Toro 30856TE, 30868TE, Groundsmaster 4700-D, 30868 Operator's Manual

Page 1
FormNo.3358-752Rev D
Groundsmaster
®
4500-Dor
4700-DTractionUnit
ModelNo.30856—SerialNo.280000001andUp
ModelNo.30856TE—SerialNo.280000001andUp
ModelNo.30868—SerialNo.280000001andUp
ModelNo.30868TE—SerialNo.280000001andUp
ToregisteryourproductordownloadanOperator'sManualorPartsCatalogatnocharge,gotowww.T oro.com.OriginalInstructions(EN)
Page 2
CALIFORNIA
Proposition65Warning
Dieselengineexhaustandsomeofits constituentsareknowntotheStateof
Californiatocausecancer,birthdefects,
andotherreproductiveharm.
Becauseinsomeareastherearelocal,state,orfederal regulationsrequiringthatasparkarresterbeusedonthe engineofthismachine,asparkarresterisincorporated withthemuferassembly.
GenuineTorosparkarrestersareapprovedbytheUSDA ForestryService.
Figure1
Important:Thisengineisequippedwithaspark
arrestermufer.ItisaviolationofCaliforniaPublic ResourceCodeSection4442touseoroperate theengineonanyforest-covered,brush-covered, orgrass-coveredlandwithoutasparkarrester mufermaintainedinworkingorder,ortheengine constricted,equipped,andmaintainedforthe preventionofre.Otherstatesorfederalareasmay havesimilarlaws.
ThissparkignitionsystemcomplieswithCanadian ICES-002.
Theenclosed
EngineOwner’sManual
issupplied forinformationregardingtheUSEnvironmental ProtectionAgency(EPA)andtheCalifornia EmissionControlRegulationofemissionsystems, maintenance,andwarranty.Replacementsmaybe orderedthroughtheenginemanufacturer.
Introduction
Readthisinformationcarefullytolearnhowtooperate andmaintainyourproductproperlyandtoavoidinjury andproductdamage.Youareresponsibleforoperating theproductproperlyandsafely.
ModelNo.
SerialNo.
Thismanualidentiespotentialhazardsandhas safetymessagesidentiedbythesafetyalertsymbol (Figure2),whichsignalsahazardthatmaycauseserious injuryordeathifyoudonotfollowtherecommended precautions.
Figure2
1.Safetyalertsymbol.
Thismanualusestwootherwordstohighlight information.Importantcallsattentiontospecial mechanicalinformationandNoteemphasizesgeneral informationworthyofspecialattention.
YoumaycontactTorodirectlyatwww .Toro.comfor productandaccessoryinformation,helpndinga dealer,ortoregisteryourproduct.
Wheneveryouneedservice,genuineToroparts,or additionalinformation,contactanAuthorizedService DealerorToroCustomerServiceandhavethemodel andserialnumbersofyourproductready.Figure1 identiesthelocationofthemodelandserialnumbers ontheproduct.Writethenumbersinthespace provided.
©2007—TheToro®Company 8111LyndaleAvenueSouth Bloomington,MN55420
Contactusatwww.Toro.com.
2
PrintedintheUSA.
AllRightsReserved
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Contents
Introduction.................................................................2
Safety...........................................................................4
SafeOperatingPractices.......................................4
ToroRidingMowerSafety....................................6
SoundPressureLevelfora4500-D.......................7
SoundPressureLevelfora4700-D.......................7
SoundPowerLevel...............................................7
VibrationLevel.....................................................7
SafetyandInstructionalDecals.............................8
Setup..........................................................................13
1InstallingtheSeat,SeatBelt,andManual
Tube...............................................................13
2GreasingtheMachine......................................14
3CheckingFluidLevels......................................14
4ReadingtheManualsandViewingthe
TrainingMaterial............................................14
ProductOverview......................................................15
Controls.............................................................15
Specications.....................................................19
TractionUnitSpecications................................19
Attachments/Accessories...................................19
Operation...................................................................20
CheckingtheEngineOilLevel............................20
CheckingtheCoolingSystem..............................20
FillingtheFuelTank...........................................21
CheckingtheHydraulicFluidLevel.....................22
CheckingtheTirePressure.................................23
StartingandStoppingtheEngine........................23
CheckingtheInterlockSwitches.........................24
PushingorTowingtheMachine..........................25
JackingPoints.....................................................25
TieDowns.........................................................25
OperatingCharacteristics...................................25
StandardControlModule(SCM)........................26
OperatingTips...................................................28
Maintenance...............................................................29
RecommendedMaintenanceSchedule(s)................29
DailyMaintenanceChecklist...............................30
ServiceIntervalChart.........................................31
PremaintenanceProcedures....................................32
RemovingtheHood...........................................32
Lubrication.............................................................32
GreasingtheBearingsandBushings....................32
EngineMaintenance...............................................34
ServicingtheAirCleaner....................................34
ServicingtheEngineOilandFilter......................35
AdjustingtheThrottle........................................35
FuelSystemMaintenance.......................................36
FuelTank...........................................................36
FuelLinesandConnections................................36
ServicingtheWaterSeparator.............................36
FuelPick-upTubeScreen...................................36
BleedingtheFuelSystem....................................36
BleedingAirfromtheInjectors...........................37
ElectricalSystemMaintenance................................38
ChargingandConnectingtheBattery..................38
BatteryCare.......................................................39
Fuses..................................................................39
DriveSystemMaintenance.....................................40
CheckingtheTorqueoftheWheel
Nuts...............................................................40
CheckingthePlanetaryGearDrive
Oil..................................................................40
ChangingthePlanetaryGearDrive
Oil..................................................................40
CheckingtheRearAxleLubricant.......................41
ChangingtheRearAxleLubricant.......................41
AdjustingtheTractionDriveforNeutral.............42
CheckingtheRearWheelT oe-In.........................42
CoolingSystemMaintenance..................................43
ServicingtheEngineCoolingSystem..................43
BrakeMaintenance.................................................44
AdjustingtheServiceBrakes...............................44
BeltMaintenance....................................................45
ServicingtheAlternatorBelt...............................45
HydraulicSystemMaintenance...............................45
ChangingtheHydraulicFluid.............................45
ReplacingtheHydraulicFilters...........................45
CheckingtheHydraulicLinesandHoses.............46
HydraulicSystemTestPorts...............................46
AdjustingtheCounterbalance.............................47
Cleaning.................................................................48
ServicingtheSparkArrestorMufer...................48
Storage.......................................................................49
TractionUnit......................................................49
Engine...............................................................49
Schematics.................................................................50
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Safety
ThismachinemeetsorexceedsCENstandardEN 836:1997(whenappropriatedecalsapplied),andANSI B71.4-2004specicationsineffectatthetimeof productionwhenequippedwithrequiredweightsas listedintheweightchart.
Improperuseormaintenancebytheoperatoror ownercanresultininjury.Toreducethepotential forinjury,complywiththesesafetyinstructions andalwayspayattentiontothesafetyalertsymbol, whichmeansCAUTION,WARNING,orDANGER­"personalsafetyinstruction."Failuretocomplywiththe instructionmayresultinpersonalinjuryordeath.
SafeOperatingPractices
ThefollowinginstructionsarefromtheCENstandard EN836:1997,ISOstandard5395:1990,andANSI B71.4-2004.
◊lackofawarenessoftheeffectofground
conditions,especiallyslopes;
Theowner/usercanpreventandisresponsiblefor accidentsorinjuriesoccurringtohimselforherself, otherpeople,orproperty.
Preparation
Whilemowing,alwayswearsubstantialfootwear, longtrousers,hardhat,safetyglasses,andhearing protection.Longhair,looseclothing,orjewelrymay gettangledinmovingparts.Donotoperatethe equipmentwhenbarefootorwearingopensandals.
Thoroughlyinspecttheareawheretheequipment istobeusedandremoveallobjectswhichmaybe thrownbythemachine.
Warning-Fuelishighlyammable.Takethe followingprecautions:
–Storefuelincontainersspecicallydesignedfor
thispurpose.
Training
Readtheoperator’smanualandothertraining materialcarefully .Befamiliarwiththecontrols, safetysigns,andtheproperuseoftheequipment.
Iftheoperatorormechaniccannotreadthelanguage ofthismanual,itistheowner’sresponsibilityto explainthismaterialtothem.
Neverallowchildrenorpeopleunfamiliarwiththese instructionstouseorservicethemower.Local regulationsmayrestricttheageoftheoperator.
Nevermowwhilepeople,especiallychildren,orpets arenearby .
Keepinmindthattheoperatororuserisresponsible foraccidentsorhazardsoccurringtootherpeopleor theirproperty.
Donotcarrypassengers.
