Groundsmaster® 4000 or 4010 Rotary Mower

Move the seat-adjustment lever on the side of the seat outward, slide the seat to the desired position, and release the lever to lock the seat into position (Figure 7).

Figure 7

1. Weight gauge
2. Weight-adjustment lever
3. Seat-adjustment lever
4. Seat-back adjustment lever
5. Armrest-adjustment knob (not shown; located under arm rest)

Rotate the knob to adjust the armrest angle.

Note: The adjustment knob is located under the armrest.

Move the lever to adjust the seat-back angle (Figure 7).

The weight gauge indicates when the seat is adjusted to the weight of the operator (Figure 7). Adjust the height by positioning the suspension within the range of the green region.

Use this lever to adjust to the proper weight of the operator (Figure 7). Pull up the lever to increase the air pressure and push down to decrease the air pressure. The proper adjustment is correct when the weight gauge is in the green region.

The air-recirculation control sets the cab to either recirculate the air in the cabin or to draw air into the cabin from outside (Figure 8).

• Set it to recirculate the air when using the air-conditioning.

• Set it to draw air in when using the heater or fan.

Rotate the fan-control knob to regulate the speed of the fan (Figure 8).

Rotate the temperature-control knob to regulate the air temperature in the cab (Figure 8).

Use this switch to turn the windshield wipers on or off (Figure 8).

Use this switch to turn the air conditioning on or off (Figure 8).

Lift up the latches to open the windshield (Figure 9). Press in the latch to lock windshield to the OPEN position. Pull out and down on the latch to close and secure the windshield.

Figure 9

1. Windshield latch

Lift up the latches to open the rear window. Press in on the latch to lock the window in OPEN position. Pull out and down on the latch to close and secure the window (Figure 9).

Important: Close the rear window before opening the hood or damage may occur to the hood or rear window.

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

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

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

The correct air pressure in the tires is 172 to 207 kPa (25 to 30 psi).

Important: Maintain the recommended pressure in all tires to ensure a good quality of cut and proper machine performance. Do not under-inflate the tires.Check the air pressure in all the tires before operating the machine.

Figure 11

Torque the wheel lug nuts to 115 to 136 N∙m (85 to 100 ft-lb) in the order shown in Figure 12 and Figure 13.

Figure 12

Front Wheels

Figure 13

Rear Wheels

Important: Always use the seat belt when the roll bar is in the raised and locked position. Do not use the seat belt when the roll bar is in the lowered position.

Lowering the Roll Bar

Important: Lower the roll bar only when necessary.

Important: Ensure that the seat is secured with the seat latch.

Figure 14

Raising the Roll Bar

Figure 15

Mount the skids in the lower position when operating at heights of cut greater than 64 mm (2-1/2 inches) and in the higher position when operating at heights of cut lower than 64 mm (2-1/2 inches).

Note: When the skids become worn, you can switch them to the opposite sides of the mower by flipping them over. This allows you to use the skids longer before replacing them.

Adjust the skids (Figure 26).

Important: Torque the screw at the front of each skid to 9 to 11 N·m (80 to 100 in-lb).

Figure 26

The cutting unit rollers should be mounted in the lower position when operating at height of cuts greater than 64 mm (2-1/2 inches), and in the higher position when operating in height of cuts lower than 64 mm (2-1/2 inches).

Figure 27

Due to differences in grass conditions and the counterbalance setting of the traction unit, a sample area of grass should be cut and the appearance checked before formal cutting is started.

1. Set all cutting units to the desired height of cut; refer to Adjusting the Height of Cut.

2. Check and adjust the air pressure in the front and rear tire of the machine to 172 to 207 kPa (25 to 30 psi).

3. Check and adjust the air pressure in all of the caster tires for the cutting unit to 345 kPa (50 psi).

4. Check the charge and counterbalance pressures with the engine at HIGH IDLE, using hydraulic-test ports.

   Note: Adjust the counterbalance to 2241 kPa (325 psi).

5. Check for bent blades; refer to Checking for a Bent Blade.

6. Cut grass in a test area to determine if all cutting units are cutting at the same height.

7. If mower-deck adjustments are still needed, find a flat surface using a 2 m (6 ft) or a longer straight edge.

8. To ease measuring the blade plane, raise the height-of-cut to 7.6 to 10.1 cm (3 to 4 inches); refer to Adjusting the Height of Cut.

9. Lower the cutting units onto a flat surface and remove the covers from the top of the cutting units.

10. Loosen the flange nut, securing the idler pulley, to release the belt tension on each cutting unit.

The machine has interlock switches in the electrical system. These switches disengage either the traction unit or the PTO whenever you leave the seat. If you disengage the PTO and engage the parking brake before you leave the seat, the engine continues to run.

1. Drive the machine slowly to a large, open area. Lower the cutting unit, shut off the engine, and apply the parking brake.

2. Sit on the seat and press the traction pedal. Try to start the engine. The engine should not start. If the engine starts, there is a malfunction in the interlock system that should be corrected before beginning operation.

3. Sit on the seat, start the engine, and engage the PTO. While sitting in the seat with the PTO engaged, rise from the seat. The PTO should disengage after a slight delay. If the PTO remains engaged, there is a malfunction in the interlock system that should be corrected before beginning operation.

4. Sit on the seat, engage the parking brake and start the engine. Move the traction pedal out of the NEUTRAL position. The InfoCenter should display “traction not allowed” and the machine should not move. If the engine does move, there is a malfunction in the interlock system that should be corrected before beginning operation.

