Groundsmaster® 4500-D or 4700-D 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 9).

Figure 9

1. Weight gauge
2. Weight adjustment lever
3. Seat adjustment lever
4. Seat-back adjustment lever
5. Armrest adjustment knob

Rotate the knob to adjust the armrest angle (Figure 9).

Move the lever to adjust the seat-back angle (Figure 9).

The weight gauge indicates when the seat is adjusted to the operator’s weight (Figure 9). Adjust the height by positioning the suspension within the range of the green region.

Use this lever to adjust the seat to your weight (Figure 9). Pull the lever up to increase the air pressure and push the lever down to decrease the air pressure. The proper adjustment is correct when the weight gauge is in the green region.

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 Level.

Drain water or other contaminants from the water separator; refer to Draining Water from the Fuel/Water Separator.

Check the rear axle and rear-axle gearbox for leaks; refer to Checking the Rear Axle and Gearbox for Leaks.

The correct air pressure in the tires is 138 kPa (20 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 12

Torque the wheel lug nuts to 115 to 136 N∙m (85 to 100 ft-lb) in the order shown in Figure 13 and Figure 14.

Figure 13

Front Wheels

Figure 14

Rear Wheels

Important: The rotary cutting units often cut approximately 6 mm (1/4 inch) lower than a reel cutting unit with the same bench setting. It may be necessary to set the rotary cutting-unit bench measurement at 6 mm (1/4 inch) above that of reel cutting units cutting in the same area.

Important: Access to the rear cutting units is greatly improved by removing the cutting unit from the machine.

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

2. Loosen the bolt securing each height-of-cut bracket to the height-of-cut plate (front and each side) as shown in Figure 15.

3. Beginning with front adjustment, remove the bolt.

   

   Figure 15

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

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

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

   

   Figure 16

6. Position the tapped plate in-line with the spacer.

7. Install the bolt finger-tight.

8. Repeat steps 4 through 7 for each side adjustment.

9. Torque all 3 bolts to 41 N∙m (30 ft-lb). Always tighten the front bolt first.

   Note: Adjustments of more than 3.8 cm (1-1/2 inches) may require temporary assembly to an intermediate height to prevent binding (e.g., changing from 3.1 to 7 cm (1-1/4 to 2-3/4 inches) height of cut).

The interlock switches are designed to shut off the machine when you rise from the seat when the traction pedal is pressed. However, you can rise from the seat while the engine is running and the traction pedal is in the NEUTRAL position. Although the engine continues to run when you disengage the PTO switch and release the traction pedal, shut off the engine before rising from the seat.

1. Park the machine on a level surface, engage the parking brake, lower the cutting units, and turn the key to the OFF position.

2. Press the traction pedal and turn the key to the ON position.

   Note: If the engine cranks, there is a malfunction in the interlock system. Correct this malfunction before operating the machine.

3. Turn the key to the ON position, rise from the seat, and move the PTO switch to ON.

   Note: The PTO should not engage. If the PTO engages, there is a malfunction in the interlock system. Correct this malfunction before operating the machine.

4. Engage the parking brake, turn the key to the ON position and move the traction pedal out of the NEUTRAL position.

   Note: The InfoCenter displays "traction denied" and the machine should not move. If the machine does move, there is a malfunction in the interlock system. Correct this malfunction before operating the machine.

Note: Lower the cutting units onto a clean section of turf or hard surface to avoid throwing dust and debris.

To verify this stopping time, sit in the seat and disengage the PTO. Listen for the rotating blades and record the time it takes for the blades to come to a complete stop. If it takes longer than 7 seconds, adjust the braking valve. Call your authorized Toro distributor for assistance in making this adjustment.

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 17

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
	Virtual pedal stop settings
	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.
	The power take-off is disabled.
	The PTO is on.
	Battery
	Warning
	Active
	Inactive
	Previous
	Next
	Increase
	Decrease
	Previous screen
	Next screen
	Increase value
	Decrease value
	Menu
	Scroll up/down
	Scroll left/right
	Hydraulic-fluid temperature (°C or °F)
	Fast or High range (transport)
	Slow or Low range (mow)
	Fan (fan reversal)
	All cutting units up
	All cutting units down
	Center cutting units up
	Center cutting units down
	Left cutting units up
	Left cutting units down
	Right cutting units up
	Right cutting units down
	Locked