Alldriversandmechanicsshouldseekandobtain professionalandpracticalinstruction.Theowneris responsiblefortrainingtheusers.Suchinstruction shouldemphasize:
–theneedforcareandconcentrationwhen
workingwithride-onmachines;
–controlofaride-onmachineslidingonaslope
willnotberegainedbytheapplicationofthe brake.Themainreasonsforlossofcontrolare:
◊insufcientwheelgrip; ◊beingdriventoofast; ◊inadequatebraking; ◊thetypeofmachineisunsuitableforthetask;
–Refueloutdoorsonlyanddonotsmokewhile
refueling.
–Addfuelbeforestartingtheengine.Never
removethecapofthefueltankoraddfuelwhile theengineisrunningorwhentheengineishot.
–Iffuelisspilled,donotattempttostartthe
enginebutmovethemachineawayfromthe areaofspillageandavoidcreatinganysourceof ignitionuntilfuelvaporshavedissipated.
–Replaceallfueltankandcontainercapssecurely.
Replacefaultysilencers/mufers.
Evaluatetheterraintodeterminewhataccessories andattachmentsareneededtoproperlyand safelyperformthejob.Onlyuseaccessoriesand attachmentsapprovedbythemanufacturer.
Checkthatoperator’spresencecontrols,safety switchesandshieldsareattachedandfunctioning properly.Donotoperateunlesstheyarefunctioning properly.
Operation
Donotoperatetheengineinaconnedspacewhere dangerouscarbonmonoxidefumescancollect.
Mowonlyindaylightoringoodarticiallight.
Beforeattemptingtostarttheengine,disengageall bladeattachmentclutches,shiftintoneutral,and engagetheparkingbrake.
Donotputhandsorfeetnearorunderrotatingparts. Keepclearofthedischargeopeningatalltimes.
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Rememberthereisnosuchthingasasafeslope. Travelongrassslopesrequiresparticularcare.To guardagainstoverturning:
–donotstoporstartsuddenlywhengoingupor
downhill;
–machinespeedsshouldbekeptlowonslopes
andduringtightturns;
–stayalertforhumpsandhollowsandother
hiddenhazards;
–nevermowacrossthefaceoftheslope,unless
themowerisdesignedforthispurpose.
–Usecounterweight(s)orwheelweightswhen
suggestedintheoperator’smanual.
Stayalertforholesintheterrainandotherhidden hazards.
Watchoutfortrafcwhencrossingornearroadways.
Stopthebladesfromrotatingbeforecrossing surfacesotherthangrass.
Whenusinganyattachments,neverdirectdischarge ofmaterialtowardbystandersnorallowanyonenear themachinewhileinoperation.
Neveroperatethemachinewithdamagedguards, shields,orwithoutsafetyprotectivedevicesinplace. Besureallinterlocksareattached,adjustedproperly, andfunctioningproperly.
Donotchangetheenginegovernorsettingsor overspeedtheengine.Operatingtheengineat excessivespeedmayincreasethehazardofpersonal injury.
Beforeleavingtheoperator’ sposition:
–stoponlevelground; –disengagethepowertake-offandlowerthe
attachments; –changeintoneutralandsettheparkingbrake; –stoptheengineandremovethekey .
Important:Allowenginetoidlefor5
minutesbeforeshuttingitoffafterafull
loadoperation.Failuretodosomayleadto
turbo-chargertrouble.
Disengagedrivetoattachmentswhentransporting ornotinuse.
Stoptheengineanddisengagedrivetoattachment
–beforerefuelling; –beforeremovingthegrasscatcher/catchers; –beforemakingheightadjustmentunless
adjustmentcanbemadefromtheoperator’s position.
–beforeclearingblockages;
–beforechecking,cleaningorworkingonthe
mower;
–afterstrikingaforeignobjectorifanabnormal
vibrationoccurs.Inspectthemowerfordamage andmakerepairsbeforerestartingandoperating theequipment.
Reducethethrottlesettingduringenginerun-out and,iftheengineisprovidedwithashut-offvalve, turnthefueloffattheconclusionofmowing.
Keephandsandfeetawayfromthecuttingunits.
Lookbehindanddownbeforebackinguptobesure ofaclearpath.
Slowdownandusecautionwhenmakingturnsand crossingroadsandsidewalks.Stopbladesfrom rotating.
Beawareofthemowerdischargedirectionanddo notpointitatanyone.
Donotoperatethemowerundertheinuenceof alcoholordrugs
Usecarewhenloadingorunloadingthemachine intoatrailerortruck
Usecarewhenapproachingblindcorners,shrubs, trees,orotherobjectsthatmayobscurevision.
MaintenanceandStorage
Keepallnuts,boltsandscrewstighttobesurethe equipmentisinsafeworkingcondition.
Neverstoretheequipmentwithfuelinthetank insideabuildingwherefumesmayreachanopen ameorspark.
Allowtheenginetocoolbeforestoringinany enclosure.
Toreducetherehazard,keeptheengine, silencer/mufer,batterycompartmentandfuel storageareafreeofgrass,leaves,orexcessivegrease.
Keepallpartsingoodworkingconditionandall hardwareandhydraulicttingstightened.Replaceall wornordamagedpartsanddecals.
Ifthefueltankhastobedrained,dothisoutdoors.
Becarefulduringadjustmentofthemachineto prevententrapmentofthengersbetweenmoving bladesandxedpartsofthemachine.
Onmulti-spindlemowers,takecareasrotatingone bladecancauseotherbladestorotate.
Disengagedrives,lowerthecuttingunits,setparking brake,stopengineandremovekeyanddisconnect sparkplugwire(gasengineonly).Waitforall movementtostopbeforeadjusting,cleaningor repairing.
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Cleangrassanddebrisfromcuttingunits,drives, silencers/mufers,andenginetohelppreventres. Cleanupoilorfuelspillage.
Wearingsafetyshoesandlongpantsisadvisableand requiredbysomelocalordinancesandinsurance regulations.
Usejackstandstosupportcomponentswhen required.
Carefullyreleasepressurefromcomponentswith storedenergy.
Disconnectbatteryandremovesparkplugwire(gas engineonly)beforemakinganyrepairs.Disconnect thenegativeterminalrstandthepositivelast. Reconnectpositiverstandnegativelast.
Usecarewhencheckingtheblades.Wearglovesand usecautionwhenservicingthem.
Keephandsandfeetawayfrommovingparts.If possible,donotmakeadjustmentswiththeengine running.
Chargebatteriesinanopenwellventilatedarea, awayfromsparkandames.Unplugchargerbefore connectingordisconnectingfrombattery.Wear protectiveclothinganduseinsulatedtools.
Storethemachinewiththecuttingunitsinthe loweredpositionorsecurethewingdeckswiththe storagelatchestopreventthemfromunintentionally lowering.
Handlefuelcarefully.Wipeupanyspills.
Checkthesafetyinterlockswitchesdailyforproper operation.Ifaswitchshouldfail,replacetheswitch beforeoperatingthemachine.
Beforestartingtheengine,sitontheseat.
Usingthemachinedemandsattention.Toprevent lossofcontrol:
–Donotdriveclosetosandtraps,ditches,creeks,
embankments,orotherhazards.
–Reducespeedwhenmakingsharpturns.Avoid
suddenstopsandstarts.
–Whennearorcrossingroads,alwaysyieldthe
right-of-way.
–Applytheservicebrakeswhengoingdownhillto
keepforwardspeedslowandtomaintaincontrol ofthemachine.
WhenoperatingamachinewithROPS(roll-over protectionsystem)neverremovetheROPSand alwaysusetheseatbelt.
Raisethecuttingunitswhendrivingfromonework areatoanother.
ToroRidingMowerSafety
Thefollowinglistcontainssafetyinformationspecic toToroproductsorothersafetyinformationthatyou mustknowthatisnotincludedintheCEN,ISO,or ANSIstandard.
Thisproductiscapableofamputatinghandsand feetandthrowingobjects.Alwaysfollowallsafety instructionstoavoidseriousinjuryordeath.
Useofthisproductforpurposesotherthanitsintended usecouldprovedangeroustouserandbystanders.
Engineexhaustcontainscarbonmonoxide, whichisanodorless,deadlypoisonthatcan killyou.
Donotrunengineindoorsorinanenclosed area.
Knowhowtostoptheenginequickly.
Donotoperatethemachinewhilewearingtennis shoesorsneakers.
Donottouchtheengine,silencer/mufer,or exhaustpipewhiletheengineisrunningorsoon afterithasstoppedbecausetheseareascouldbehot enoughtocauseburns.
Onanyhill,thereisthepossibilityoftippingor rollingover,buttheriskincreasesastheslopeangle increases.Steephillsshouldbeavoided.
Cuttingunitsmustbeloweredwhengoingdown slopestomaintainsteeringcontrol
Engagetractiondriveslowly,alwayskeepfooton tractionpedal,especiallywhentravelingdownhill.
Usereverseontractionpedalforbraking.
Ifthemachinestallswhenclimbingaslope,do notturnthemachinearound.Alwaysbackslowly, straightdowntheslope.
Whenapersonorpetappearsunexpectedlyin ornearthemowingarea,stopmowing.Careless operation,combinedwithterrainangles,ricochets, orimproperlypositionedguardscanleadtothrown objectinjuries.Donotresumemowinguntilthe areaiscleared.