1. Loosen the mounting nuts and position each headlight so that it points straight ahead.

   Note: Tighten the mounting nut just enough to hold the headlight in position.

2. Place a flat piece of sheet metal over the face of the headlight.

3. Mount a magnetic protractor onto the plate.

4. While holding the assembly in place, carefully tilt the headlight downward 3°, then tighten the nut.

5. Repeat the procedure on the other headlight.

When the machine is in Quiet Mode, the sound pressure level at the operator's position is less than 80dBA with a K-factor of 1.0 dBA, when evaluated per EN ISO 5395:2013-1 Annex F.

Contact your authorized Toro distributor to set the machine software to activate Quiet Mode.

The display shows information about your machine such as the operating status, various diagnostics, and other information about the machine. There are multiple screens on the display. You can switch between the screens at any time by pressing any of the display buttons and then selecting the appropriate directional arrow.

Figure 31

1. Indicator light
2. Display brightness sensor
3. Navigational button— up
4. Back/exit button
5. Navigational button— decrease/ left
6. Navigational button— down
7. Navigational button— increase/ right
8. Enter/select button

Note: The purpose of each button may change depending on what is required at the time. Each button is labeled with an icon displaying its current function.

InfoCenter Icon Description

	Hour meter
	Page change
	Virtual pedal stop settings
	The glow plugs are active.
	The operator must sit in the seat.
	The parking brake is engaged.
	Engine coolant temperature (°C or °F)
	Traction or Traction Pedal
	The cruise control is engaged.
	Reset-standby regeneration request
	Parked or recovery regeneration request
	A parked or recovery regeneration is processing.
	High exhaust temperature
	NOx control diagnosis malfunction; drive the machine back to the shop and contact your authorized Toro distributor (software version U and later).
	The power take-off is disabled.
	The PTO is on.
	Battery
	Fuel level
	Warning
	Active
	Inactive
	Previous
	Next
	The cutting units are raising.
	The cutting units are lowering.
	Previous screen
	Fast
	Slow
	Increase value
	Decrease value
	Menu
	Scroll up/down
	Scroll left/right
	Locked
	PIN Passcode

To access the InfoCenter menu system, press the menu access button while at the main screen. This brings you to the main menu. Refer to the following tables for a synopsis of the options available from the menus:

Main Menu—Menu Item	Description
Faults	The Faults menu contains a list of the recent machine faults. Refer to the Service Manual or contact your authorized Toro distributor for more information on the Faults menu and the information contained there.
Service	The Service menu contains information on the machine such as hours of use, counters, and other similar numbers.
Diagnostics	The Diagnostics menu displays the state of each machine switch, sensor, and control output. You can use this to troubleshoot certain issues as it quickly tells you which machine controls are ON and which are OFF.
Settings	The Settings menu allows you to customize and modify configuration variables on the display.
Machine Settings	The Machine Settings menu allows you to adjust the auto idle, speed, Smart Power, backup alarm, and slope sensor thresholds.
About	The About menu lists the model number, serial number, and software version of your machine.

Service—Menu Item	Description
Hours	Lists the total number of hours that the machine, engine, and PTO have been on, as well as the number of hours the machine has been transported and service due.
Counts	Lists numerous counts the machine has experienced.
DPF Regeneration	The diesel particulate filter regeneration option and DPF submenus
Fan Reverse	Allows you to initiate a reverse fan cycle.
Fuel Rate	Lists the average fuel rate.
Traction Pedal	Lists the traction pedal calibration values and allows the traction pedal to be calibrated.

Settings—Menu Item	Description
Enter PIN	Allows a person (superintendent/mechanic) authorized by your company with the PIN code to access protected menus.
Protected Settings	Allows a person authorized by your company with the PIN code to access protected settings.
Reset Defaults	Resets the settings to the default settings.
Backlight	Controls the brightness of the LCD display.
Language	Controls the language used on the InfoCenter*.
Font Size	Controls the size of the font on the display.
Units	Controls the units used on the InfoCenter (English or Metric).

Note: The Machine Settings menu will only show when the PIN is entered.

Machine Settings—Menu Item	Description
Auto Idle	Controls the amount of time allowed before idling the engine when the machine is not in use
Mow Speed	Controls the maximum speed while in mow (low range).
Transport Speed	Controls the maximum speed while in transport (high range).
Smart Power	Turns Smart Power on and off.
Backup Alarm	Indicates there is a backup alarm installed.
Slope Sensor Installed	Indicates there is a slope sensor installed.

About—Menu Item	Description
Model	Lists the model number of the machine.
SN	Lists the serial number of the machine.
S/W Rev	Lists the software revision of the primary controller.
Stage V	Shows yes or no depending on the engine.
XDM-2700	Lists the software revision of the InfoCenter
CAN	Lists the machine communication bus status
S/W Rev-S	Lists the software revision of the secondary controller.

Protected under Protected Menus—accessible only by entering PIN

There are operating configuration settings that are adjustable within the SETTINGS of the InfoCenter. To lock these settings, use the PROTECTED MENU.

Note: At the time of delivery, the initial password code is programmed by your distributor.

Figure 34

1. Diagnostic light

• Flashing red—active fault

• Solid red—active advisory

• Solid green—normal operation

• Blinking green—updating code

Practice driving the machine, because it has a hydrostatic transmission and its characteristics may differ from other turf-maintenance machines. Some points to consider when operating the traction unit, cutting unit, or other implements are that the transmission, engine speed, and the load on the mower blades or other implements affect machine performance.