Accessible only by entering PIN

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:

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.
Traction Pedal
Traction Pump
Fan	Indicates if the fan is active in the following instances: Engine high temp, oil high temp, engine or hydraulic high temp, and fan on
Fuel Rate	Shows the fuel rate being used.
DPF Regeneration	The diesel particulate filter regeneration option and DPF submenus

Diagnostics—Menu Item	Description
Left Cutting Unit	Refer to the Service Manual or your authorized Toro distributor for more information on the Engine Run menu and the information contained there.
Center Cutting Unit
Right Cutting Unit
Traction
HI/LO Range
PTO
Engine
CAN Statistics

Settings—Menu Item	Description
Enter PIN	Allows a person (superintendent/mechanic) authorized by your company with the PIN code to access protected menus.
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).
Protected Menus	Allows a person authorized by your company with the PIN code to access protected menus
Protect Settings	Allows the ability to change the settings in the protected settings.

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

Machine Settings—Menu Item	Description
Mow Speed	Controls the maximum speed while in mow (low range)
Trans. Speed	Controls the maximum speed while in transport (high range)
Smart Power	Turns Smart Power on and off
Counterbalance	Controls the amount of counterbalance applied by the cutting units
Turnaround	Turns Turnaround on and off
Acceleration	Low, Medium, and High settings control how quickly the traction speed reacts when you move the traction pedal.

Protected under Protected Menus—accessible only by entering PIN

About—Menu Item	Description
Model	Lists the model number of the machine.
SN	Lists the serial number of the machine.
Machine Controller Revision	Lists the software revision of the master controller.
S/W Revision	Lists the software revision of the primary controller.
InfoCenter Revision	Lists the software revision of the InfoCenter
Secondary software	Shows the part number and revision of the cutting unit controller for the Groundsmaster 4700 model.
Stage V	Shows yes or no depending on the engine.

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.

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

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

1. In SETTINGS, scroll down to DPF RENGERATION and press the select button.

2. In DPF RENGERATION, scroll down to TECHNICIAN and press the select button.

   

   Figure 20

Figure 21

1. Diagnostic light

• Flashing red—active fault

• Solid red—active advisory

• Solid blue—calibration/dialog messages

• Solid green—normal operation

This machine displays estimated traction speeds in a percentage.

The speed is displayed between 10 and 100% for the cruise and virtual pedal stop screens, and displayed between 30 and 100% in the MACHINE SETTINGS menu.

When starting the machine in cold weather, warm-up mode limits the engine speed to low idle for a short period after the engine is started, preventing potential component damage from operating the machine with cold oil.

A snowflake icon on the InfoCenter screen denotes when warm-up mode is active. Do not operate the machine until after the warm-up period.

• This machine has an automotive-style throttle that is controlled by the traction pedal.

• This machine does not have a separate throttle switch or throttle lever.

• When you remove your foot from the traction pedal, the machine dynamically brakes to a stop.

• The pedal controls are optimized to provide a reactive yet stable response, allowing you to maintain consistent control over rough terrain, while still allowing for quick, smooth braking.

• While transporting, the traction pedal will operate similar to a car and change the engine and traction speed dependent on the traction pedal position.

• When mowing, the engine speed will automatically raise to high idle.

• If the engine is at low idle, performing a function like lifting the cutting units or pressing the traction pedal raises the engine speed to a minimum working speed, providing enough power to efficiently perform the function.

• Limit the machine idle time as recommended for diesel particulate filter (DPF) regeneration. Shut of the machine to prevent extended idling time.

• The maximum speeds set in the PIN protected menu settings are set by the supervisor to limit the machine’s maximum traction speed.

• The achievable traction pedal use, cruise control, and pedal stop traction speeds are all limited by the maximum speeds set in the PIN protected menu.

• When you start the engine and the hydraulic fluid temperature is low, the engine speed automatically increases to optimize operation and warms up the machine. The engine speed automatically returns to low idle after the hydraulic fluid temperature is in a normal operating range.

• Under normal operating conditions, this machine is intended to operate in the H/L AUTO position on the speed range switch (Figure 22). This position allows the machine to automatically switch between low and high speed ranges, depending on whether the machine is being used for mowing or transporting.

• When you select the LOW position on the speed range switch (Figure 22), the machine will always operate in low speed range. This setting is preferable for operation in a shop area, loading or unloading from a trailer, climbing steep inclines, or any other operation where the higher traction speeds of the high speed range is not desired.