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MaintenanceandStorage
Makesureallhydrauliclineconnectorsaretightand allhydraulichosesandlinesareingoodcondition beforeapplyingpressuretothesystem.
Keepyourbodyandhandsawayfrompinhole leaksornozzlesthatejecthydraulicuidunder highpressure.Usepaperorcardboard,notyour hands,tosearchforleaks.Hydraulicuidescaping underpressurecanhavesufcientforcetopenetrate theskinandcauseseriousinjury.Seekimmediate medicalattentionifuidisinjectedintoskin.
Beforedisconnectingorperforminganyworkon thehydraulicsystem,allpressureinthesystemmust berelievedbystoppingtheengineandloweringthe cuttingunitsandattachmentstotheground.
Checkallfuellinesfortightnessandwearona regularbasis.Tightenorrepairthemasneeded.
Iftheenginemustberunningtoperforma maintenanceadjustment,keephands,feet,clothing, andanypartsofthebodyawayfromthecutting units,attachments,andanymovingparts.
Toensuresafetyandaccuracy,haveanAuthorized ToroDistributorcheckthemaximumenginespeed withatachometer.
Ifmajorrepairsareeverneededorifassistanceis desired,contactanAuthorizedToroDistributor.
UseonlyToro-approvedattachmentsand replacementparts.Thewarrantymaybevoidedif usedwithunapprovedattachments.
VibrationLevel
Hand-Arm
Thisunitdoesnotexceedavibrationlevelof2.5m/s thehandsbasedonmeasurementsofidenticalmachines perEN836andEN1033procedures.
WholeBody
Thisunitdoesnotexceedavibrationlevelof0.5m/s attheposteriorbasedonmeasurementsofidentical machinesperEN836andEN1032procedures.
2
at
2
SoundPressureLevelfora 4500-D
ThisunithasanequivalentcontinuousA-weighted soundpressurelevelattheoperatorearof89dBA,based onmeasurementsofidenticalmachinesperDirective 98/37/ECandamendments.
SoundPressureLevelfora 4700-D
ThisunithasanequivalentcontinuousA-weighted soundpressurelevelattheoperatorearof90dBA, basedonmeasurementsofidenticalmachinesperEN 836andISO11201.
SoundPowerLevel
Thisunithasaguaranteedsoundpowerlevelof 105dBA/1pW ,basedonmeasurementsofidentical machinesperISO11094.
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SafetyandInstructionalDecals
Safetydecalsandinstructionsareeasilyvisibletotheoperatorandarelocatednearanyareaof potentialdanger.Replaceanydecalthatisdamagedorlost.
108–5278
1.ReadtheOperator’sManual.
93-7275
1.ReadtheOperator’sManual.
2.Donotusestartingaids.
105-3888
1.ReadtheOperator’sManual.
2.Tolocktheparkingbrake,securethebrakepedalswiththe lockingpin,pressthebrakepedals,andpullouttheparking brakeknob.
3.Tounlocktheparkingbrake,pressthebrakepedal.
114–9600
93-7272
1.Cutting/dismembermenthazard;fan—stayawayfrom movingparts.
1.Enginecoolantunder pressure.
2.Explosionhazard—read theOperator’sManual.
106-6755
3.Warning—donottouch thehotsurface.
4.Warning—readthe
Operator’sManual.
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1.ReadtheOperator’s
Manual.
2.Engine—stop5.Engine—start
3.On
1.Machinespeed
2.Slow
105-9830
(AfxforCE)
1.Lock2.Unlock
105-7506
4.Engine—preheat
1.Hydraulicoil
93-6686
2.ReadtheOperator’s Manual.
BatterySymbols
Someorallofthesesymbolsareonyourbattery
93-6699
3.Continuousvariable setting
4.Fast
1.Explosionhazard
2.Nore,opename,or smoking.
3.Causticliquid/chemical burnhazard
4.Weareyeprotection9.Flusheyesimmediately
5.ReadtheOperator’s
Manual.
6.Keepbystandersasafe distancefromthebattery .
7.Weareyeprotection; explosivegasescan causeblindnessandother injuries
8.Batteryacidcancause blindnessorsevereburns.
withwaterandgetmedical helpfast.
10.Containslead;donot discard.
106-6754
1.Warning—donottouchthehotsurface.
2.Cutting/dismembermenthazard,fanandentanglement hazard,belt—stayawayfrommovingparts.
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112-5297
1.Warning—readtheOperator’sManual,donotoperatethismachineunlessyouaretrained.
2.Warning—readtheOperator’sManualbeforetowingthemachine.
3.Tippinghazard—slowmachinebeforeturning,donotturnathighspeeds;lowerthecuttingunitwhendrivingdownslopes;usea rolloverprotectionsystemandweartheseatbelt
4.Warning—donotparkthemachineonslopes;engagetheparkingbrake,lowerthecuttingunits,stoptheengineandremovethe ignitionkeybeforeleavingthemachine.
5.Thrownobjecthazard—keepbystandersasafedistancefromthemachine.
6.Entanglementhazard,belt—donotremovecoverwhilepartsaremoving,keepallguardsinplace.
112–5298
(Afxoverpartno.112–5297forCE*
*ThissafetydecalincludesaslopewarningrequiredonthemachineforcompliancetotheEuropeanLawnMowerSafetyStandardEN836:1997.Theconservativemaximum
slopeanglesindicatedforoperationofthismachineareprescribedbyandrequiredbythisstandard.
1.Warning—readtheOperator’sManual.
2.Warning—readtheOperator’sManualbeforetowingthemachine.
3.Tippingandcrushinghazard—donotdrivemachineonaslopegreaterthan15degrees,weartheseatbelt,andlowerthe cuttingunitwhendrivingdownslopes.
4.Warning—locktheparkingbrake,stoptheengine,andremovetheignitionkeybeforeleavingthemachine.
5.Thrownobjecthazard—keepbystandersasafedistancefromthemachine.
6.Entanglementhazard,belt—donotremovecoverwhilepartsaremoving,keepallguardsinplace.
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108-4044
1.Lowerthecuttingunit(s).
2.Raisethecuttingunit(s).11.PowerT ake-off(PTO)
3.Rightcuttingunit(GM4700-Donly)
4.Centercuttingunits
5.Leftcuttingunit(GM4700-Donly)
6.Fast
7.Continuousvariablesetting
8.Slow
9.Engage
10.Disengage
12.High
13.Low
14.Transmission
15.Warning—readtheOperator’sManual.
16.Tostarttheengine;sitintheoperator’sseat,turntheignition keytoengine-onandwaitfortheglowplugindicatorlightto extinguish,turntheignitionkeytoengine-start,releasethe parkingbrake.
17.Tostoptheengine;lowerthedeckanddisengagethepower take-off,turntheignitionkeytoengine-stopandremovethe key,engagetheparkingbrake.
106–9290
1.Input5.Inseat
2.Backlap
3.Hightempshutdown
4.Hightempwarning8.Neutral12.ETR
6.PTOswitch10.PTO
7.Parkbrakeoff11.Start
11
9.Output13.Start
14.Power
Page 12
105-9895
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Setup
LooseParts
Usethechartbelowtoverifythatallpartshavebeenshipped.
ProcedureDescription
1
2
3
4
SeatKit,Model30398(soldseparately) SeatSuspensionKit,Model30312
(Mechanical)or30313(Air)(sold separately)
Seatbelt Capscrew,7/16-20x1inch Lockwasher,7/16inch ManualTube1 R-clamp2
Nopartsrequired
Nopartsrequired
Operator’sManual EngineOperator’sManual PartsCatalog OperatorTrainingMaterial
Qty.
1
1
1 2 2
2 1 1 1
Note:Determinetheleftandrightsidesofthemachinefromthenormaloperatingposition.
1.Mountthemanualtubetotheseatsuspensionwith the2R-clampsincludedinlooseparts(Figure3).
Use
Installtheseat,seatbelt,andmanual tube.
Greasethemachine.
Checktherearaxlelubricant,hydraulic uid,andengineoillevels
Readthemanualsandwatchthe trainingmaterialbeforeoperatingthe machine.
1
InstallingtheSeat,SeatBelt, andManualTube
Partsneededforthisprocedure:
1
SeatKit,Model30398(soldseparately)
SeatSuspensionKit,Model30312(Mechanical)or
1
30313(Air)(soldseparately)
1
Seatbelt
2
Capscrew,7/16-20x1inch
2
Lockwasher,7/16inch
1ManualTube
2R-clamp
Procedure
Themachineisshippedwithouttheseatassembly . DeluxeSeatKit,ModelNo.30398,andSeatSuspension Kit,ModelNo.30312or30313,mustbepurchasedand installed.
Figure3
1.Manualtube
2.R-clamp
3.Seatbeltretractor
4.Seatbeltbuckle
2.Installtheseatbelttoeachsideoftheseatwithabolt andlockwasher,suppliedinlooseparts(Figure3). Theseatbeltretractoristobemountedtotheright sideoftheseatandtheseatbeltbuckletotheleft side.