With Toro Smart Power™, you do not need to listen to the engine speed in heavy load conditions. Smart Power prevents the engine from bogging down in heavy cutting conditions by automatically controlling the machine speed and optimizing cutting performance.

You can use the brakes to assist in turning the machine. However, use them carefully, especially on soft or wet grass, because the turf may be torn accidentally. Another benefit of the brakes is to maintain traction. For example, in some slope conditions, the uphill wheel slips and loses traction. If this situation occurs, press the uphill brake pedal gradually and intermittently until the uphill wheel stops slipping, This action increases the traction on the downhill wheel.

Traction Assist is automatic and requires no operator input. When a wheel starts to slip, flow is automatically split between the front and rear wheels to minimize wheel slip and loss of traction.

Before stopping the engine, disengage all controls and change the throttle to the SLOW position. Changing the throttle to the SLOW position reduces high-engine speed, noise, and vibration. Turn the key to the OFF position to shut off the engine. Remove the key if you are leaving the operator’s position.

Before transporting the machine, raise the cutting units and secure the transport latches (Figure 35).

Figure 35

1. Transport latch (side cutting units)

• Start the engine and run it at the HALF IDLE position until it warms up. Move the engine-speed switch to HIGH IDLE, lift the cutting units, disengage the parking brake, press the forward traction pedal, and carefully drive to an open area.

• Practice moving forward and reverse, and starting and stopping the machine. To stop the machine, remove your foot from the traction pedal and let it return to NEUTRAL or press down on the reverse pedal.

  Note: When going downhill in the machine, you may need to use the reverse pedal to stop.

• Practice driving around obstacles with the cutting units up and down. Be careful when driving between narrow objects so that you do not damage the machine or cutting units.

• Always drive slowly in rough areas.

• If an obstacle is in the way, lift the cutting units to mow around it.

• When transporting the machine from 1 work area to another, raise the cutting units to the fully upward position, shut off the PTO, press the mow/transport switch to the TRANSPORT position, and place the throttle in the FAST position.

The counterbalance system maintains hydraulic back pressure on the deck-lift cylinders. This pressure improves traction by transferring the mower-deck weight to the mower-drive wheels. The counterbalance pressure has been set at the factory to an optimal balance of after-cut appearance and traction capability in most turf conditions.

Decreasing the counterbalance setting can produce a more stable cutting unit, but can decrease the traction capability. Increasing the counterbalance setting can increase the traction capability, but may result in a poor after-cut appearance. Refer to the machine Service Manual for your traction unit for instructions to adjust the counterbalance pressure.

Important: In emergency braking situations, remove your foot from the traction pedal and then press the brake pedals.

In the low speed range only, you can use the brakes individually for turning or to improve traction. Perform the following when using the brakes individually:

• Disconnect the pedal-locking latch (Figure 4).

• For turning assist, press the corresponding brake pedal to the side you are turning. This allows a tighter turning radius.

  Note: Use the individual brakes carefully, especially on soft or wet grass, because the turf may be torn accidentally.

• For traction assist, apply light pressure to the brake pedal corresponding to the front tire that is slipping. For example, in some slope conditions, the uphill wheel slips and loses traction. If this situation occurs, press the uphill brake pedal gradually and intermittently until the uphill wheel stops slipping, This action increases the traction on the downhill wheel.

With Smart Power, the operator does not have to listen to the engine speed in heavy load conditions. Smart Power prevents the engine from bogging down in heavy cutting conditions by automatically controlling the machine speed and optimizing cutting performance.

Note: By default, the Smart Power feature is ON.

The machine-fan speed is controlled by the hydraulic-fluid temperature and engine-coolant temperature. When the hydraulic fluid or coolant reaches a certain temperature, a reverse fan cycle is automatically initiated. This cycle blows debris off the rear screen and lowers the engine-coolant and hydraulic-fluid temperatures.

You can complete a manually-initiated reverse cycle from the service menu or by simultaneously pressing the inner right and left buttons from a RUN SCREEN, when the fan icons show in the context menu. It is recommended that you manually reverse the fan before you leave the work area or enter the maintenance or storage area.

Note: When your request is recognized, there is a temporary screen (3-4 seconds) depicting a fan inside a rectangle. This means that your request was sent, but there are certain conditions that prevent the fan from being reversed.

The machine is equipped with auto idle, which automatically idles the engine when all the following functions are not used for a pre-determined time as previously set in the InfoCenter.

• The traction pedal is returned to the NEUTRAL position.

• The PTO is disengaged.

• None of the lift switches are activated.

  When you initiate any of the above functions, the machine automatically returns to the previous throttle position.

The cruise-control switch locks in the pedal position to maintain the desired ground speed. Pressing the rear of the switch turns the cruise control off, the middle position of the switch enables the cruise-control function, and the front of the switch sets the desired ground speed.

Note: Pressing either the brake pedal or moving the traction pedal into the REVERSE position, for 1 second, also disengages the pedal position.

Important: Bleed the fuel system if any of the following have occurred:

• The engine has shut off 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 engaged.

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

3. Turn the ignition key to the RUN position. The glow indicator should light.

4. When the glow indicator dims, turn the ignition key to the START 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, check the controls and procedures, wait 15 additional seconds, and repeat the starting procedure.

5. Release the key immediately when the engine starts and allow it to return to the RUN position.

6. Move the throttle control to the desired position.

   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.

   Important: Shut off the engine and allow the engine to cool before you check for oil leaks, loose parts, or other malfunctions.