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

• When transporting the machine between work areas, engage the AUTO HI/LOW range, shut off the PTO, and raise the cutting units to the fully upward position. This allows the traction pedal to operate like a car.

• Always drive slowly in rough areas.

This machine is equipped with 2 traction speed ranges; low and high. The speed range switch allows you to select the following positions (Figure 22):

• High/Low Auto range:

  Selecting the H/L AUTO position allows the machine to automatically select between the low and high speed ranges. The H/L AUTO position is comparable to selecting D (drive) in your car with an automatic transmission.

  Note: To prevent potential turf damage, the machine will only shift between low and high range when the traction pedal is in NEUTRAL position and the wheels have stopped moving.

  Note: The cutting units cannot be lowered from the transport position while you drive the machine in the high speed range.

  • When H/L AUTO position is selected and the cutting units are lowered for mowing, the speed range is limited to the low speed range.

  • To get to high speed range, select the H/L AUTO position on the speed range switch, disengage the PTO, and fully raise the cutting units.

  • When H/L AUTO position is selected, the machine will automatically switch between high and low traction ranges based on the position of the cutting units and/or the position of the PTO switch.

• Low range:

  Selecting the LOW position on the switch keeps the machine in the low speed range at all times. The LOW position is comparable to selecting 2, 1 OR L in your car with an automatic transmission.

  • When the LOW position is selected, the machine only operates in low range.

  • Use the LOW position when loading the machine on a trailer or navigating tight areas like a shop.

  

  Figure 22

  Speed Range Switch

  1. H/L AUTO position
  2. LOW position

This pedal controls the forward and reverse speed of the machine and the dynamic braking when you return it to neutral.

• The traction pedal is an automotive-style throttle—the engine speed and the machine speed respond to the pedal movement.

• While transporting, the traction pedal will operate similar to a car and change the engine and traction speed dependent on the traction pedal position.

• While mowing, the engine automatically raises to high idle to optimize mowing performance, and the traction pedal only controls traction speed.

• The further you push the pedal forward or reverse, the faster the machine moves.

• To control the machine to a smooth stop while transporting or mowing, use your foot to return the traction pedal to neutral at your desired rate.

• To engage maximum braking, remove your foot from the traction pedal, allowing it to return to neutral. The machine dynamically brakes to a stop.

This traction system allows you to customize the acceleration settings for operator comfort and course conditions. Refer to Understanding the Acceleration Mode for changing the settings.

Figure 23

1. Traction pedal

The virtual pedal stop (VPS) feature allows you to set the temporary maximum traction-speed limits for both the mow and transport range.

To access this feature, select the InfoCenter up or down navigation button from the main menu (Figure 24).

• Use the VPS to adjust the maximum traction speed to match your comfort level or to fit the application.

• You cannot adjust the VPS speed limit faster than the supervisor-protected maximum traction speed.

• VPS is a temporary setting. This feature reverts back to the supervisor speed settings when the key is switched to the OFF position.

• When the traction speed is changed by the supervisor in the protected menu settings or by you through the VPS, the traction pedal automatically reprograms to use the full pedal stroke between neutral and the new maximum-speed setting.

• Lowering the maximum traction-speed settings allows you to precisely control the traction system.

  

  Figure 24

  1. Indicates the maximum traction speed (pedal stop)
  2. This speed is locked out under the protected PIN menu.

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 25).

• 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.

Figure 25

1. Left brake pedal
2. Pedal-locking latch
3. Parking-brake pedal
4. Right brake pedal

This setting determines how quickly the machine changes traction speed, and effects the deceleration of the machine in the low speed range. Enter the protect menus in the InfoCenter to change the acceleration mode. The acceleration mode has the following 3 positions:

• Low—low acceleration and deceleration

• Medium—medium acceleration and deceleration

• High—highest acceleration and deceleration

The turnaround mode allows you convenient, 1-touch control to raise the cutting units above the turf while temporarily stopping the blades, allowing you to focus on driving the machine at the end of a mowing pass, or while navigating other obstacles.

Note: The turnaround mode is a feature in the protected settings.