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Important:Makesurethattheseatswitchis connectedtotheseatswitchconnectoronthe harness.
3.Slidetheseatcompletelyforwardandbackwardto ensureproperoperationandthatseatswitchwires andconnectorsarenotpinchedordonocontactany movingparts.
2
GreasingtheMachine
NoPartsRequired
Procedure
Beforethemachineisoperated,itmustbegreasedto ensureproperlubrication.RefertoLubricationsection. Failuretoproperlygreasethemachinewillresultin prematurefailureofcriticalparts.
4
ReadingtheManualsand ViewingtheTrainingMaterial
Partsneededforthisprocedure:
2
Operator’sManual
1
EngineOperator’sManual
1
PartsCatalog
1
OperatorTrainingMaterial
Procedure
1.Readthemanuals.
2.Viewthetrainingmaterial.
3.Storethedocumentationinasafeplace.
3
CheckingFluidLevels
NoPartsRequired
Procedure
1.Checktherearaxlelubricantlevelbeforetheengine isrststarted,refertoCheckingtheRearAxle LubricantinDriveSystemMaintenance.
2.Checkthehydraulicuidlevelbeforetheengineis rststarted,refertoCheckingtheHydraulicFluid LevelinOperation.
3.Checktheengineoillevelbeforeandaftertheengine isrststarted,refertoCheckingtheEngineOil LevelinOperation.
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ProductOverview
1.Steeringwheel
2.Brakes5.Manualtube
3.Cuttingunit6.Hood/enginecompartment
4.Tractionpedal
Controls
TractionPedal
Thetractionpedal(Figure5)controlsforwardand reverseoperation.Depressthetopofthepedaltomove forwardandthebottomtomovebackward.Ground speeddependsonhowfarthepedalisdepressed.For noload,maximumgroundspeed,fullydepressthepedal whilethethrottleisinFast.
Tostop,reduceyourfootpressureonthetractionpedal andallowittoreturntothecenterposition.
ForwardSpeedControl
Presettheforwardspeedcontrol(Figure5)tolimit theamountthetractionpedalcanbedepressedinthe forwarddirectiontomaintainaconstantmowingspeed.
Figure4
7.ROPS(RolloverProtectionSystem)
ChargeIndicator
Thechargeindicator(Figure5)illuminateswhenthe systemchargingcircuitmalfunctions.
EngineCoolantTemperatureWarning Light
Thelight(Figure5)illuminatesandtheengineshuts downwhencoolantreachesanexcessivelyhigh temperature.
GlowPlugIndicatorLight
Whenlit,theglowplugindicatorlight(Figure5) indicatesthattheglowplugsareon.
EngineOilPressureWarningLight
KeySwitch
Thekeyswitch(Figure5)hasthreepositions:Off, On/Preheat,andStart.
Thelight(Figure5)illuminateswhentheengineoil pressureisdangerouslylow .
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Figure5
1.Tractionpedal
2.Forwardspeedcontrol6.Enginecoolant
3.Keyswitch
4.Engineoilpressure warninglight
5.Chargeindicator
7.Glowplugindicatorlight
temperaturewarning light
obtainingbettersidehilltraction.Alatchconnectsthe pedalsforparkingbrakeoperationandtransport.
Figure7
1.Brakepedals3.Parkingbrakelatch
2.Pedallockinglatch
PedalLockingLatch
Thepedallockinglatch(Figure7)connectsthepedals togethertoengagetheparkingbrake.
ParkingBrakeLatch
SpeedLimiterScrews
Adjustthescrew(s)(Figure6)tolimittheamountthe tractionpedalcanbedepressedintheforwardorreverse directiontolimitspeed.
Important:Thespeedlimiterscrewmuststopthe tractionpedalbeforethepumpreachesfullstroke ordamagetothepumpmayoccur.
Figure6
1.Forwardspeedlimiter screw
2.Reversespeedlimiter screw
Aknobontheleftsideoftheconsoleactuatesthe parkingbrakelock(Figure7).Toengagetheparking brake,connectthepedalswiththelockinglatch,push downonbothpedals,andpulltheparkingbrakelatch out.Toreleasetheparkingbrake,depressbothpedals untiltheparkingbrakelatchretracts.
ThrottleControl
Movethecontrol(Figure8orFigure9)forwardto increasetheenginespeedandrearwardtodecreasethe speed.
BrakePedals
Twofootpedals(Figure7)operateindividualwheel brakesforturningassistance,parking,andtoaidin
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Model4500-D
PTOSwitch
ThePTOswitch(Figure8)hastwopositions:On (engage)andOff(disengage).PushthePTOswitch forwardtotheOnpositiontostarttheimplementor cuttingunitblades.PushtheswitchbackwardtotheOff positiontostopimplementoperation.
Hi-LoSpeedControl
Theswitch(Figure8)allowsthespeedrangetoincrease fortransportofthemachine.Cuttingdeckswillnot operateinhighrange.
Figure8
PowerPoint
1.Throttlecontrol
2.Liftlever
3.Hourmeter7.Powerpoint
4.Enginetemperaturegauge
Model4700-D
1.Throttlecontrol
2.Liftlever
3.Hourmeter7.Powerpoint
4.Enginetemperaturegauge
5.PTOswitch
6.Hi-Lospeedcontrol
Figure9
5.PTOswitch
6.Hi-Lospeedcontrol
Thepowerpoint(Figure8)isusedtopoweroptional12 voltelectricalaccessories.
FuelGauge
Thefuelgauge(Figure10)indicatestheleveloffuelin thetank.
Figure10
1.Fuelgauge
CuttingUnitLiftLatch(CE)
Thecuttingunitliftlatch(Figure11orFigure12)locks thecentervecuttingunitliftleverswhenthecutting unitsareintheraisedposition.
LiftLever
Thelever(Figure8)raisesandlowersthecuttingunits.
HourMeter
Thehourmeter(Figure8)showsthetotalhoursthatthe machinehasbeenoperated.
EngineTemperatureGauge
Thisgauge(Figure8)indicatestheenginecoolant temperature.
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1.Cuttingunitliftlatch
1.Cuttingunitliftlatch
Figure11
Model4500-D
Figure12
Model4700-D
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Specications
Note:Specicationsanddesignaresubjecttochange
withoutnotice.
TractionUnitSpecications
4500-D4700-D
Widthofcut109inches(2.8m)150inches(3.8m)
Overallwidth,
cuttingunits
down
Overallwidth,
cuttingunitsup
(transport)
Overalllength145.8inches(370cm)145.8inches(370cm)
Heightwith
ROPS
Ground
clearance
TrackWidth,
front
TrackWidth,rear
Wheelbase
Weight(with
cuttingunitsand
nouids)
112.8inches(286cm)153.8inches(391cm)
88.25inches(224cm)88.25inches(224cm)
85inches(216cm)85inches(216cm)
6inches(15cm)6inches(15cm)
88.25inches(224cm)88.25inches(224cm)
55.5inches(141cm)55.5inches(141cm)
67-1/2inches(171cm)67-1/2inches(171cm)
4123lb(1400kg)4674lb(2120kg)
Attachments/Accessories
AselectionofToroapprovedattachmentsand accessoriesareavailableforusewiththemachineto enhanceandexpanditscapabilities.Contactyour AuthorizedServiceDealerorDistributororgoto www.Toro.comforalistofallapprovedattachments andaccessories.
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Operation
Note:Determinetheleftandrightsidesofthe
machinefromthenormaloperatingposition.
Thismachineproducessoundlevelsinexcess of85dBAattheoperator’searandcancause hearinglossthroughextendedperiodsof exposure.
Wearhearingprotectionwhenoperatingthis machine.
Ifyouleavethekeyintheignitionswitch, someonecouldaccidentlystarttheengineand seriouslyinjureyouorotherbystanders.
Removethekeyfromtheignitionbeforeyoudo anymaintenance.
Figure13
1.Dipstick
4.IftheoilisbelowtheFULLmark,removethell cap(Figure14)andaddoiluntilthelevelreaches theFULLmark.Donotoverll.
CheckingtheEngineOilLevel
ServiceInterval:Beforeeachuseordaily
Theengineisshippedwithoilinthecrankcase; however,theoillevelmustbecheckedbeforeandafter theengineisrststarted.
Thecrankcasecapacityisapproximately8qt.(7.6l) withthelter.
Usehigh-qualityengineoilthatmeetsthefollowing specications:
APIClassicationLevelRequired:CH-4,CI-4or higher.
Preferredoil:SAE15W -40(above0°F)
Alternateoil:SAE10W -30or5W-30(all temperatures)
Note:ToroPremiumEngineoilisavailable fromyourdistributorineither15W-40or10W-30 viscosity.Seethepartscatalogforpartnumbers.
1.Parkthemachineonalevelsurface.