Important: Allow the engine to idle for 5 minutes before shutting it off after a full-load operation. This allows the turbocharger to cool down before shutting off the engine. Failure to do so may lead to turbocharger 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 throttle control backward to the SLOW position.

2. Move the PTO switch to the OFF position.

3. Engage the parking brake.

4. Rotate the ignition key to the OFF position.

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

The engine-speed switch has 2 modes to change the engine speed. By momentarily tapping the switch, the engine speed increases or decreases in 100-rpm increments. By holding the switch down, the engine automatically moves to HIGH or LOW IDLE, depending on which part of the switch you pressed.

Supervisor (Protected Menu)

This feature allows the supervisor to set the maximum mowing speed in increments of 5% between 30 and 100%, at which the operator can mow (low range).

Refer to Setting the Maximum Allowed Mow Speed for the procedure to set the mow speed.

Operator

This feature allows the operator to adjust the maximum mowing speed (low range), within the supervisors pre-adjusted settings. When in the InfoCenter splash or main screen, press the middle button ( icon) to adjust the speed.

Note: When switching between low and high ranges, the settings will transfer based on the previous setting. The settings are reset when the machine is turned off.

Note: This feature may also be used in conjunction with cruise control.

Supervisor (Protected Menu)

This feature allows the supervisor to set the maximum transport speed in increments of 5% between 30 and 100%, at which the operator can transport (high range).

Refer to Setting the Maximum Allowed Transport Speed for the procedure to set the transport speed.

Operator

This feature allows the operator to adjust the maximum transport speed (high range) within the supervisor’s pre-adjusted settings. When in the InfoCenter splash or main screen, press the middle button ( icon) to adjust the speed.

Note: When switching between low and high ranges, the settings transfer based on the previous setting. The settings are reset when the machine is turned off.

Note: You can also use this feature in conjunction with cruise control.

The diesel-particulate filter (DPF) removes soot from the engine exhaust.

The DPF regeneration process uses heat from the engine exhaust that is increased by the catalyst to reduce accumulated soot into ash.

To keep the DPF clean, remember the following:

• Run the engine at full engine speed when possible to promote DPF self-cleaning.

• Use the correct engine oil.

• Minimize the amount of time that you idle the engine.

• Use only ultra low sulfur diesel fuel.

Operate and maintain your machine with the function of the DPF in mind. Engine under load generally produces adequate exhaust temperature for DPF regeneration.

Important: Minimize the amount of time that you idle the engine or operate the engine at low-engine speed to help reduce the accumulation of soot in the DPF.

Understanding the Regeneration Icons

Icon	Icon Definition
	• Parked or recovery regeneration icon-regeneration is requested.
	• Perform the regeneration immediately.
	• A regeneration is acknowledged and the request is processing.
	• A regeneration is in progress and the exhaust temperature is elevated.
	• NOx control system malfunction; the machine requires service.

Types of Diesel Particulate Filter Regeneration

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

Type of Regeneration	Conditions that cause DPF regeneration	DPF description of operation
Passive	Occurs during normal operation of the machine at high-engine speed or highengine 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.
Assist	Occurs because of low-engine speed, low-engine load, or after the computer detects the DPF is becoming obstructed with soot	•The InfoCenter does not display an icon indicating assist regeneration.
		• During assist regeneration, the engine computer adjusts the engine settings to raise the exhaust temperature.
Reset	Occurs every 100 hours	• When the high exhaust-temperature icon is displayed in the InfoCenter, a regeneration is in progress.
	Also occurs if normal engine operation surpasses the allowed soot accumulation amount within the filter
		• During reset regeneration, the engine computer maintains an elevated engine speed to ensure filter regeneration.

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

Type of Regeneration	Conditions that cause DPF regeneration	DPF description of operation
Parked	Occurs because the computer determines that the automatic DPF cleaning has not been sufficient.	• When the reset-standby/parked or recovery regeneration icon or a regeneration is requested.
	Also occurs because you initiate a parked regeneration
	May occur because the inhibit regen has been initiated and has disabled the automatic DPF cleaning from occuring	• Perform the parked regeneration as soon as possible to avoid needing a recovery regeneration.
	May result from using the incorrect fuel or engine oil	• A parked regeneration requires 30 to 60 minutes to complete.
		• You must have at least a 1/4 tank of fuel in the tank.
		• You must park the machine to perform a parked regeneration.
Recovery	Occurs because the request for parked recovery has been ignored, allowing the DPF to be critically plugged	• When the reset-standby/parked or recovery regeneration icon a recovery regeneration is requested.
		• A recovery regeneration requires up to 3 hours to complete.
		• You must have at least a 1/2 tank of fuel in the machine.
		• You must park the machine to perform a recovery regeneration.

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

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

1. Raise the seat and locate the bypass valves, which are located below the front of the fuel tank (Figure 39).

   

   Figure 39

   1. Bypass valve (2)

2. Rotate each valve 3 counter-clockwise turns to open and allow the fluid to bypass internally.

   Note: Do not open more than 3 turns. Because the fluid is bypassed, the machine can be slowly moved without damaging the transmission.

3. Push or tow the machine.

4. Finish pushing or towing the machine and close the bypass valves. Torque the valve to 70 N∙m (52 ft-lb).

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

Important: If you must push or tow the machine in reverse, bypass the check valve in the 4-wheel drive manifold.To bypass the check valve, connect a hose assembly to the reverse traction pressure test port (located on the hydrostat) and on the port located between ports M8 and P2 on the rear traction manifold (located behind the front tire). The hose assembly includes 1 hose (Part No. 95-8843), 2 coupler fittings (Part No. 95-0985), and 2 hydraulic fittings (Part No. 340-77).

