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;

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

    • Insufficient wheel grip

    • Being driven too fast

    • Inadequate braking

    • The type of machine is unsuitable for the task

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

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

• While mowing, always wear substantial, slip-resistant footwear, long trousers, safety glasses, and hearing protection. Long hair, loose clothing, or jewelry may get tangled in moving parts. Do not operate the equipment when barefoot or wearing open sandals.

• Thoroughly inspect the area where the equipment is to be used and remove all objects which may be thrown by the machine.

• Replace faulty silencers/mufflers.

• Evaluate the terrain to determine what accessories and attachments are needed to properly and safely perform the job.

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

• To 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 and other exhaust gasses can collect.

• Mow only in daylight or in good artificial light.

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

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

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

  • Do not stop or start suddenly when going up or downhill.

  • Machine speeds should be kept low on slopes and during tight turns.

  • Stay alert for humps and hollows and other hidden hazards.

  • Nver mow across the face of the slope, unless the mower is designed for this purpose.

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

• Watch out for traffic when crossing or near roadways.

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

• Never operate the machine with damaged guards, shields, or without safety protective devices in place. Be sure all interlocks are attached, adjusted properly, and functioning properly.

• Before leaving the operator's position:

  • Stop on level ground

  • Disengage the power takeoff and lower the attachments

  • Set the parking brake

  • 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.

• Drain the fuel tank outdoors.

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

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

• Disengage drives, lower the cutting units, set the parking brake, turn the key in the ignition switch to the OFF position, and remove 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

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.

Fuel tank capacity: 83 L (22 US gallons)

Important: Use only ultra-low sulphur diesel fuel. Fuel with higher rates of sulfur degrades the diesel oxidation catalyst (DOC), which causes operational problems and shortens the service life of engine components.Failure to observe the following cautions may damage the engine.

• Never use kerosene or gasoline instead of diesel fuel.

• Never mix kerosene or used engine oil with the diesel fuel.

• Never keep fuel in containers with zinc plating on the inside.

• Do not use fuel additives.

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

1. Park the machine on a level surface.

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

3. Remove the cap from the fuel tank (Figure 20).

   

   Figure 20

   1. Fuel-tank cap

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

5. Install the fuel-tank cap tightly.

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

Note: If possible, fill the fuel tank after each use; this will minimize possible buildup of condensation inside the fuel tank.

Important: You must bleed the fuel system before starting the engine if the engine has stopped 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, and engage the parking brake.

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

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

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

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

   Caution

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

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

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

1. Move the PTO switch to the OFF position.

2. Set the parking brake.

3. Return the engine low idle.

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

• Over time, the DPF accumulates soot in the soot filter. The computer for the engine monitors the soot level in the DPF.

• When enough soot accumulates, the computer informs you that it is time to regenerate the diesel particulate filter.

• DPF regeneration is a process that heats the DPF to convert the soot to ash.

• In addition to the warning messages, the computer reduces the power produced by the engine at different soot-accumulation levels.

Engine Warning Messages—Soot Accumulation

Indication Level	Fault Code	Engine Power Rating	Recommended Action
Level 1: Engine Warning	Figure 22 Check EngineSPN 3719, FMI 16	The computer de-rates the engine power to 85%	Perform a parked regeneration as soon as possible; refer to Parked Regeneration.
Level 2: Engine Warning	Figure 23 Check EngineSPN 3719, FMI 0	The computer de-rates the engine power to 50%	Perform a recovery regeneration as soon as possible; refer to Recovery Regeneration.

• The lighter ash is discharged through the exhaust system; the heavier ash collects in the soot filter.

• Ash is a residue of the regeneration process. Over time, the diesel particulate filter accumulates ash that does not discharge with the engine exhaust.

• The computer for the engine calculates the amount of ash accumulated in the DPF.

• When enough ash accumulates, the engine computer sends information to the InfoCenter in the form of a system advisory or an engine fault to indicate the accumulation of ash in the DPF.

• The advisory and faults are indications that it is time to service the DPF.

• In addition to the warnings, the computer reduces the power produced by the engine at different ash-accumulation levels.

