Groundsmaster® 4500-D Rotary Mower

• 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.

• 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.

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

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

• Use only an approved fuel container.

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

• Allow engine to cool before refueling.

• Never refuel the machine indoors.

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

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

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

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

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

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

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

• Mow only in daylight or in good artificial light.

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

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

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

• 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 engine speed setting during engine run-out.

• Keep hands and feet away from the cutting units.

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

• Slow down and use caution when making turns and crossing roads and sidewalks. Stop blades from rotating.

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

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

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

• Use care when 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.

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

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

• Tie the machine down securely using straps, chains, cable, or ropes. Both front and rear straps should be directed down and outward from the machine

• 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 14).

Rotate the knob to adjust the seat arm rest angle.

Move the lever to adjust the seat back angle (Figure 14).

Indicates when the seat is adjusted to the weight of the operator (Figure 14). Height adjustment is made by positioning the suspension within the range of the green region.

Figure 14

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

Adjust for operator weight (Figure 14). 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.

To access the Protected Menu Settings

• From the Main Menu, scroll down to the Settings Menu and press the right button.

• In the Settings Menu, scroll down to the Protected Menu and press the right button.

• To enter the passcode, use the center button to set the first digit then press the right button to move on to the next digit.

• Use the center button to set the second digit then press the right button to move on to the next digit.

• Use the center button to set the third digit then press the right button to move on to the next digit.

• Use the center button to set the fourth digit then press the right button.

• Press the middle button to enter the code.

The ability to view and change the settings in the Protected Menu can be changed. Once the Protected Menu has been accessed, scroll down to Protect Settings. Using the right button, changing Protect Settings to OFF will allow the ability to view and change the settings in the Protected Menu without entering the passcode. Changing Protect Settings to ON will hide the protected options and will require entering a passcode to change the setting in the Protected Menu. After the passcode has been set, the key switch must be turned off and back on to enable and save this feature.

• In the Settings Menu, scroll down to Auto Idle

• Press the right button to change the auto idle time between OFF, 8S, 10S, 15S, 20s, & 30S.

• In the Settings Menu, Scroll down to Mow Speed and press the right button.

• Use the right button to increase the max full mow speed (50%, 75%, or 100%).

• Use the center button to decrease the max full mow speed (50%, 75%, or 100%).

• Press the left button to exit.

• In the Settings Menu, scroll down to Transport Speed and press the right button.

• Use the right button to increase the max transport speed (50%, 75%, or 100%).

• Use the center button to decrease the max transport speed (50%, 75%, or 100%).

• Press the left button to exit.

• In the settings menu, scroll down to Smart Power.

• Press the right button to switch between ON and OFF.

• Press the left button to exit.

• In the Settings Menu, scroll down to Counter Balance and press the right button.

• Press the right button to switch between Low, Med, and High.

When finished with the Protected Menu, press the left button to exit to the Main Menu, then press the left button to exit to the Run Menu.

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 the neutral position. Ensure that the parking brake is set.

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

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

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

   When the temperature is less than -7°C (20°F), the starter motor can be run for 30 seconds on then 60 seconds off for 2 attempts.

   Caution

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

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

Note: Lower the cutting units to the ground whenever machine is parked. This relieves the hydraulic load from the system, prevents wear on system parts and also prevents accidental lowering of the cutting units.

1. Move the PTO switch to the Off position.

2. Set the parking brake.

3. Return the engine low idle.

4. Rotate the ignition key to Off.

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

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

Attributes: Excellent lift and dispersion in most conditions.

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

Attributes:

• Discharge remains more even at lower heights of cut.

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

• Lower power requirement at lower heights and dense turf.

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

Attributes:

• More lift and higher discharge velocity.

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

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

• Requires more horsepower to run.

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

This blade was designed to provide excellent leaf mulching.

Attributes: Excellent leaf mulching

• To begin cutting, engage the cutting units, then approach the mowing area slowly. Once the front cutting units are over the mowing area, lower the cutting units.

• To achieve the professional straight-line cut and striping that is desirable for some applications, find a tree or other object in the distance and drive straight toward it.