There are jacking points located at the front and rear of the machine.

• On the frame at the inside of each front drive tire

• At the center of the rear axle

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

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

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

• Tie the machine down securely.

There are tie downs located at the front and rear sides of the machine (Figure 40).

Note: Use properly-rated DOT-approved straps in 4 corners to tie down the machine.

• 2 on the front of the operator's platform

• Rear bumper

Figure 40

1. Rear tie-down point
2. Front tie-down points

1. Unlatch and raise the hood.

2. Remove the hairpin cotter securing the hood pivot to the mounting brackets (Figure 41).

   

   Figure 41

   1. Hairpin cotter

3. Slide the hood to the right side, lift the other side, and pull it out of the brackets.

Note: Reverse this procedure to install the hood.

The machine has grease fittings that you must lubricate regularly with No. 2 lithium grease. Also, lubricate the machine immediately after every washing.

The grease-fitting locations and quantities are as follows:

Traction Unit

• 2 front and rear-axle-pivot bushings (Figure 42)

• 2 steering-cylinder-ball joints (Figure 43)

• 2 tie-rod-ball joints (Figure 43)

• 2 king-pin bushings (Figure 43).Lubricate the top fitting on the king pin annually (2 pumps).

Figure 42

Figure 43

Front Cutting Unit

• 2 caster-fork-shaft bushings (Figure 44)

• 3 spindle-shaft bearings—located under the pulley (Figure 45)

• 2 idler-arm-pivot bushings (Figure 45)

Figure 44

Figure 45

Front Lift Assemblies

• 2 (each side) lift-arm-cylinder bushings (Figure 46)

• 2 lift-arm-ball joints (Figure 47)

Figure 46

Figure 47

Side Cutting Unit

• 1 caster-fork-shaft bushing (Figure 48)

• 2 (each side) spindle-shaft bearings—located under the pulley

• 1 idler-arm-pivot bushings—located on the idler arm

Figure 48

Side Lift Assemblies

• 6 main lift-arm bushings (Figure 49 and Figure 50)

• 2 bell-crank-pivot bushings (Figure 51)

• 4 rear arm bushings (Figure 51)

• 4 lift-cylinder bushings (Figure 52)

Figure 49

Figure 50

Figure 51

Figure 52

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

Service the air-cleaner filter only when the service indicator (Figure 55) requires it. Changing the air filter before it is necessary only increases the chance of dirt entering the engine when you remove the filter.

Figure 55

1. Air-cleaner indicator

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

1. Replace the air cleaner (Figure 56).

   

   Figure 56

   Note: Do not clean a used element because cleaning it can damage the filter media.

   Important: Do not 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

2. Reset the indicator (Figure 55) if it shows red.

If engine faults , , or in the InfoCenter (Figure 58) display in the InfoCenter, clean the soot filter using the steps that follow:

Figure 58

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.

Service the water separator as shown in Figure 59.

After replacing the water separator, turn the key to ON for 10 seconds, but do not start the engine. Turn the key off and repeat this 2 more times.

Figure 59

1. Clean the area around the fuel-filter head (Figure 60).

   

   Figure 60

   1. Fuel-filter head
   2. Fuel filter

2. Remove the filter and clean the filter head mounting surface (Figure 60).

3. Lubricate the filter gasket with clean lubricating engine oil; refer to the engine owner's manual for additional information.

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

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

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, 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.

1. Open the battery cover on the side of the shroud (Figure 61).

   Note: Press down on the flat surface above the battery cover to ease the removal of the cover (Figure 61).

   

   Figure 61

   1. Battery cover
   2. Press down here.
   

   Figure 62

   1. Battery

2. Remove the rubber boot from the positive terminal and inspect the battery.

   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.

3. Coat both battery connections with Grafo 112X (skin-over) grease, Toro Part No. 505-47, petroleum jelly, or light grease to prevent corrosion.

4. Slide the rubber boot over the positive terminal.

5. Close the battery cover.

The traction-unit fuses are located under the power-center cover (Figure 63, Figure 64, and Figure 65).

Remove the 2 screws securing the power-center cover to the frame and remove the cover (Figure 63).

Figure 63

1. Power-center cover
2. Screws

Figure 64

1. Fuses

Figure 65

The cab fuses are located in the fuse box in the cab headliner (Figure 66 and Figure 67).

Note: Cab model only

Figure 66

1. Cab fuse box
2. Fuses

Figure 67

You can adjust the operating angle of the traction pedal for your comfort.

1. Loosen the 2 nuts and bolts securing the left side of the traction pedal to the bracket (Figure 68).

   

   Figure 68

   1. Traction pedal
   2. Mounting nuts and bolts

2. Pivot the pedal to the desired operating angle and tighten the nuts (Figure 68).

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

1. With machine on level surface, position the wheel so 1 check plug is at the 12 o'clock position and the other is at 3 o'clock position (Figure 69).

   

   Figure 69

   1. Check/drain plug (2)

2. Remove the plug at the 3 o’clock position (Figure 69).

   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.

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

1. With the machine on a level surface, position a wheel so a check plug is at the lowest (6 o'clock) position (Figure 70).

   

   Figure 70

   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 71).

   

   Figure 71

   1. Drain plug
   2. Brake housing

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 12 o'clock position.

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

   Important: If the planetary fills before the 0.65 L (22 fl 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 filled with SAE 85W-140 gear lube. The capacity is 2.4 L (80 fl 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 and ensure that the lubricant is up to the bottom of the hole (Figure 72).