InfoCenter Advisory and Engine Warning Messages—Ash Accumulation

Indication Level	Advisory or Fault Code	Engine Speed Reduction	Engine Power Rating	Recommended Action
Level 1: System Advisory	Figure 24 Advisory #179	None	100%	Notify your service department that advisory #179 displays in the InfoCenter.
Level 2: Engine Warning	Figure 25 Check EngineSPN 3720, FMI 16	None	The computer de-rates the engine power to 85%	Service the DPF; refer to Servicing the Diesel-Oxidation Catalyst (DOC) and the Soot Filter
Level 3: Engine Warning	Figure 26 Check EngineSPN 3720, FMI 0	None	The computer de-rates the engine power to 50%	Service the DPF; refer to Servicing the Diesel-Oxidation Catalyst (DOC) and the Soot Filter
Level 4: Engine Warning	Figure 27 Check EngineSPN 3251, FMI 0	Engine speed at max torque + 200 rpm	The computer de-rates the engine power to 50%	Service the DPF; refer to Servicing the Diesel-Oxidation Catalyst (DOC) and the Soot Filter

Types of diesel particulate filter regeneration that are performed while the machine is operating:

Type of Regeneration	Conditions for DPF regeneration	DPF description of operation
Passive	Occurs during normal operation of the machine at high-engine speed or high-engine load	The InfoCenter does not display an icon indicating passive regeneration.
		During passive regeneration, the DPF processes high-heat exhaust gasses; oxidizing harmful emissions and burning soot to ash.
		Refer to Passive DPF Regeneration.
Assist	Occurs as a result of low-engine speed, low-engine load, or after the computer detects back pressure in the DPF	When the assist/reset-regeneration icon is displayed in the InfoCenter, an assist regeneration is in progress.
		During assist regeneration, the computer controls the intake throttle to increase the exhaust temperature, enabling assist regeneration to occur.
		Refer to Assist DPF Regeneration.
Reset	Occurs after assist regeneration only if the computer detects that assist regeneration did not sufficiently reduce the soot level	When the assist/reset-regeneration icon is displayed in the InfoCenter, a regeneration is in progress.
	Also occurs every 100 hours to reset baseline sensor readings
		During reset regeneration, the computer controls the intake throttle and fuel injectors to increase the exhaust temperature during regeneration.
		Refer to Reset Regeneration.

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

Type of Regeneration	Conditions for DPF regeneration	DPF description of operation
Parked	Soot buildup occurs as a result of prolonged operation at low-engine speed or low-engine load. May also occur as a result of using incorrect fuel or oil	When the parked-regeneration icon is displayed in the InfoCenter, a regeneration is requested.
	The computer detects back pressure due to soot buildup and requests a parked regeneration
		• Perform the parked regeneration as soon as possible to avoid needing a recovery regeneration.
		• A parked regeneration requires 30 to 60 minutes to complete.
		• You must have at least a 1/4 tank of fuel in the tank.
		• You must park the machine to perform a recovery regeneration.
		Refer to Parked Regeneration.
Recovery	Occurs as a result of ignoring parked regeneration requests and continuing operation, adding more soot when the DPF is already in need of a parked regeneration	When the recovery-regeneration icon is displayed in the InfoCenter, a recovery regeneration is requested.
		Contact your Authorized Toro Distributor to have a service technician perform the recovery regeneration.
		• A recovery regeneration requires up to 4 hours to complete.
		• You must have at least a 1/2 tank of fuel in the machine.
		• You must park the machine to perform a recovery regeneration.
		Refer to Recovery Regeneration.

• Passive regeneration occurs as part of normal engine operation.

• While operating the machine, run the engine at full-engine speed when possible to promote DPF regeneration.

Figure 28

Assist/reset-regeneration icon

• The assist/reset-regeneration icon displays in the InfoCenter (Figure 28).

• The computer takes control of the intake throttle to increase the temperature of the engine exhaust.

• While operating the machine, run the engine at full engine speed when possible to promote DPF regeneration.