2.Unlocktheenginecoverlatchesandopenthe enginecover.
3.Removethedipstick,wipeitclean,installthe dipstickintothetube,andpullitoutagain.
Figure14
1.Oilllcap
Note:Whenusingdifferentoil,drainalloldoil fromthecrankcasebeforeaddingnewoil.
5.Installtheoilllcapanddipstick.
6.Closetheenginecoverandsecureitwiththelatches.
CheckingtheCoolingSystem
ServiceInterval:Beforeeachuseordaily
Checklevelofcoolantatthebeginningofeachday. Capacityofsystemis2-3/4gal.(10.4l).
1.Carefullyremovetheradiatorcapandexpansion tankcap(Figure15).
TheoillevelshouldbeuptotheFULLmark (Figure13).
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ashpointandcoldowcharacteristicswhichwillease startingandreducefuellterplugging.
Iftheenginehasbeenrunning,thepressurized, hotcoolantcanescapeandcauseburns.
Donotopentheradiatorcapwhenthe engineisrunning.
Usearagwhenopeningtheradiatorcap, andopenthecapslowlytoallowsteamto escape.
Figure15
1.Expansiontank
Useofsummergradefuelabove20°F(-7°C)will contributetowardlongerfuelpumplifeandincreased powercomparedtowintergradefuel.
Important:Donotusekeroseneorgasoline insteadofdieselfuel.Failuretoobservethis cautionwilldamagetheengine.
Fuelisharmfulorfatalifswallowed.Long-term exposuretovaporscancauseseriousinjuryand illness.
Avoidprolongedbreathingofvapors.
Keepfaceawayfromnozzleandgastankor conditioneropening.
Keepfuelawayfromeyesandskin.
BiodieselReady
Thismachinecanalsouseabiodieselblendedfuel ofuptoB20(20%biodiesel,80%petrodiesel).The petrodieselportionshouldbeloworultralowsulfur. Observethefollowingprecautions:
Thebiodieselportionofthefuelmustmeet specicationASTMD6751orEN14214.
2.Checkthecoolantlevelintheradiator.Theradiator shouldbelledtothetopofthellerneckandthe expansiontanklledtotheFULLmark.
3.Ifthecoolantislow ,adda50/50mixtureofwater andethyleneglycolanti-freeze.Donotusewater onlyoralcohol/methanolbasecoolants.
4.Installtheradiatorcapandexpansiontankcap.
FillingtheFuelTank
Useonlyclean,freshdieselfuelorbiodieselfuelswith low(<500ppm)orultralow(<15ppm)sulfurcontent. Theminimumcetaneratingshouldbe40.Purchase fuelinquantitiesthatcanbeusedwithin180daysto ensurefuelfreshness.
Fueltankcapacity:21gallons(79l).
Usesummergradedieselfuel(No.2-D)attemperatures above20°F(-7°C)andwintergrade(No.1-Dor No.1-D/2-Dblend)belowthattemperature.Useof wintergradefuelatlowertemperaturesprovideslower
TheblendedfuelcompositionshouldmeetASTM D975orEN590.
Paintedsurfacesmaybedamagedbybiodiesel blends.
UseB5(biodieselcontentof5%)orlesserblends incoldweather.
Monitorseals,hoses,gasketsincontactwithfuelas theymaybedegradedovertime.
Fuellterpluggingmaybeexpectedforatimeafter convertingtobiodieselblendsd.
Contactyourdistributorifyouwishformore informationonbiodiesel.
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Incertainconditions,fuelisextremely ammableandhighlyexplosive.Areor explosionfromfuelcanburnyouandothers andcandamageproperty.
Fillthefueltankoutdoors,inanopenarea, whentheengineiscold.Wipeupanyfuel thatspills.
Neverllthefueltankinsideanenclosed trailer.
Neversmokewhenhandlingfuel,andstay awayfromanopenameorwherefuel fumesmaybeignitedbyaspark.
Storefuelinanapprovedcontainerandkeep itoutofthereachofchildren.Neverbuy morethana180-daysupplyoffuel.
Donotoperatewithoutentireexhaust systeminplaceandinproperworking condition.
Incertainconditionsduringfueling,static electricitycanbereleasedcausingaspark whichcanignitethefuelvapors.Areor explosionfromfuelcanburnyouandothers andcandamageproperty.
Alwaysplacefuelcontainersontheground awayfromyourvehiclebeforelling.
Donotllfuelcontainersinsideavehicle oronatruckortrailerbedbecauseinterior carpetsorplastictruckbedlinersmay insulatethecontainerandslowthelossof anystaticcharge.
Whenpractical,removeequipmentfromthe truckortrailerandrefueltheequipment withitswheelsontheground.
Ifthisisnotpossible,thenrefuelsuch equipmentonatruckortrailerfroma portablecontainer,ratherthanfromafuel dispensernozzle.
Figure16
1.Fueltankcap
2.Fillthetanktoabout1inch(25mm)belowthetop ofthetank,notthellerneck,withNo.2diesel fuel.Theninstallthecap.
Note:Ifpossible,llthefueltankaftereachuse. Thiswillminimizepossiblebuildupofcondensation insidethefueltank.
Undercertainconditions,dieselfuelandfuel vaporsarehighlyammableandexplosive.A reorexplosionfromfuelcanburnyouand othersandcancausepropertydamage.
Useafunnelandllthefueltankoutdoors, inanopenarea,whentheengineisoffand iscold.Wipeupanyfuelthatspills.
Donotllthefueltankcompletelyfull.Add fueltothefueltankuntilthelevelis1in.(25 mm)belowthetopofthetank,nottheller neck.Thisemptyspaceinthetankallows thefueltoexpand.
Neversmokewhenhandlingfuel,andstay awayfromanopenameorwherefuel fumesmaybeignitedbyaspark.
Storefuelinaclean,safety-approved containerandkeepthecapinplace.
Ifafueldispensernozzlemustbeused,keep thenozzleincontactwiththerimofthefuel tankorcontaineropeningatalltimesuntil fuelingiscomplete.
1.Removethefueltankcap(Figure16).
CheckingtheHydraulicFluid Level
ServiceInterval:Beforeeachuseordaily
Themachinesreservoirislledatthefactorywith approximately7.5U .S.gallons(13.2l)ofhighquality
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hydraulicuid.Checkthelevelofthehydraulicuid beforetheengineisrststartedanddailythereafter. Therecommendedreplacementuidisasfollows:
ToroPremiumAllSeasonHydraulicFluid(Availablein5 gallonpailsor55gallondrums.SeepartscatalogorT oro distributorforpartnumbers.)
Alternateuids:IftheT orouidisnotavailable,other uidsmaybeusedprovidedtheymeetallthefollowing materialpropertiesandindustryspecications.Wedo notrecommendtheuseofsyntheticuid.Consult withyourlubricantdistributortoidentifyasatisfactory productNote:T orowillnotassumeresponsibilityfor damagecausedbyimpropersubstitutions,souseonly productsfromreputablemanufacturerswhowillstand behindtheirrecommendation.
HighViscosityIndex/LowPourPointAnti-wearHydraulic Fluid,ISOVG46
MaterialProperties:
Viscosity,ASTMD445cSt@40°C44to48
ViscosityIndexASTM D2270 PourPoint,ASTMD97-34°Fto-49°F
IndustrySpecications:
VickersI-286-S(QualityLevel),VickersM-2950-S (QualityLevel),DenisonHF-0
cSt@100°C7.9to8.5 140to160
Note:Manyhydraulicuidsarealmostcolorless, makingitdifculttospotleaks.Areddyeadditivefor thehydraulicsystemoilisavailablein2/3oz.(20ml) bottles.Onebottleissufcientfor4-6gal(15-221) ofhydraulicoil.Orderpartno.44-2500fromyour authorizedTorodistributor.
BiodegradableHydraulicFluid-Mobil224H
ToroBiodegradableHydraulicFluid(Availablein5
gallonpailsor55gallondrums.SeepartscatalogorT oro distributorforpartnumbers.)
Alternateuid:MobilEAL224H
Note:Thisisvegetable-oilbasedbiodegradableoil
testedandapprovedbyToroforthismodel.Thisuid isnotasresistanttohightemperaturesasstandard uidsomakesuretofollowtherecommendeduid changeintervalswiththisuid.Contamination bymineral-basedhydraulicuidswillchangethe biodegradabilityandtoxicityofthisoil.Whenchanging fromstandarduidtothebiodegradabletype,be certaintofollowtheapprovedushingprocedure. ContactyourlocalToroDistributorfordetails.
1.Positionthemachineonalevelsurface,lowerthe cuttingunits,stoptheengine,andremovethekey.
2.Cleantheareaaroundthellerneckandcapofthe hydraulictank(Figure17).Removethecapfrom thellerneck.
Figure17
1.Hydraulictankcap
3.Removethedipstickfromthellerneckandwipe itwithacleanrag.Insertthedipstickintotheller neck;thenremoveitandchecktheuidlevel.The uidlevelshouldbebetweenthetwomarksonthe dipstick.