   Note: If the level is low, remove the fill plug and add enough lubricant to bring the level up to the bottom of the check-plug holes.

   

   Figure 72

   1. Check plug
   2. Fill plug

The gearbox is filled with SAE 85W-140 gear lube. The capacity is 0.5 L (16 fl oz). Visually inspect for leaks daily.

1. Position the machine on a level surface.

2. Remove the check/fill plug from the left side of the gear box and ensure that lubricant is up to the bottom of the hole (Figure 73).

   Note: If the level is low, add enough lubricant to bring the level up to the bottom of the hole.

   

   Figure 73

   1. Gearbox
   2. Check/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 74).

3. Remove the check plugs to make draining the oil easier.

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

   

   Figure 74

   1. Drain-plug location

5. Clean the area around the drain plug at the bottom of the gear box (Figure 75).

6. Remove the drain plug from the gearbox and allow the oil to drain into a pan.

   Note: Remove the fill plug to make draining the oil easier.

   

   Figure 75

   1. Drain plug

7. Add enough oil to bring the level up to the bottom of the check plug holes; refer to Checking the Rear-Axle Lubricant.

8. Install the plugs.

1. Measure the center-to-center distance (at axle height) at the front and rear of the steering tires.

   Note: The front measurement must be 6 mm (1/4 inch) less than the rear measurement.

2. To adjust, loosen the clamps at both ends of the tie rods.

3. Rotate the tie-rod end to move the front of the tire inward or outward.

4. Tighten the tie-rod clamps when the adjustment is correct.

The coolant reservoir is filled at the factory with a 50/50 solution of water and ethylene glycol base extended-life coolant.

Important: Use only commercially available coolants that meet the specifications listed in the Extended Life Coolant Standards Table.Do not use conventional (green) inorganic-acid technology (IAT) coolant in your machine. Do not mix conventional coolant with extended-life coolant.

Coolant Type Table

Extended Life Coolant Standards

Important: Coolant concentration should be a 50/50 mixture of coolant to water.

• Preferred: When mixing coolant from a concentrate, mix it with distilled water.

• Preferred option: If distilled water is not available, use a pre-mix coolant instead of a concentrate.

• Minimum requirement: If distilled water and pre-mix coolant are not available, mix concentrated coolant with clean drinkable water.

Check the coolant level at the beginning of each day. The capacity of the system is 8.5 L (9 US qt).

1. Carefully remove the radiator cap and expansion-tank cap (Figure 76).

2. Check the coolant level in the radiator.

   Note: The radiator should be filled to the top of the filler neck and the expansion tank filled to the Full mark.

   

   Figure 76

   1. Expansion tank

3. If the coolant is low, add a 50/50 mixture of water and ethylene glycol anti-freeze.

   Important: Do not use water only or alcohol/methanol based coolants, as this may cause damage.

4. Install the radiator cap and expansion-tank cap.

Remove debris from the oil radiator/oil cooler 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 the radiator/oil cooler and screen debris buildup. While this feature can help reduce the time required to clean radiator/oil cooler, it does not eliminate the need for routine cleaning. Periodic cleaning and inspection of the radiator/oil cooler is still required.

1. Shut off the engine, remove the key, and raise the hood.

2. Clean the engine area thoroughly of all debris.

3. Clean both sides of the radiator/oil cooler area thoroughly with compressed air (Figure 77).

   Note: Start from the fan side and blow the debris out toward the back. Then, clean from the back side and blow toward the front. Repeat this procedure several times until all chaff and debris is removed.

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

   

   Figure 77

   1. Radiator/oil cooler

4. Close the hood.

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 you feel braking resistance.

1. Release 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 as follows:

   1. Loosen the front nut on the threaded end of the brake cable (Figure 78).

      

      Figure 78

      1. Brake cable

   2. Tighten the rear nut to move the cable rearward 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.

Proper tension of the belt allows 10 mm (3/8 inch) of deflection when a force of 44 N∙m (10 ft-lb) is applied on the belt midway between the pulleys.

If the deflection is not 10 mm (3/8 inch), loosen the alternator-mounting bolts (Figure 79).

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

Figure 79

1. Alternator
2. Mounting bolt
3. Compressor
4. Idler pulley

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

2. If the deflection is not 10 mm (3/8 inch), loosen the idler pulley mounting bolt (Figure 79).

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

When properly tensioned, the inside measurement of the extension spring (hook to hook) should be approximately 8.3 to 9.5 cm (3-1/4 to 3-3/4 inches). Once the correct spring tension is attained, adjust the stop bolt (carriage bolt) until there is approximately 2 to 5 mm (0.065 to 0.185 inch) clearance between the head of the bolt and the idler arm (Figure 80).

Note: Ensure that the belt is positioned on the spring side of the belt guide (Figure 80).

Figure 80

1. Extension spring
2. Stop bolt
3. Flange nut
4. Belt guide
5. Measurement (hook to hook)—approximately 8.3 to 9.5 cm (3-1/4 to 3-3/4 inches)
6. Eye bolt
7. Belt

The blade-drive belt, tensioned by the spring-loaded idler pulley, is very durable. However, after many hours of use, the belt will show signs of wear. Signs of a worn belt include squealing when the belt is rotating, blades slipping when cutting grass, frayed edges, burn marks, and cracks. Replace the belt if any of these conditions are evident.

1. Lower the cutting unit to the shop floor, remove the belt covers from the top of the cutting unit, and set the covers aside.