• The icon displays in the InfoCenter while the assist regeneration is processing.

• Whenever possible, do not shut off the engine or reduce engine speed while the assist regeneration is processing.

  Important: Allow the machine to complete the assist regeneration process before shutting off the engine.

  Note: The assist regeneration is finished processing when the icon disappears from the InfoCenter.

Figure 29

Assist/reset-regeneration icon

• The assist/reset-regeneration icon displays in the InfoCenter (Figure 29).

• The computer takes control of the intake throttle and changes the fuel injection operation to increase the temperature of the engine exhaust.

  Important: The assist/reset-regeneration icon indicates that the exhaust temperature discharged from of your machine may be hotter than during regular operation.

• While operating the machine, run the engine at full engine speed when possible to promote DPF regeneration.

• The icon displays in the InfoCenter while the reset regeneration is processing.

• Whenever possible, do not shut off the engine or reduce engine speed while the reset regeneration is processing.

  Important: Allow the machine to complete the reset regeneration process before shutting off the engine.

  Note: The reset regeneration is finished processing when the icon disappears from the InfoCenter.

Figure 30

Parked-regeneration request icon

• The parked-regeneration requested icon displays in the InfoCenter (Figure 30).

• If a parked regeneration is needed, the InfoCenter displays engine warning SPN 3719, FMI 16 (Figure 31) and the engine computer derates engine power to 85%.

  

  Figure 31

  Important: If you do not complete a parked regeneration within 2 hours, the engine computer derates engine power to 50%.

• A parked regeneration requires 30 to 60 minutes to complete.

• If you are authorized by your company, you need the PIN code to perform the parked-regeneration process.

• If you ignore the request for a parked regeneration (displayed in the InfoCenter) and continue to operate the machine, a critical amount of soot builds up in the DPF.

• If a recovery regeneration is needed, the InfoCenter displays engine warning SPN 3719, FMI 16 (Figure 43) and the engine computer derates engine power to 85%.

  

  Figure 43

  Important: If you do not complete a recovery regeneration within 15 minutes, the engine computer derates engine power to 50%.

• Perform a recovery-regeneration whenever there is a loss of engine power and a parked regeneration cannot effectively clean the DPF of soot.

• A recovery regeneration requires up to 4 hours to complete.

• You need a distributor technician to perform the recovery regeneration process; contact your Authorized Toro Distributor.

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 inches).

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 inches).

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

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

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

Under most normal conditions you need to mow approximately every 4-5 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 1 direction.

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

Use the 2 rear-transport latches for the outer cutting units when transporting over long distances, rough terrain, or when trailering.

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

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

1. Release the hood latches (Figure 47) and pivot the hood open.

   

   Figure 47

   1. Hood latch (2)

2. Remove the cotter pins securing the rear-hood brackets to the frame pins and lift off the hood.

The machine has grease fittings that must be lubricated regularly with No. 2 lithium grease.

The grease fitting locations and quantities are as follows:

• Brake-shaft pivot bearings (5) (Figure 48)

  

  Figure 48

• Rear-axle pivot bushings (2) (Figure 49)

  

  Figure 49

• Steering-cylinder ball joints (2) (Figure 50)

  

  Figure 50

  1. Top fitting on king pin

• Tie-rod ball joints (2) (Figure 50)

• King-pin bushings (2) (Figure 50). The top fitting on the king pin should only be lubricated annually (2 pumps).

• Lift-arm bushings (1 per deck) (Figure 51)

  

  Figure 51

• Lift-cylinder bushings (2 per deck) (Figure 51)

• Cutting unit spindle-shaft bearings (2 per cutting unit) (Figure 52)

  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 52

• Cutting unit carrier-arm bushings (1 per cutting unit) (Figure 52)

• Rear-roller bearings (2 per cutting unit) (Figure 53 )

  

  Figure 53

  Important: Make sure that the grease groove in each roller mount aligns with the grease hole in each end of the roller shaft. To help align the groove and hole, there is also an alignment mark on 1 end of the roller shaft.