4.Ifthelevelislow ,addtheappropriateuidtoraise theleveltotheuppermark.
5.Installthedipstickandcapontothellerneck.
CheckingtheTirePressure
ServiceInterval:Beforeeachuseordaily
Thetiresareover-inatedforshipping.Therefore, releasesomeoftheairtoreducethepressure.The correctairpressureinthetiresis20psi(138kPa). Checkthetirepressuredaily.
Important:Maintaintherecommendedpressure inalltirestoensureagoodquality-of-cut andpropermachineperformance.Donot under-inate.
StartingandStoppingthe Engine
StartingtheEngine
Important:Thefuelsystemmustbebledifanyof
thefollowingsituationshaveoccurred:
Theenginehasceasedrunningduetolackoffuel.
Maintenancehasbeenperformeduponthefuel systemcomponents.
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RefertoBleedingtheFuelSystemin,page.
1.Removeyourfootfromthetractionpedaland ensurethatitisinneutral.Ensurethattheparking brakeisset.
2.Movethethrottlecontroltothelowidleposition.
3.TurntheignitionkeytotheRunposition.Theglow indicatorwilllight.
1.MovethethrottlecontrolbackwardtotheSlow position.
2.MovethePTOlevertotheOffposition.
3.Settheparkingbrake.
4.RotatetheignitionkeytoOff.
5.Removethekeyfromtheswitchtoprevent accidentalstarting.
4.Whentheglowindicatordims,turntheignitionkey totheStartposition.Releasethekeyimmediately whentheenginestartsandallowittoreturnto theRunposition.Movethethrottlecontroltothe desiredposition.
Important:Donotrunthestartermotor morethan15secondsatatimeorpremature starterfailuremayresult.Iftheenginefailsto startafter15seconds,turnthekeytotheOff position,recheckthecontrolsandprocedures, wait15additionalseconds,andrepeatthe startingprocedure.
Whenthetemperatureislessthan20°F(-7°C),the startermotorcanberunfor30secondsonthen60 secondsofffor2attempts.
5.Whentheengineisstartedforthersttime,or afteranoverhauloftheengine,transmission,or axle,operatethemachineinforwardandreversefor oneortwominutes.Alsooperatetheliftleverand PTOlevertoensureproperoperationofallparts. Turnthesteeringwheeltotheleftandrightto checksteeringresponse.Thenshuttheengineoff andcheckforoilleaks,looseparts,andanyother noticeabledifculties.
CheckingtheInterlock Switches
ServiceInterval:Beforeeachuseordaily
Ifsafetyinterlockswitchesaredisconnected ordamagedthemachinecouldoperate unexpectedlycausingpersonalinjury.
Donottamperwiththeinterlockswitches.
Checktheoperationoftheinterlock switchesdailyandreplaceanydamaged switchesbeforeoperatingthemachine.
Themachinehasinterlockswitchesintheelectrical system.Theseswitchesaredesignedtostoptheengine whenoperatorgetsoffoftheseatwhenthetraction pedalisdepressed.However,theoperatormaygetoff oftheseatwhiletheengineisrunningandthetraction pedalisinneutral.Althoughtheenginewillcontinue torunifthePTOleverisdisengagedandthetraction pedalisreleased,itisstronglyrecommendedthatthe enginebestoppedbeforerisingfromtheseat.
Shuttheengineoffandwaitforallmoving partstostopbeforecheckingforoilleaks,loose parts,andothermalfunctions.
StoppingtheEngine
Important:Allowenginetoidlefor5minutes
beforeshuttingitoffafterafullloadoperation. Thisallowstheturbochargertocooldownbefore shuttingtheengineoff.Failuretodosomaylead toturbo-chargertrouble.
Note:Lowercuttingunitstothegroundwhenever machineisparked.Thisrelievesthehydraulicloadfrom thesystem,preventswearonsystempartsandalso preventsaccidentalloweringofthecuttingunits.
Tochecktheoperationoftheinterlockswitches, performthefollowingprocedure:
1.Drivethemachineslowlytoalarge,relativelyopen area.Lowerthecuttingunit,stoptheengine,and applytheparkingbrake.
2.Sitontheseatanddepressthetractionpedal.Try tostarttheengine.Theengineshouldnotcrank. Iftheenginecranks,thereisamalfunctioninthe interlocksystemthatshouldbecorrectedbefore beginningoperation.
3.Sitontheseatandstarttheengine.Risefromthe seatandmovethePTOlevertoOn.ThePTO shouldnotengage.IfthePTOengages,thereisa malfunctionintheinterlocksystemthatshouldbe correctedbeforebeginningoperation.
4.Sitontheseat,engagetheparkingbrakeandstart theengine.Movethetractionpedaloutofthe neutralposition.Theengineshouldkill.Ifthe
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enginedoesnotkill,thereisamalfunctioninthe interlocksystemthatshouldbecorrectedbefore beginningoperation.
Note:Thesafetyinterlockswitchescanalsobe checkedusingthediagnosticLED’sontheSCM.
PushingorTowingthe Machine
Inanemergency,themachinecanbemovedforwardby actuatingthebypassvalveinthevariabledisplacement hydraulicpumpandpushingortowingthemachine. Donotpushortowthemachineformorethan1/4 mile(0.4km).
Important:Donotpushortowthemachine fasterthan2-3MPH(3-4.8km/h)becauseinternal transmissiondamagemayoccur.Thebypassvalve mustbeopenwheneverthemachineispushedor towed.
Important:Ifthemachinemusttobepushedor towedinreverse,thecheckvalveinthefour-wheel drivemanifoldmustalsobebypassed.T obypass thecheckvalve,connectahoseassembly(Hose PartNo.95-8843,CouplerFittingNo.95-0985 [Qty.2],andHydraulicFittingNo.340-77[Qty .2]) tothereversetractionpressuretestportandthe reversefour-wheeldrivepressureport.
1.Openhoodandremovethecentershroud
2.Rotatethebypassvalve90°(1/4turn)ineither directiontoopenandallowoiltobypassinternally (Figure18).Becauseuidisbypassed,themachine canbeslowlymovedwithoutdamagingthe transmission.Notethepositionofthevalvewhen openingorclosing.
Figure18
1.Bypassvalve
3.Rotatethebypassvalve90°(1/4turn)backbefore startingtheengine.Donotexceed5-8ft.-lb. (7-11N·m)torquetoclosethevalve.
JackingPoints
Onthefrontofthemachineontheframeonthe insideofeachdrivetire
Ontherearofthemachineatthecenteroftheaxle
TieDowns
Oneachsideoftheframeunderthefrontsteps
Therearbumper
OperatingCharacteristics
Practicedrivingthemachinebecauseithasahydrostatic transmissionanditscharacteristicsaredifferentthan manyturfmaintenancemachines.Somepointsto considerwhenoperatingthetractionunit,cutting units,orotherimplementsarethetransmission,engine speed,loadonthecuttingbladesorotherimplement components,andtheimportanceofthebrakes.
Tomaintainenoughpowerforthetractionunitand implementwhileoperating,regulatethetractionpedal tokeeptheengineRPMhighandsomewhatconstant. Agoodruletofollowistodecreasethegroundspeed astheloadontheimplementincreases,andincreasethe groundspeedastheloaddecreases.
Therefore,allowthetractionpedaltomovebackward astheengineRPMdecreases,anddepressthepedal slowlyastheRPMincreases.Bycomparison,when drivingfromoneworkareatoanother,withnoload andcuttingunitraised,havethethrottleintheFast positionanddepressthetractionpedalslowlybutfully toattainmaximumgroundspeed.
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Anothercharacteristictoconsideristheoperation ofthepedalsthatareconnectedtothebrakes.The brakescanbeusedtoassistinturningthemachine. However,usethemcarefully,especiallyonsoftor wetgrassbecausetheturfmaybetornaccidentally . Anotherbenetofthebrakesistomaintaintraction. Forexample,insomeslopeconditions,theuphillwheel slipsandlosestraction.Ifthissituationoccurs,depress theuphillturnpedalgraduallyandintermittentlyuntil theuphillwheelstopsslipping,thus,increasingtraction onthedownhillwheel.
moduleenergizesoutputsincludingPTO ,Starter,and ETR(energizetorun)solenoid.
Themoduleisdividedintoinputsandoutputs.Inputs andoutputsareidentiedbygreenLEDindicators mountedontheprintedcircuitboard.
Thestartcircuitinputisenergizedby12VDC.All otherinputsareenergizedwhenthecircuitisclosedto ground.EachinputhasaLEDthatisilluminatedwhen thespeciccircuitisenergized.UsetheinputLED’ s forswitchandinputcircuittroubleshooting.
Useextracarewhenoperatingthemachineonslopes. Makesurethattheseatlatchisproperlysecuredandthe seatbeltisbuckled.Driveslowlyandavoidsharpturns onslopestopreventrollovers.Forsteeringcontrol,the cuttingunitmustbeloweredwhengoingdownhill.