• When the turnaround mode is set to the ON position, you momentarily press the lift switch rearward (Figure 6) to automatically raise all cutting units from the float position to a preset height, automatically disengaging the PTO. To resume mowing, press the lift switch forward. All the cutting units lower, and the PTO starts again.

• When the turnaround mode is set to the OFF position, you manually raise the cutting units from the float position by pressing and holding all lift switches rearward until the cutting units raise to the desired height. For Groundsmaster 4700 machines, press all 3 lift switches to raise all 7 cutting units (Figure 6). The PTO does not disengage until the cutting units raise to the same preset height to which the cutting units raise when the turnaround-mode is set to ON.

Note: By default, the turnaround mode is ON.

The counterbalance system maintains hydraulic back pressure on the cutting-unit lift cylinders. The counterbalance system monitors the real-time traction pressure, dynamically changing the lift-cylinder back pressure to optimize traction capability and after-cut appearance. 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 Setting the Counterbalance.

The customizable counterbalance setting controls are as follows:

• Low—the most amount of weight on cutting units and the lowest weight on the drive wheels

• Medium—medium weight on cutting units and the drive wheels

• High—the least amount of weight on cutting units and the highest weight on machine drive wheels

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.

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. Turn the key to the RUN position. The glow indicator should illuminate.

3. When the glow indicator dims, turn the 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.

4. Release the key immediately when the engine starts and allow it to return to the RUN 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 premature turbocharger failure.

Note: Lower the cutting units to the ground whenever the 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. Engage the parking brake.

3. Rotate the ignition key to the OFF position.

4. Remove the key to prevent accidental starting.

Note: Cutting grass at a rate that loads the engine promotes DPF regeneration.

1. Disengage the brake, disengage the PTO, and raise the cutting units.

2. Select the H/L AUTO or LOW position with the speed range switch. Refer to Using the High and Low Speed Range Switch.

   Note: When the H/L AUTO position is selected and the cutting units are raised, the machine will automatically select the high speed range.

3. Using the traction pedal like an accelerator pedal on a car, drive the machine to the job site.

4. Align the machine outside the cutting area for the first cutting pass.

5. Lower the cutting units with the rocker switch or switches.

6. Tap the lift switch (GM4500) or middle-lift switch (GM4700) rearward to lift the cutting units to the turnaround position.

   Note: The turnaround position is only available if it is activated under the protected menus in the InfoCenter. Tapping the rocker switch without holding it raises the cutting units to the turn around position and stops the rotation of the blades until the cutting units are lowered.

7. Pull the PTO switch to engage the cutting units.

   Note: The engine speed automatically rises to high idle when you lower the cutting units and activate the PTO switch.

8. Using the traction pedal, approach the mowing area slowly and lower the cutting units with the rocker switch once the front cutting units are over the mowing area.

   Note: Practice to ensure the cutting units do not lower early or mow an unintended area.

9. Begin mowing the area.

10. When you complete the mowing pass, tap the lift switch (GM4500) or middle-lift switch (GM4700) rearward to lift the cutting units to the turn around position.

11. Perform a tear-shaped turn to quickly line up for your next pass.

12. Press the lift switch (GM4500) or middle-lift switch (GM4700) down to automatically lower the cutting units from the turnaround position and continue mowing.

The engine cooling fan is normally controlled by the machine. The machine has the ability to reverse the fan to blow debris off the rear screen. Under normal operating conditions, the machine controls the fan speed and direction based on coolant and hydraulic-fluid temperature, and the fan automatically reverses direction to blow debris off the rear screen.

You can manually reverse the fan by the 2 inside left and right buttons of the InfoCenter (Figure 28) for 2 seconds—the fan completes a manually initiated reverse cycle. Reverse the fan when the rear screen is clogged or prior to moving the machine into the shop or a storage area.

Figure 28

1. Outer buttons
2. Inside left and right buttons

Use the cutting-unit storage lanyards to prevent the forward outer cutting units from settling when the machine is parked overnight or if it is being stored for an extended period. You can also use the cutting-unit storage lanyards to prevent the cutting units from settling while the machine is transporting between mowing tasks.

Figure 29

Stowing the Lanyards

Note: Stow the lanyards when you are not using them.

1. Ensure that the PTO is disengaged.

2. Park the machine on a level surface.

3. Engage the parking brake.

4. With the cutting units lowered, slip the loop of the lanyard into the slot in the reinforcement plate of the roller support (Figure 31).