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

Service the air-cleaner filter only when the service indicator (Figure 54) 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 54

1. Air-cleaner indicator

Important: Make 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 55).

   

   Figure 55

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

2. Remove the cover from the air cleaner body.

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

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

4. Remove and replace the primary filter (Figure 56).

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

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

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

   

   Figure 56

   1. Air-cleaner primary filter

   Important: Never attempt to clean the safety filter (Figure 57). Replace the safety filter after every 3 primary filter services.

   

   Figure 57

   1. Air-cleaner safety filter

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

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

9. Reset the indicator (Figure 54) if it shows red.

• If advisory message displays in the InfoCenter, the DPF is nearing the recommended point for servicing the diesel-oxidation catalyst and the soot filter.

  

  Figure 61

• If engine faults , , or in the InfoCenter (Figure 62) display in the InfoCenter, clean the soot filter using the steps that follow:

  

  Figure 62

  1. Refer to the Engine section in the Service Manual for information on disassembling and assembling the diesel-oxidation catalyst and the soot filter of the DPF.

  2. Refer to your Authorized Toro Distributor for diesel-oxidation catalyst and the soot filter replacement parts or service.

  3. Contact your Authorized Toro Distributor to have them reset the engine ECU after you install a clean DPF.

Drain and clean the tank if fuel system becomes contaminated or if the machine will be stored for an extended period of time. Use clean fuel to flush out the tank.

Inspect them for deterioration, damage, or loose connections.

1. Clean the area around the fuel-filter head (Figure 63).

   

   Figure 63

   1. Fuel-filter head
   2. Fuel filter

2. Remove the filter and clean the filter head mounting surface (Figure 63).

3. Lubricate the filter gasket with clean lubricating engine oil; refer to the Engine Operator's Manual.

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

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

1. Place a clean container under the fuel filter (Figure 64).

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

   

   Figure 64

   1. Water separator filter canister

3. Clean the area where the filter canister mounts.

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

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

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

7. Tighten the drain plug on the bottom of the filter canister and close the vent on the top of the canister mount.

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 65).

   

   Figure 65

   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 A battery charger to the battery posts. Charge the battery at a rate of 3 to 4 A for 4 to 8 hours.

3. When the battery is charged, disconnect the charger from the power 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 66). 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 66

   1. Positive battery cable
   2. Negative battery cable

5. Secure the cables to the posts with capscrews and nuts.

   Note: Make sure that the positive (+) terminal is all of the way onto the post and the cable is positioned snug to the battery. The cable must not contact the battery cover.

6. Slide the rubber boot over the positive terminal to prevent a possible short from occurring.

   Warning

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

7. Coat both battery connections with Grafo 112X (skin-over) grease, Part Number 505-47, petroleum jelly, or light grease to prevent corrosion. Slide the rubber boot over the positive terminal.

8. Close the console panel and secure the latch.

   Warning

   Battery terminals or metal tools could short against metal components causing sparks. Sparks can cause the battery gasses to explode, resulting in personal injury.

   • When removing or installing the battery, do not allow the battery terminals to touch any metal parts of the machine.

   • Do not allow metal tools to short between the battery terminals and metal parts of the machine.

   Warning

   Incorrect battery cable routing could damage the machine and cables causing sparks. Sparks can cause the battery gasses to explode, resulting in personal injury.

   • Always disconnect the negative (black) battery cable before disconnecting the positive (red) cable.

   • Always connect the positive (red) battery cable before connecting the negative (black) cable.

Important: Before welding on the machine, disconnect the negative (black) cable from the battery to prevent damage to the electrical system.

Note: Keep the terminals and the entire battery case clean to avoid slow discharge. To clean the battery, remove it from the machine and wash the entire case with a solution of baking soda and water. Rinse with clear water. Coat the battery posts and cable connectors with Grafo 112X (skin-over) grease (Par Number 505-47) or petroleum jelly to prevent corrosion.

Figure 67

Unhook the latch and raise the operator's console panel (Figure 68) to expose the fuses (Figure 69).

Figure 68

1. Latch
2. Operator's console panel

Figure 69

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 70

   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).