Thisproductisdesignedtodriveobjectsinto thegroundwheretheyloseenergyquickly ingrassareas.However,carelessoperation, combinedwithterrainangle,ricochets,or improperlypositionedsafetyguardcanleadto thrownobjectinjuries.
Whenapersonorpetappearssuddenlyinor nearthemowingarea,stopmowing.
Donotresumemowinguntiltheareais cleared.
Important:Allowenginetoidlefor5minutes beforeshuttingitoffafterafullloadoperation. Thisallowstheturbochargertocooldownbefore shuttingtheengineoff.Failuretodosomaylead toturbo-chargertrouble.
Outputcircuitsareenergizedbyanappropriatesetof inputconditions.ThethreeoutputsincludePTO,ETR, andSTART.OutputLED’smonitorrelaycondition indicatingthepresenceofvoltageatoneofthree specicoutputterminals.
Outputcircuitsdonotdetermineoutputdevice integritysoelectricaltroubleshootingincludesoutput LEDinspectionandconventionaldeviceandwire harnessintegritytesting.Measuredisconnected componentimpedance,impedancethroughwire harness(disconnectatSCM),orbytemporarily"test energizing"thespeciccomponent.
TheSCMdoesnotconnecttoanexternalcomputeror handhelddevice,cannotbere-programmed,anddoes notrecordintermittentfaulttroubleshootingdata.
ThedecalontheSCMonlyincludessymbols.Three LEDoutputsymbolsareshownintheoutputbox. AllotherLED’sareinputs.Figure19identiesthe symbols.
Beforestoppingtheengine,disengageallcontrolsand movethethrottletoSlow .MovingthethrottletoSlow reduceshighengineRPM,noise,andvibration.Turn thekeytoOfftostoptheengine.
StandardControlModule (SCM)
TheStandardControlModuleisa"potted"electronic deviceproducedina"onesizetsall"conguration. Themoduleusessolidstateandmechanical componentstomonitorandcontrolstandardelectrical featuresrequiredforsafeproductoperation.
Themodulemonitorsinputsincludingneutral,parking brake,PTO ,start,backlap,andhightemperature.The
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1.Input5.Inseat
2.Backlap
3.Hightempshutdown
4.Hightempwarning(Not used)
6.PTOswitch10.PTO
7.Parkbrakeoff11.Start
8.Neutral12.ETR
Figure19
9.Output13.Start
14.Power
HerearethelogicaltroubleshootingstepsfortheSCM device.
1.Determinetheoutputfaultyouaretryingtoresolve (PTO,START,orETR).
2.Movekeyswitchto"ON"andensurethered "power"LEDisilluminated.
3.MoveallinputswitchestoensureallLED’schange state.
4.Positioninputdevicesatappropriatepositionto achievetheappropriateoutput.Usethefollowing logiccharttodeterminetheappropriateinput condition.
5.IfspecicoutputLEDisilluminatedwithout appropriateoutputfunction,checkoutputharness, connections,andcomponent.Repairasrequired.
6.IfspecicoutputLEDisnotilluminated,check bothfuses.
7.IfspecicoutputLEDisnotilluminatedandinputs areinappropriatecondition,installnewSCMand determineiffaultdisappears.
Eachrow(across)inthelogicchartbelowidenties inputandoutputrequirementsforeachspecic productfunction.Productfunctionsarelistedin theleftcolumn.Symbolsidentifyspeciccircuit conditionincluding:energizedtovoltage,closedto ground,andopentoground.
Note:-Indicatesacircuitclosedtoground.-LEDON OIndicatesacircuitopentogroundorde-energized-LEDOFF +Indicatesanenergizedcircuit(clutchcoil,solenoid,orstartinput)LEDON. ""ABlankindicatesacircuitthatisnotinvolvedwiththelogic.
Totroubleshoot,turnonthekeywithoutstarting theengine.Identifythespecicfunctionthatdoes notworkandworkacrossthelogicchart.Inspect
theconditionofeachinputLED’stoensureit matchesthelogicchart.
IftheinputLED’ sarecorrect,checktheoutput LED.IftheoutputLEDisilluminatedbutthe
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deviceisnotenergized,measureavailablevoltageat theoutputdevice,continuityofthedisconnected device,andpotentialvoltageonthegroundcircuit (oatingground).Repairswillvarydependingon yourndings.
OperatingTips
MowWhenGrassisDry
Moweitherinthelatemorningtoavoidthedew ,which causesgrassclumping,orinlateafternoontoavoidthe damagethatcanbecausedbydirectsunlightonthe sensitive,freshlymowedgrass.
SelecttheProperHeight-of-CutSetting toSuitConditions
Removeapproximately1in.(25mm)ornomorethan 1/3ofthegrassbladewhencutting.Inexceptionally lushanddensegrass,youmayhavetoraisethe height-of-cuttothenextsetting.
allowedtobuildupinthemowerhousing,cutting performancewilldecrease.
Note:Lowercuttingunitstothegroundwhenever machineisparked.Thisrelievesthehydraulicloadfrom thesystem,preventswearonsystempartsandalso preventsaccidentalloweringofthecuttingunits.
MowatProperIntervals
Undermostnormalconditionsyouwillneedtomow approximatelyevery4-5days.Butremember,grass growsatdifferentratesatdifferenttimes.Thismeans thatinordertomaintainthesameheight-of-cut,which isagoodpractice,youwillneedtocutmorefrequently inearlyspring;asthegrassgrowthrateslowsinmid summer,cutonlyevery8-10days.Ifyouareunableto mowforanextendedperiodduetoweatherconditions orotherreasons,mowrstwiththeheight-of-cutata highlevel;thenmowagain2-3dayslaterwithalower heightsetting.
AlwaysMowwithSharpBlades
Asharpbladecutscleanlyandwithouttearingor shreddingthegrassbladeslikeadullblade.Tearingand shreddingcausesthegrasstoturnbrownattheedges whichimpairsgrowthandincreasessusceptibilityto diseases.
Transporting(Groundsmaster4700–D Only)
Usethetworeartransportlatcheswhentransporting overlongdistances,roughterrain,orwhentrailering.
AfterOperating
Toensureoptimumperformance,cleantheunderside ofthemowerhousingaftereachuse.Ifresidueis
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Page 29
Maintenance
Note:Determinetheleftandrightsidesofthemachinefromthenormaloperatingposition.
RecommendedMaintenanceSchedule(s)
MaintenanceService
Interval
Aftertherst8hours
Aftertherst50hours
Aftertherst200hours
Beforeeachuseordaily
Every50hours
Every100hours
Every150hours
Every200hours
MaintenanceProcedure
•Torquethewheelnuts.
•Changetheengineoilandlter.
•Changetheplanetarygeardriveoil.
•Changetherearaxlelubricant.
•Changethehydrauliclters.
•Checktheengineoillevel.
•Checkthecoolingsystem.
•Checkthehydraulicuidlevel.
•Checkthetirepressure.
•Checktheinterlockswitches.
•Drainwaterorothercontaminantsfromthewaterseparator.
•Removedebrisfromtheenginearea,oilcooler,andradiator.
•Inspectthehydrauliclinesandhosesforleaks,kinkedlines,loosemounting supports,wear,loosettings,weatherdeterioration,andchemicaldeterioration.
•Greasethebearingsandbushings.
•Checkthebatterycondition.
•Checktheconditionandtensionofthealternatorbelt.
•Changetheengineoilandlter.
•Torquethewheelnuts.
•Cleanthesparkarrestormufer.
Every400hours
Every800hours
Beforestorage
Yearly
Important:Refertoyourengine maintenanceprocedures.
•Servicetheaircleaner.(Servicetheaircleanerearlieriftheaircleanerindicator showsred.Serviceitmorefrequentlyinextremelydirtyordustyconditions.)
•Checkthefuellinesandconnections.
•Replacethefuelltercanister.
•Checktheplanetarygeardriveoillevel(soonerifexternalleakageisnoticed).
•Checktherearaxlelubricantlevel.
•Drainandcleanthefueltank.
•Changetheplanetarygeardriveoil.
•Changetherearaxlelubricant.
•Checktherearwheeltoe-in.
•Changethehydraulicuid.
•Changethehydrauliclters.
•Drainandcleanthefueltank.
•Checkthetirepressure.
•Checkallfasteners.
•Greaseoroilallgreasettingsandpivotpoints.
•Paintchippedsurfaces.
•Checkthefuellinesandconnections.
•Changetheplanetarygeardriveoil.
•Checktherearwheeltoe-in.
Operator’sManual
andcuttingunit
Operator’sManual
foradditional
29
Page 30
DailyMaintenanceChecklist
Duplicatethispageforroutineuse.
Maintenance CheckItem
Checkthe safetyinterlock operation.
Checkthebrake operation.
Checktheengine oilandfuellevel.
Checkthecooling systemuidlevel.
Drainthe water/fuel separator.
Checktheair lterrestriction indicator.