2. Loosen the eye bolt allowing the removal of the extension spring (Figure 80).

3. Loosen the flange nut securing the stop bolt to the mounting tab and move the idler pulley away from the belt to release the belt tension (Figure 80).

   Note: Loosen the nut enough to allow the idler arm to pass the stop bolt.

   Note: If the stop bolt is ever removed from the mounting tab, make sure that it is installed again in the hole that aligns the stop-bolt head with the idler arm.

4. Remove the bolts securing the hydraulic motor to the cutting unit (Figure 81).

   

   Figure 81

   1. Hydraulic motor
   2. Mounting bolts

5. Lift the motor off the cutting unit and lay it on top of the cutting unit.

6. Remove the old belt from around the spindle pulleys and idler pulley.

7. Route the new belt around the spindle pulleys and idler-pulley assembly.

8. Position the hydraulic motor on the cutting unit after routing the belt around the pulleys. Mount the motor to the cutting unit with the bolts previously removed.

   Note: Ensure that the belt is positioned on the spring side of the belt guide (Figure 80).

9. Connect the extension spring (Figure 80) to the eye bolt and tension the belt as follows:

   • When properly tensioned, the inside measurement of the extension spring (hook to hook) should be approximately 8.3 to 9.5 cm (3-1/4 to 3-3/4 inches).

   • When you attain the correct spring tension, adjust the stop bolt (carriage bolt) until there is approximately 2 to 5 mm (0.065 to 0.185 inches) clearance between the head of the bolt and the idler arm.

Note: Although not needed for normal maintenance procedures, you can pivot (tilt) the front cutting unit to an upright position.

1. Raise the front cutting unit slightly off the floor, engage the parking brake, shut off the engine, and remove the key.

2. Remove the hairpin cotter and clevis pin securing the deck-transport latch to the latch plate and pivot the latch toward the rear of the deck.

3. Remove the hairpin cotter and clevis pin securing the height-of-cut chains to the rear of the cutting unit.

4. Start the engine, slowly raise the front cutting unit, shut off the engine, and remove the key.

5. Grasp the front of the cutting unit and lift it to an upright position.

6. Hold the cutting unit upright, fit the cable end over the pin on the cutting unit lift arm, and secure it with the hairpin cotter (Figure 86).

   

   Figure 86

   1. Cable
   2. Pin

1. With the help of another person, hold the cutting unit upright, remove the hairpin cotter securing the cable end, and remove the cable from the pin.

2. Pivot (tilt) the cutting unit downward.

3. Store the cable under the operator's platform.

4. Sit on the seat, start the engine, and lower the cutting unit until it is slightly off the floor.

5. Shut off the engine, wait for all parts to stop moving, and remove the key.

6. Secure the height-of-cut chains to the rear of the cutting unit.

7. Pivot the transport latch upward into position and secure it with the clevis pin and cotter pin.

1. Remove the locknut from the bolt holding the caster-wheel assembly between the caster fork (Figure 90) or the caster-pivot arm (Figure 91).

   Note: Grasp the caster wheel and slide the bolt out of the fork or pivot arm.

   

   Figure 90

   1. Caster bolt
   2. Caster fork
   3. Bearing
   4. Bearing spacer
   

   Figure 91

   1. Caster wheel
   2. Caster-pivot arm
   3. Bearing
   4. Bearing spacer

2. Remove the bearing from the wheel hub and allow the bearing spacer to fall out (Figure 90 and Figure 91).

3. Remove the bearing from the opposite side of the wheel hub.

4. Check the bearings, spacer, and inside of the wheel hub for wear and replace any damaged parts.

5. To assemble the caster wheel, push the bearing into the wheel hub.

   Note: When installing the bearings, press on the outer race of the bearing.

6. Slide the bearing spacer into the wheel hub and push the other bearing into the open end of the wheel hub to captivate the bearing spacer inside the wheel hub.

7. Install the caster-wheel assembly between the caster fork and secure it in place with the bolt and locknut.

After striking a foreign object, inspect the machine for damage and make repairs before starting and operating the equipment. Torque all of the spindle-pulley nuts to 176 to 203 N∙m (130 to 150 ft-lb).

1. Position the machine on a level surface, raise the cutting unit, engage the parking brake, put the traction pedal in NEUTRAL, put the PTO lever in the OFF position, shut off the engine, and remove the ignition key.

   Note: Block the cutting unit to prevent it from accidentally falling.

2. Rotate the blade until the ends face forward and backward and measure from the inside of the cutting unit to the cutting edge at the front of the blade (Figure 92).

   Note: Remember this dimension.

   

   Figure 92

3. Rotate the opposite end of the blade forward and measure between the cutting unit and cutting edge of the blade at the same position as in step 2.

   Note: The difference between the dimensions obtained in steps 2 and 3 must not exceed 3 mm (1/8 inch). If the dimension exceeds 3 mm (1/8 inch), the blade is bent and must be replaced; refer to Removing and Installing the Cutting-Unit Blade(s).

Replace the blade if it hits a solid object, is out of balance, or is bent. Always use genuine Toro replacement blades to ensure safety and optimum performance.

1. Park the machine on a level surface, raise the cutting unit to the transport position, engage the parking brake, shut off the engine, and remove the key.

   Note: Block or lock the cutting unit to prevent it from accidentally falling.