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

1. Position the machine on a level surface and position the wheel so 1 check plug (Figure 71) is at the 12 o'clock position and the other is at 3 o'clock position.

   

   Figure 71

   1. Check/drain plug (2)

2. Remove the plug at the 3 o’clock position (Figure 71).

   Note: The 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. Install both plugs.

5. Repeat steps 1 through 4 on the opposite planetary gear assembly.

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

1. Position the machine on a level surface and position a wheel so that 1 of the check plugs is at the lowest (6 o'clock) position (Figure 72).

   

   Figure 72

   1. Check/drain plug

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

3. Place a drain pan under the brake housing, remove the drain plug, and allow the oil to drain (Figure 73).

   

   Figure 73

   1. Brake housing
   2. Drain plug

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

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

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

   Important: If the planetary fills before the 0.65 L (22 oz) of oil is added, wait 1 hour or install the plug and move the machine approximately 3 m (10 ft) to distribute the oil through the brake system. Then, remove the plug and add the remaining oil.

7. Install the plug.

8. Repeat the procedure on the opposite planetary/brake assembly.

The rear axle is shipped from the factory filled with SAE 85W-140 gear lube. The capacity is 2.4 L (80 oz). Visually inspect for leaks daily.

1. Position the machine on a level surface.

2. Remove a check plug from 1 end of the axle (Figure 74) and make sure that the lubricant is up to the bottom of the hole.

3. If the level is low, remove the fill plug (Figure 74)and add enough lubricant to bring the level up to the bottom of the check plug holes.

   

   Figure 74

   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 75).

   

   Figure 75

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

7. Install the 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 76).

   

   Figure 76

   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 77) and remove the tie-rod ball joint from the axle-case support.

   

   Figure 77

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

3. Loosen the clamps at both ends of the tie rods (Figure 77).

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

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

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

7. Repeat procedure if necessary.

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

Clean them more frequently in dirty conditions.

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

1. Unlatch and swing open the rear screen (Figure 78).

2. Clean the screen thoroughly of all debris.

   Note: To remove screen, lift off hinge pins.

   

   Figure 78

   1. Rear-screen latch

3. Thoroughly clean both sides of the oil cooler and the radiator (Figure 79) 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 79

   1. Oil cooler/radiator

   Important: Cleaning the oil cooler/radiator with water promotes premature corrosion damage to components and compacts debris.

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

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

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

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

   1. Loosen the front nut on the threaded end of the brake cable (Figure 80).

      

      Figure 80

      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.

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

1. Loosen the alternator mounting bolts (Figure 81).

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

   

   Figure 81

   1. Mounting bolt
   2. Alternator

If the fluid becomes contaminated, contact your Toro Distributor because the system must be flushed. Contaminated fluid looks milky or black when compared to clean oil.

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

2. Disconnect the hose from the bottom of the reservoir and let the hydraulic fluid flow into a large drain pan.

3. Install the hose when hydraulic fluid stop draining.

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

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

5. Install the reservoir cap.

6. Start the engine, use all of the hydraulic controls to distribute hydraulic fluid throughout the system, and check for leaks.

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

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

Use Toro replacement filters Part Number 94-2621 for the rear (cutting unit) of the machine and Part Number 75-1310 for the front (charge) of the machine.

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

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

2. Clean the area around the filter mounting area. Place a drain pan under the filter and remove the filter (Figure 82 and Figure 83).

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

   

   Figure 82

   1. Hydraulic filter
   

   Figure 83

   1. Hydraulic filter

4. Ensure that the filter mounting area is clean.

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

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

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

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

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

2. Disconnect and remove the hydraulic motor from the deck (Figure 84). Cover the top of the spindle to prevent contamination.

   

   Figure 84

   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 85).

   

   Figure 85

   1. Lynch pin
   2. Lift-arm pivot pin

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

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

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

3. Slide the deck carrier frame onto the lift-arm pivot pin. Secure with lynch pin or retaining nut (GM 4700 only) (Figure 85).

4. Install the hydraulic motor to the deck (Figure 84). 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 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.

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