Figure 31

1. Reinforcement-plate slot (roller support)
2. Lanyard loop

Use the 2 rear-transport latches for the No. 6 and 7 cutting units (Figure 10) from settling when the machine is parked overnight, when moving the machine over long distances, rough terrain, when transporting, or storing the machine.

Figure 32

• 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.

In an emergency, you can move the machine forward by actuating the bypass function 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 relief valves must be open whenever you push or tow the machine.

1. Open the hood and locate the relief valves (Figure 33) on the top of pump, behind the battery/storage boxes.

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

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

   

   Figure 33

   1. Relief valve (2)

3. Push or tow the machine forward.

   Important: If you must push or tow the machine in reverse, refer to the Reverse Tow Kit (Part No. 136-3620).

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

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

• On each side of the frame by the operator’s platform (Figure 35)

• On the rear bumper (Figure 35)

Figure 34

Figure 35

Use the following as points to lift the machine:

Front of the machine—at the frame of the machine, forward of the wheel-drive motors (Figure 36)

Important: Do not support the machine at the wheel-drive motors. Keep the lifting equipment clear of hydraulic tubing and hoses.

Figure 36

Rear of the machine—at the center of the axle (Figure 37)

Locate the jackstands of the specified capacity at both sides of the gear case and under the axle.

Important: Do not support the machine at the tie rod.

Figure 37

Tilt the hood to access the chassis as shown in Figure 38.

Figure 38

Tilt the seat to access the hydraulic lift compartment as shown in Figure 39.

Figure 39

Grease specification: No. 2 lithium grease

The grease fitting locations and quantities are as follows:

• Brake-shaft pivot bearings (5) as shown in Figure 40

  

  Figure 40

• Rear-axle-pivot bushings (2) as shown in Figure 41

  

  Figure 41

• Steering-cylinder ball joints (2) as shown in Figure 42

  

  Figure 42

  1. Top fitting on kingpin

• Tie-rod ball joints (2) as shown in Figure 42

• Kingpin bushings (2) as shown in Figure 42

  Important: Lubricate the top fitting on the kingpin no more than annually (2 pumps).

• Lift-arm bushings (1 per cutting unit) as shown in Figure 43

  

  Figure 43

• Lift-cylinder bushings (2 per cutting unit) as shown in Figure 43

• Cutting-unit spindle-shaft bearings (2 per cutting unit) as shown in Figure 44

  Note: You can use either fitting, whichever is more accessible. Pump grease into the fitting until a small amount appears at the bottom of the spindle housing (under the cutting unit).

  

  Figure 44

• Cutting-unit carrier-arm bushings (1 per cutting unit) as shown in Figure 44

• Rear roller bearings (2 per cutting unit) as shown in Figure 45

  

  Figure 45

  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 the 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 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 46) 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 46

1. Air-cleaner indicator

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

1. Replace the air cleaner (Figure 47).

   

   Figure 47

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

   Important: Never attempt to clean the safety filter (Figure 48). Replace the safety filter after every 3 primary filter services.

   

   Figure 48

   1. Air-cleaner safety filter

2. Reset the indicator (Figure 46) if it shows red.

In addition to the listed service interval, drain and clean the tank if the fuel system becomes contaminated or if you are storing the machine for an extended period. Use clean fuel to flush out the tank.

Inspect the fuel lines for deterioration, damage, or loose connections.

1. Clean the area around the fuel-filter head (Figure 54).

   

   Figure 54

   1. Fuel-filter head
   2. Fuel filter

2. Remove the filter and clean the filter head mounting surface (Figure 54).

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. Prime the filter and the lines to the high pressure pump; refer to Priming the Fuel System.

6. Start the engine and inspect for leaks around the filter head again.

The fuel-pickup tube, located inside the fuel tank, is equipped with a screen to help prevent debris from entering the fuel system. Remove the fuel-pickup tube and clean the screen as required.

1. Remove the hose clamp that secures the fuel supply hose to the fitting of the fuel-pickup tube (Figure 55).

   

   Figure 55

   1. Fitting (fuel-pickup tube)
   2. Hose clamp
   3. Fuel supply hose
   4. Rubber bushing
   5. Screen

2. Separate the hose from the fitting (Figure 55).

3. Lift the fuel-pickup tube from the fuel tank (Figure 55).

   Note: Lift the tube straight from the bushing in the tank.

