighten jam nuts to secure adjustment.

6. Stop the engine and release the right brake. Remove jack stands and lower the machine to the shop floor. Test drive the machine to make sure it does not creep.

1. Measure the center-to-center distance (at axle height) at the front and rear of the steering tires. The front measurement must be 1/8 in. (3 mm) less than the rear measurement (Figure 49).

   

   Figure 49

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

2. To adjust, remove the cotter pin and nut from either tie rod ball joint (Figure 50). Remove tie rod ball joint from axle case support.

   

   Figure 50

   1. Tie rod clamp
   2. Tie rod ball joint

3. Loosen the clamps at both ends of the tie rods (Figure 50).

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

5. Rotate the entire tie rod assembly the same direction (inward or outward) one (1) complete revolution. Tighten clamp at connected end of tie rod.

6. Install the ball joint in the axle case support and tighten the nut finger tight. Measure toe-in.

7. Repeat procedure if necessary.

8. Tighten the nut and install a new cotter pin when the adjustment is correct.

Remove debris from the engine area, oil cooler and radiator daily. Clean them more frequently in dirty conditions.

1. Unlatch and swing open rear screen (Figure 51). Clean the screen thoroughly of all debris.

   Note: To remove screen, lift off hinge pins.

   

   Figure 51

   1. Rear screen latch

2. Rotate latches (Figure 52) securing the oil cooler to the frame.

   

   Figure 52

   1. Oil cooler latches

3. Pivot the oil cooler rearward. Clean both sides of the oil cooler and radiator area (Figure 53) thoroughly 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 53

   1. Oil cooler
   2. Radiator

   Important: Cleaning the radiator or oil cooler with water will promote premature corrosion damage to components and compact debris.

4. Pivot the oil cooler back into position. Secure it to the frame with the latches, close the screen.

Adjust the service brakes when there is more than 1 in. (25 mm) 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 54).

      

      Figure 54

      1. Brake cable

   2. Tighten the rear nut to move the cable backward until the brake pedals have 1/2 to 1 in. (13 to 25 mm) of free travel.

   3. Tighten the front nuts after the brakes are adjusted correctly.

Check the condition and tension of the belts (Figure 55) after every 100 operating hours.

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

2. If the deflection is not 3/8 in. (10 mm), loosen the alternator mounting bolts (Figure 55). 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 55

   1. Alternator
   2. Mounting bolt

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

1. Turn the engine off and raise the hood.

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

3. Fill the reservoir with approximately 7.5 gallons of hydraulic fluid; refer to Checking the Hydraulic Fluid.

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

4. Install the reservoir cap. Start the engine and use all of the hydraulic controls to distribute hydraulic fluid throughout the system. Also check for leaks; then stop the engine.

5. Check the fluid level and add enough to raise level the level to the FULL mark on the dipstick. Do not overfill.

Change the 2 hydraulic filters initially after the first 200 operating hours. Thereafter, change the filters after every 800 operating hours, in normal conditions.

Use Toro replacement filters Part No. 94-2621 for the rear (cutting unit) of the machine and 75-1310 for the front (charge) of the machine.

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

1. Position the machine on a level surface, lower the cutting units, stop the engine, engage the parking brakes, and remove the ignition key.

2. Clean the area around the filter mounting area. Place a drain pan under the filter and remove the filter (Figure 56 and Figure 57).

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

   

   Figure 56

   1. Hydraulic filter
   

   Figure 57

   1. Hydraulic filter

4. Ensure that the filter mounting area is clean. Screw the filter on until the gasket contacts the mounting plate; then tighten the filter an additional 1/2 turn.

5. Start the engine and let it run for about two minutes to purge air from the system. Stop the engine and check for leaks.

Inspect the hydraulic lines and hoses daily for leaks, kinked lines, loose mounting supports, wear, loose fittings, weather deterioration, and chemical deterioration. Make all necessary repairs before operating.

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, stop the engine, engage the parking brake, and remove the key from the ignition switch.

2. Remove the access panel below the front of the seat.

3. Locate the two capped counterbalance jumper wires inside the compartment (Figure 58)

   

   Figure 58

   1. Counterbalance jumper wires
   2. Wire cap

4. With the key in the OFF position, remove the cap from jumper wires and plug the wires together (Figure 59).

   

   Figure 59

5. Turn the key to the RUN position but DO NOT start the machine.

6. The current counterbalance setting will flash on the diagnostic light. The system allows for 3 settings.

7. The counterbalance setting is changed by using the center Raise-Lower switch. To change the counterbalance setting proceed as follows:

   • Moving the switch forward to the lower position and releasing it will lower the counterbalance setting, thus increasing the effective weight of each cutting deck in the turf

   • Moving the switch rearward to the raise position and releasing it will increase the counterbalance setting, thus decreasing the effective weight of each cutting deck in the turf

   • After the switch is released, the diagnostic light will flash the new counterbalance setting (1, 2, or 3).

8. When the desired setting is attained, rotate the key to the Off position.

9. Unplug the jumper wires, install the cap on the wires and put the wires back into the compartment.

10. Replace the access cover.

    Note: The machine cannot be operated while in the counterbalance adjustment mode. 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.

Every 200 hours operation, clear the muffler of carbon buildup.

1. Remove the pipe plug from the clean-out port at the lower side of the muffler.

   Caution

   The muffler may be hot and could cause injury.

   Be careful while working around the muffler.

2. Start the engine. Plug the normal muffler exit with a block of wood or metal plate so that the exhaust flow will be forced out of the clean-out port. Continue to block the exit until carbon deposits cease coming out of the port.

   Caution

   Do not stand in line with the clean-out port.

   Always wear safety glasses.

3. Stop the engine and replace the pipe plug.