• As soon as the front cutting units reach the edge of the mowing area, lift the cutting units and perform a tear drop shaped turn to quickly line you up for your next pass.

• The cutting units tend to throw grass to the left side of the machine. If trimming around bunkers, it is best to mow in a clockwise direction to prevent throwing clippings into the bunker.

• The cutting units can be equipped with bolt-in mulching baffles. The mulching baffles perform well when turf is maintained on a regular schedule to avoid removing more than 25 mm (1 inch) of growth per cutting. When too much growth is cut with the mulching baffles installed, after-cut appearance may deteriorate and the observed power to cut the turf increases. The mulching baffles also perform well for shredding leaves in the fall of the year.

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

Remove approximately 25 mm (1 inch) or no more than 1/3 of the grass blade when cutting. In exceptionally lush and dense grass, you may have to raise the height-of-cut to the next setting.

Under most normal conditions you 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.

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 22) and pivot open the hood.

   

   Figure 22

   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 23)

  

  Figure 23

• Rear axle pivot bushings (2) (Figure 24)

  

  Figure 24

• Steering cylinder ball joints (2) (Figure 25)

  

  Figure 25

  1. Top fitting on king pin

• Tie rod ball joints (2) (Figure 25)

• King pin bushings (2) (Figure 25). The top fitting on the king pin should only be lubricated annually (2 pumps).

• Lift arm bushings (1 per deck) (Figure 26)

  

  Figure 26

• Lift cylinder bushings (2 per deck) (Figure 26)

• Cutting unit spindle shaft bearings (2 per cutting unit) (Figure 27)

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

  

  Figure 27

• Cutting unit carrier arm bushings (1 per cutting unit) (Figure 27)

• Rear roller bearings (2 per cutting unit) (Figure 28 )

  

  Figure 28

  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 29) 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 29

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 30).

   

   Figure 30

   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 31).

   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 31

   1. Air cleaner primary filter

   Important: Never attempt to clean the safety filter (Figure 32). Replace the safety filter with a new one after every three primary filter services.

   

   Figure 32

   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 29) if it shows red.

Change the oil and filter every 250 hours.

1. Remove the drain plug (Figure 33) and let the oil flow into a drain pan. When the oil stops, install the drain plug.

   

   Figure 33

   1. Engine oil drain plug

2. Remove the oil filter (Figure 34). Apply a light coat of clean oil to the new filter seal before screwing it on. Do not overtighten.

   

   Figure 34

   1. Engine oil filter

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

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.

1. Unlatch and raise the operator's console panel (Figure 36).

   

   Figure 36

   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 37). 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 37

   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.

Figure 38

Unhook latch and raise operator's console panel (Figure 39) to expose the fuses (Figure 40).

Figure 39

1. Latch
2. Operator's console panel

Figure 40

1. Fuses

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 41

   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.

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

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

1. With machine on level surface, position the wheel so one check plug (Figure 42) is at the 12 o'clock position and the other is at 3 o'clock position.

   

   Figure 42

   1. Check/drain plug (2)

2. Remove the plug at the 3 o’clock position (Figure 42). Oil level should be at the bottom of the check plug hole.

3. If the oil level is low, remove the plug at the 12 o’clock position and add oil until it begins to flow out of the hole at the 3 o’clock position.

4. Re-install both plugs.

5. Repeat steps 1 through 4 on the opposite planetary 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 as replacement.

1. With the machine on a level surface, position a wheel so that one of the check plugs is at the lowest (6 o'clock) position (Figure 43).

   

   Figure 43

   1. Check/drain plug

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

3. Place a drain pan under the brake housing, remove the drain plug and allow the oil to drain (Figure 44).

   

   Figure 44

   1. Brake housing
   2. Drain plug

4. When all of the oil has drained from both locations, re-install the plug in the brake housing.

5. Rotate the wheel until the open plug hole in the planetary is at the twelve o'clock position.

6. Through the open hole, slowly fill the planetary with 0.65 liter (22 ounces) of high quality SAE 85W-140 wt. gear lube.