4. Clean any debris from the screen at the end of the fuel-pickup tube (Figure 55).

5. Insert the fuel-pickup tube through the rubber bushing and into the tank (Figure 55).

   Note: Ensure that the fuel-pickup tube is fully seated into the rubber bushing.

6. Install the supply hose onto the fitting of the fuel-pickup tube, and secure the hose with the hose clamp that you removed in step 1.

Prime the fuel system before starting the engine for the first time, after running out of fuel, or after fuel system maintenance (e.g., draining the filter/water separator, replacing a fuel hose).

To prime the fuel system, perform the following steps:

1. Ensure that fuel is in the fuel tank.

2. Perform the following steps to prime the filter and the lines to the high pressure pump to prevent wear or damage to the pump:

   1. Cycle the key to the ON position for 15 to 20 seconds.

   2. Cycle the key to the OFF position for 30 to 40 seconds.

      Note: This allows the ECU to power down.

   3. Cycle the key to the ON position for 15 to 20 seconds.

   4. Inspect for leaks around the filter and hoses.

Important: Do not use the engine starter motor to crank the engine to prime the fuel system.

Important: Before welding on the machine, disconnect the negative cable from the battery to prevent damage to the electrical system. Also, you must disconnect the engine, InfoCenter, and machine controllers before welding on the machine.

Note: Keep the terminals and the entire battery case clean, because a dirty battery discharges 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. Loosen the latch for the cover of the right storage box and raise the cover (Figure 58).

   Danger

   Battery electrolyte contains sulfuric acid, which is fatal if consumed 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. Remove the rubber boot from the positive terminal and inspect the battery.

3. Remove the negative cable (black) from the negative (-) terminal and the positive cable (red) from the positive (+) terminal of the battery (Figure 56).

   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.

   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.

   

   Figure 56

   1. Positive battery cable
   2. Negative battery cable

4. 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.

   Warning

   Charging the battery produces gasses that can explode.

   Never smoke near the battery and keep sparks and flames away from battery.

5. When the battery is charged, disconnect the charger from the power outlet and battery posts.

6. Install the positive cable (red) to the positive (+) terminal and the negative cable (black) to the negative (-) terminal of the battery (Figure 56).

7. Secure the cables to the posts with bolts and nuts.

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

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

9. Slide the rubber boot over the positive terminal.

10. Close the console panel and secure the latch.

The fuse block for the machine is located in the right storage box

Figure 57

1. Loosen the latch for the cover of the right storage box and raise the cover (Figure 58) to expose the fuse block (Figure 59).

   

   Figure 58

   1. Latch
   2. Right storage box

2. Replace the open fuse(s) as needed (Figure 59).

   

   Figure 59

   1. Fuses

3. Close the cover of the right storage box and secure the cover with the latch (Figure 58).

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 61

   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.

Lubricant Specification: high quality SAE 85W-140 gear lubricant

1. Park the machine on level surface, position the wheel so that the fill plug is at the 12 o'clock position, the check plug is at 3 o'clock position, and the drain plug is at the 6 o'clock position (Figure 62).

   

   Figure 62

   1. Fill plug (12 o’clock position)
   2. Check plug (3 o’clock position)
   3. Drain plug (6 o’clock position)

2. Remove the check plug at the 3 o’clock position (Figure 62).

   The oil level should be at the bottom of the check-plug hole.

   

   Figure 63

   1. Check-plug hole
   2. Check plug

3. If the oil level is low, remove the fill 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. Check the O-ring for the plug(s) for wear or damage.

   Note: Replace the O-ring(s) as needed.

5. Install the plug(s).

6. Repeat steps 1 through 5 on the planetary gear assembly at the other side of the machine.

Lubricant specification: high quality SAE 85W-140 gear lubricant

Planetary and brake housing lubrication capacity: 0.65 L (22 fl oz)

Visually inspect the rear axle and rear-axle gearbox for leaks.

Figure 68

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

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 69).

   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 69

   1. Check plug
   2. Fill plug

Lubricant specification: high-quality SAE 85W-140 gear lubricant

Axle capacity: 2.4 L (80 fl oz)

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. Clean the area around the 3 drain plugs—1 on each end and 1 in the center (Figure 70).