2. Grasp the end of the blade using a rag or thickly-padded glove.

3. Remove the blade bolt, anti-scalp cup, and blade from the spindle shaft (Figure 93).

   

   Figure 93

   1. Blade bolt
   2. Anti-scalp cup

4. Install the blade, anti-scalp cup, and blade bolt and tighten the blade bolt to 115 to 149 N∙m (85 to 110 ft-lb).

   Important: The curved part of the blade must be pointing toward the inside of the cutting unit to ensure proper cutting.

   Note: After striking a foreign object, torque all spindle-pulley nuts to 115 to 149 N∙m (85 to 110 ft-lb).

Both cutting edges and the sail, which is the turned-up portion opposite of the cutting edge, contribute to a good quality of cut.

Maintain sharp blades throughout the cutting season. Sharp blades create a clean cut without tearing or shredding the grass blades.

Check the blades for any wear or damage. The sail lifts the grass up straight, thereby producing an even cut and gradually wears down during operation.

1. Park the machine on a level surface, raise the cutting unit, engage the parking brake, put the traction pedal in NEUTRAL, put the PTO lever in the OFF position, shut off the engine, and remove the key from the ignition.

2. Examine the cutting ends of the blade carefully, especially where the flat and curved parts of the blade meet (Figure 94).

   Note: Because sand and abrasive material can wear away the metal that connects the flat and curved parts of the blade, check the blade before using the mower. If you notice wear (Figure 94), replace the blade.

   

   Figure 94

   1. Cutting edge
   2. Curved area
   3. Wear/slot forming
   4. Crack

3. Examine the cutting edges of all of the blades and sharpen the cutting edges if they are dull or nicked (Figure 95).

   Note: Sharpen only the top of the cutting edge and maintain the original cutting angle to ensure sharpness (Figure 95). The blade remains balanced if the same amount of metal is removed from both cutting edges.

   

   Figure 95

   1. Sharpen at the original angle.

   Note: Remove the blades and sharpen them on a grinder. After sharpening the cutting edges, install the blade with the anti-scalp cup and blade bolt; refer to Removing and Installing the Cutting-Unit Blade(s).

When there is mismatch between the blades on a single cutting unit, the grass appears streaked when it is cut. You can correct this problem by ensuring that the blades are straight.

1. Park the machine on a level surface.

2. Raise the height of cut to the highest position; refer to Adjusting the Height of Cut.

3. Lower the cutting unit onto the flat surface and remove the covers from the top of the cutting unit.

4. Loosen the flange nut that secures the idler pulley to release the belt tension.

5. Rotate the blades until the ends face forward and rearward and measure from the floor to the front tip of the cutting edge. Remember this dimension.

6. Rotate the same blade so that the opposite end is forward, and measure again. The difference between the dimensions must not exceed 3 mm (1/8 inch). If the dimension exceeds 3 mm (1/8 inch), replace the blade, as it is bent. Measure all the blades.

7. Compare the measurements of the outer blades with the center blade.

   Note: The center blade must not be more than 10 mm (3/8 inch) lower than the outer blades. If the center blade is more than 10 mm (3/8 inch) lower than the outer blades, proceed to step 8 and add shims between the spindle housing and the bottom of the cutting unit.

8. Remove the bolts, flat washers, lock washers, and nuts from the outer spindle in the area where you must add the shims.

   Note: To raise or lower the blade, add a shim (Part No. 3256-24) between the spindle housing and the bottom of the cutting unit. Continue to check the alignment of the blades and add shims until the tips of the blades are within the required dimension.

   Important: Do not use more than 3 shims at any 1 hole location. Use decreasing numbers of shims in adjacent holes if more than 1 shim is added to any 1 hole location.

9. Adjust the idler pulley and install the belt covers.

Important: Use care around the cab seals and lights (Figure 96). If you are using a pressure washer, keep the washer wand at least 0.6 m (2 ft) away from the machine. Do not use the pressure washer directly on the cab seals and lights or under the rear overhang.

Figure 96

1. Seal
2. Light
3. Keep wand 0.6 m (2 ft) away.
4. Do not pressure-wash under the rear overhang.

1. Remove the screws and grates from both the in-cab and rear cab air filters (Figure 97 and Figure 98).

   

   Figure 97

   In-Cab Air Filter

   1. Filter
   2. Grate
   3. Screw
   

   Figure 98

   Rear Cab Air Filter

   1. Filter
   2. Grate
   3. Screw

2. Clean the filters by blowing clean, oil-free, compressed air through them.

   Important: If either filter has a hole, tear, or other damage, replace the filter.

3. Install the filters and the grate with the thumbscrews.

The purpose of the cab pre-filter is to prevent large debris, such as grass and leaves, from entering the cab filters.

1. Rotate the screen cover down.

2. Clean the filter with water.

   Note: Do not use a pressure washer.

   Important: If the filter has a hole, tear, or other damage, replace the filter.

3. Allow the pre-filter to dry before installing it into the machine.

4. Rotate the filter screen around the tabs until the latch locks into the latch-mount assembly (Figure 99).

   

   Figure 99

   1. Latch-mount assembly
   2. Latch
   3. Screen cover

1. Disconnect the wire for each fan.

   

   Figure 100

   Right fan shown

   1. Fan
   2. Wire
   3. Knob

2. Remove the 2 knobs and remove the fan assembly.

3. Open the 4 latches on the air-conditioning assembly and remove the screen.

   

   Figure 101

   1. Air-conditioning coil
   2. Latch
   3. Air-conditioning screen

4. Remove the air filters (see Figure 98).

5. Clean the air-conditioning assembly.

6. Install the air filters, screen, and fan assembly (Figure 98, Figure 100, and Figure 101).

7. Connect the wire for each fan (Figure 100).