   Important: If the planetary fills before the 0.65 liter (22 ounces) of oil is added, wait one hour or install the plug and move the machine approximately ten feet to distribute the oil through the brake system. Then, remove the plug and add the remaining oil.

7. Re-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 2.4liters. (80 oz). 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 45) and make sure that the lubricant is up to the bottom of the hole. If the level is low, remove the fill plug (Figure 45) and add enough lubricant to bring the level up to the bottom of the check plug holes.

   

   Figure 45

   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 46).

   

   Figure 46

   1. Drain plug location

3. Remove the (3) oil level check plugs and main axle vent cap to ease in draining of the oil.

4. Remove the drain plugs and allow the oil to drain into the pans.

5. Install the plugs.

6. Remove a check plug and fill axle with approximately 2.4liters. (80 oz.) of 85W-140 gear lube or until lubricant is up to bottom of hole.

7. Install check plug.

1. Measure the center-to-center distance (at axle height) at the front and rear of the steering tires. The front measurement must be 3 mm (1/8 inch) less than the rear measurement (Figure 47).

   

   Figure 47

   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 48). Remove tie rod ball joint from axle case support.

   

   Figure 48

   1. Tie rod clamp
   2. Tie rod ball joint

3. Loosen the clamps at both ends of the tie rods (Figure 48).

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.

This machine is equipped with a hydraulically driven fan drive system that automatically (or manually) reverses to reduce oil cooler/radiator and screen debris build-up. While this feature can help reduce the time required to clean oil cooler/radiator, it does not eliminate the need for routine cleaning. Periodic cleaning and inspection of the radiator/cooler is still required.

1. Unlatch and swing open the rear screen (Figure 49). Clean the screen thoroughly of all debris.

   Note: To remove screen, lift off hinge pins.

   

   Figure 49

   1. Rear screen latch

2. Clean both sides of the oil cooler/radiator area (Figure 50) 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 50

   1. Oil cooler/radiator

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

3. Close the rear screen and secure it with the latch.

Adjust the service brakes when there is more than 25 mm (1 inch) of “free travel" of the brake pedal, or when the brakes do not work effectively. Free travel is the distance the brake pedal moves before braking resistance is felt.

1. Disengage the locking latch from the brake pedals so that both pedals work independently of each other.

2. To reduce free travel of the brake pedals, tighten the brakes:

   1. Loosen the front nut on the threaded end of the brake cable (Figure 51).

      

      Figure 51

      1. Brake cable

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

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

Check the condition and tension of the belts (Figure 52) after every 100 operating hours.

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

2. If the deflection is not 10 mm (3/8 inch), loosen the alternator mounting bolts (Figure 52). 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 52

   1. Mounting bolt
   2. Alternator

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 28.4 liters (7.5 U.S. 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 53 and Figure 54).

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

   

   Figure 53

   1. Hydraulic filter
   

   Figure 54

   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.

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

2. Disconnect and remove the hydraulic motor from the deck (Figure 55). Cover the top of the spindle to prevent contamination.

   

   Figure 55

   1. Motor mounting screws

3. Remove the lynch pin or retaining nut (GM 4700 only) securing the deck carrier frame to the lift arm pivot pin (Figure 56).

   

   Figure 56

   1. Lynch pin
   2. Lift arm pivot pin

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

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

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

3. Slide deck carrier frame onto lift arm pivot pin. Secure with lynch pin or retaining nut (GM 4700 only) (Figure 56).

4. Install the hydraulic motor to the deck (Figure 55). Make sure that the O-ring is in position and not damaged.

5. Grease the spindle.

The rotary deck comes from the factory preset at 5 cm (2.00 inch) height-of-cut and blade rake of 7.9 mm ( 0.310 inch). The left-hand and right-hand heights are also preset to within ± 0.7 mm (0.030 inch) of the other.

The cutting deck is designed to withstand blade impacts without deformation of the chamber. If a solid object is struck, inspect the blade for damage and the blade plane for accuracy.

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