   

   Figure 70

   1. Drain-plug location

3. Remove the oil-level check plugs and the main-axle-vent cap to ease draining the gear lubricant.

4. Remove the drain plugs and allow the gear lubricant to drain into the pans.

5. Install the plugs.

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

7. Install the check plug.

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

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. 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 71).

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

   

   Figure 71

   1. Gearbox
   2. Check/fill plug

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. Measure the center-to-center distance (at axle height) at the front and rear of the steering tires (Figure 72).

   Note: The front measurement must be 3 mm (1/8 inch) less than the rear measurement.

   

   Figure 72

   1. Front of the machine
   2. 3 mm (1/8 inch) less than the rear measurement
   3. Center to center distance

3. To adjust, remove the cotter pin and nut from either tie rod ball joint (Figure 73). Remove the tie-rod ball joint from the axle-case support.

   

   Figure 73

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

4. Loosen the clamps at both ends of the tie rods (Figure 73).

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

6. 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.

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

8. Repeat procedure if necessary.

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

10. Check the opposite tie-rod and repeat the procedure if necessary.

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.

Coolant specification: 50/50 mixture of water and ethylene glycol antifreeze

Cooling system capacity: 8.5 L (9 US qt).

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. Carefully remove the radiator cap.

   

   Figure 74

   1. Expansion tank

3. Check the coolant level in the radiator. The radiator should be filled to the top of the filler neck and the expansion tank filled to the FULL mark (Figure 74).

4. If the coolant is low, add a 50/50 mixture of water and ethylene glycol anti-freeze. Do not use water only or alcohol/methanol based coolants.

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

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

2. Allow the machine to cool down; refer to Maintenance Safety and Cooling System Safety.

3. Unlatch and swing open the rear screen (Figure 75).

   Note: To remove the screen, lift it off the hinge pins.

4. Clean the screen thoroughly of all debris.

   

   Figure 75

   1. Rear-screen latch

5. Thoroughly clean both sides of the oil cooler and the radiator with compressed air (Figure 76).

   Note: Start from the front and blow the debris out toward the back. Then clean from the back side and blow toward the front. Repeat procedure several times until you remove all chaff and debris.

   

   Figure 76

   1. Oil cooler/radiator

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

6. 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 you feel braking resistance.

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

3. 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 77).

      

      Figure 77

      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 4.5 kg (10 lb) is applied on the belt midway between the pulleys.

If the deflection is not 10 mm (3/8 inch), loosen the alternator-mounting bolts (Figure 78).

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 78

1. Mounting bolt
2. Alternator

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

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. Disconnect and remove the hydraulic motor from the cutting unit (Figure 82). Cover the top of the spindle to prevent contamination.

   

   Figure 82

   1. Motor-mounting screws

3. Remove the lynch pin (for Groundsmaster 4500 machines) or retaining nut (for Groundsmaster 4700 machines) securing the cutting unit-carrier frame to the lift-arm pivot pin (Figure 83).

   

   Figure 83

   1. Lynch pin
   2. Lift-arm pivot pin

4. Roll the cutting unit away from the machine.

1. Move the cutting unit into position in front of the machine.

2. Slide the cutting unit-carrier frame onto the lift-arm-pivot pin (Figure 83). Secure the cutting unit to the pin with the lynch pin (for Groundsmaster 4500 machines) or retaining nut (for Groundsmaster 4700 machines).

3. Install the hydraulic motor to the cutting unit (Figure 82). Make sure that the O-ring is in position and not damaged.

4. Grease the spindle.

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

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

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 87).

   

   Figure 87

   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. The sail is important because it lifts the grass up straight, thereby producing an even cut. However, the sail gradually wears down during operation. As the sail wears down, the quality of cut degrades, although the cutting edges are sharp. The cutting edge of the blade must be sharp so that the grass is cut rather than torn. A dull cutting edge is evident when the tips of the grass appear brown and shredded. Sharpen the cutting edges to correct this condition.

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 88).

   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 the blade is worn (Figure 88), replace it.

   

   Figure 88

   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 89).

   Note: Sharpen only the top of the cutting edge and maintain the original cutting angle to ensure sharpness (Figure 89). The blade remains balanced if you remove the same amount of metal from both cutting edges.

   

   Figure 89

   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).

4. Ensure that the blade is straight and parallel; lay the blade on a level surface and check its ends. The ends of the blade must be slightly lower than the center, and the cutting edge must be lower than the heel of the blade.