Checkthe radiator,oilcooler, andscreenfor debris.
Checkunusual enginenoises.
Checkunusual operatingnoises.
Checkthe hydraulicsystem oillevel.
Checkhydraulic hosesfor damage.
Checkforuid leaks.
Checkthetire pressure.
Checkthe instrument operation.
Lubricateall greasettings.
Touch-up damagedpaint.
1
2
Fortheweekof:
Mon.Tues.Wed.Thurs.Fri.
Sat.Sun.
1.Checktheglowplugandinjectornozzlesifhardstarting,excesssmoke,orroughrunningisnoted.
2.Immediatelyaftereverywashing,regardlessoftheintervallisted.
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ServiceIntervalChart
Figure21
Ifyouleavethekeyintheignitionswitch,someonecouldaccidentlystarttheengineandseriously injureyouorotherbystanders.
Removethekeyfromtheignitionbeforeyoudoanymaintenance.
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Premaintenance
Lubrication
Procedures
GreasingtheBearingsand
RemovingtheHood
Togainadditionalaccesstoenginecompartment,the hoodmayberemovedfromtractionunit.
1.Releasehoodlatches(Figure22)andraisehood.
Figure22
1.Hoodlatch
2.Unhooklanyardfromhoodpin,removepinand slidehoodtubesrearwardoffguides(Figure23).
Bushings
ServiceInterval:Every50hours
Themachinehasgreasettingsthatmustbelubricated regularlywithNo.2GeneralPurposeLithiumBase Grease.Ifthemachineisoperatedundernormal conditions,lubricateallbearingsandbushingsafter every50hoursofoperationorimmediatelyafterevery washing.
Thegreasettinglocationsandquantitiesareasfollows:
Brakeshaftpivotbearings(5)(Figure24)
Figure24
Rearaxlepivotbushings(2)(Figure25)
1.Hoodpin
Figure23
Figure25
Steeringcylinderballjoints(2)(Figure26)
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Figure26
1.Topttingonkingpin
Tierodballjoints(2)(Figure26)
Kingpinbushings(2)(Figure26).Thetoptting
onthekingpinshouldonlybelubricated annually(2pumps).
Liftarmbushings(1perdeck)(Figure27)
Figure28
Cuttingunitcarrierarmbushings(1percuttingunit) (Figure28)
Rearrollerbearings(2percuttingunit)(Figure29 orFigure30)
Figure29
Important:Makesurethegreasegroovein
eachrollermountalignswiththegreaseholein eachendoftherollershaft.Tohelpalignthe grooveandhole,thereisalsoanalignmentmark ononeendoftherollershaft.
Figure27
Liftcylinderbushings(2perdeck)(Figure27)
Cuttingunitspindleshaftbearings(1percutting unit)(Figure28)
Note:Onrollersequippedwithushgrease ttings(Figure30)agreasegunnozzleadapteris required.OrderT oroPartNo.107-1998fromyour AuthorizedToroDistributor.
Figure30
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EngineMaintenance
ServicingtheAirCleaner
whichcouldforcedirtthroughthelterintothe intaketract.
Thiscleaningprocesspreventsdebrisfrommigrating intotheintakewhentheprimarylterisremoved.
ServiceInterval:Every400hours
Checktheaircleanerbodyfordamagewhichcould causeanairleak.Replaceifdamaged.Checkthewhole intakesystemforleaks,damageorloosehoseclamps.
Servicetheaircleanerlteronlywhentheservice indicator(Figure31)requiresit.Changingtheairlter beforeitisnecessaryonlyincreasesthechanceofdirt enteringtheenginewhenthelterisremoved.
Figure31
1.Aircleanerindicator
3.Removeandreplacetheprimarylter(Figure33).
Cleaningoftheusedelementisnotrecommended duetothepossibilityofdamagetotheltermedia. Inspectthenewlterforshippingdamage,checking thesealingendofthelterandthebody.Donot useadamagedelement.Insertthenewlterby applyingpressuretotheouterrimoftheelementto seatitinthecanister.Donotapplypressuretothe
exiblecenterofthelter.
Important:Besurethecoverisseatedcorrectly andsealswiththeaircleanerbody.
1.Pullthelatchoutwardandrotatetheaircleaner covercounterclockwise(Figure32).
Figure32
1.Aircleanerlatch2.Aircleanercover
2.Removethecoverfromtheaircleanerbody .Before removingthelter,uselowpressureair(40psi, cleananddry)tohelpremovelargeaccumulations ofdebrispackedbetweenoutsideofprimarylter andthecanister.Avoidusinghighpressureair
Figure33
1.Aircleanerprimarylter
Important:Neverattempttocleanthesafety lter(Figure34).Replacethesafetylterwitha newoneaftereverythreeprimarylterservices.
Figure34
1.Aircleanersafetylter
4.Cleanthedirtejectionportlocatedintheremovable cover.Removetherubberoutletvalvefromthe cover,cleanthecavityandreplacetheoutletvalve.
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5.Installthecoverorientingtherubberoutletvalvein adownwardposition—betweenapproximately5:00 to7:00whenviewedfromtheend.
6.Resettheindicator(Figure31)ifitshowsred.
ServicingtheEngineOiland Filter
ServiceInterval:Aftertherst50hours
Every150hours
Changetheoilandlterinitiallyaftertherst50hours ofoperation;thereafterchangetheoilandlterevery 150hours.
1.Removethereardrainplug(Figure35)andletthe oilowintoadrainpan.Whentheoilstops,install thedrainplug.
AdjustingtheThrottle
Adjustthethrottlecable(Figure37)sothatthegovernor leverontheenginecontactsthelowandhighspeedset boltsbeforethethrottlelevercontactstheslotinthe seatbase.
Figure37
1.Throttlecable
Figure35
1.Engineoildrainplug
2.Removetheoillter(Figure36).Applyalightcoat ofcleanoiltothenewltersealbeforescrewingit on.Donotovertighten.
Figure36
1.Engineoillter
3.Addoiltothecrankcase;refertoCheckingthe EngineOilin,page.
35
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FuelSystem Maintenance
Undercertainconditions,dieselfuelandfuel vaporsarehighlyammableandexplosive.A reorexplosionfromfuelcanburnyouand othersandcancausepropertydamage.
Useafunnelandllthefueltankoutdoors, inanopenarea,whentheengineisoffand iscold.Wipeupanyfuelthatspills.
Donotllthefueltankcompletelyfull.Add fueltothefueltankuntilthelevelis1/4to 1/2in.(6to13mm)belowthebottomof thellerneck.Thisemptyspaceinthetank allowsthefueltoexpand.
1.Placeacleancontainerunderthefuellter.
2.Loosenthedrainplugonthebottomofthelter canister.
Figure38
1.Waterseparatorltercanister
Neversmokewhenhandlingfuel,andstay awayfromanopenameorwherefuel fumesmaybeignitedbyaspark.
Storefuelinaclean,safety-approved containerandkeepthecapinplace.
FuelTank
Every800hours
Beforestorage
Drainandcleanthefueltankevery800hours.Also, drainandcleanthetankiffuelsystembecomes contaminatedorifthemachinewillbestoredforan extendedperiodoftime.Usecleanfueltoushout thetank.
FuelLinesandConnections
ServiceInterval:Every400hours
Yearly
Checkthefuellinesandconnectionsevery400hours oryearly,whichevercomesrst.Inspectthemfor deterioration,damage,orlooseconnections.
ServicingtheWaterSeparator
3.Cleantheareawheretheltercanistermounts.
4.Removetheltercanisterandcleanthemounting surface.
5.Lubricatethegasketontheltercanisterwithclean oil.
6.Installtheltercanisterbyhanduntilthegasket contactsmountingsurface,thenrotateitan additional1/2turn.
7.Tightenthedrainplugonthebottomofthelter canister.
FuelPick-upTubeScreen
Thefuelpick-uptube,locatedinsidethefueltank,is equippedwithascreentohelppreventdebrisfrom enteringthefuelsystem.Removefuelpick-uptubeand cleanscreenasrequired.
BleedingtheFuelSystem
1.Parkthemachineonalevelsurface.Makesurethat thefueltankisatleasthalffull.
2.Unlatchandraisethehood.
3.Opentheairbleedscrewonthefuelinjectionpump (Figure39).
ServiceInterval:Every400hours
Drainwaterorothercontaminantsfromwaterseparator (Figure38)daily.Replaceltercanisterafterevery400 hoursofoperation.
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Figure39
1.Fuelinjectionpumpbleedscrew
4.TurnthekeyintheignitionswitchtotheOn position.Theelectricfuelpumpwillbeginoperation, therebyforcingairoutaroundtheairbleedscrew . LeavethekeyintheOnpositionfor15seconds.Air andfuelwillbeinternallydrainedbacktofueltank. TightenthescrewandturnthekeytoOff.
Note:Normallytheengineshouldstartafterthe abovebleedingproceduresarefollowed.However, iftheenginedoesnotstart,airmaybetrapped betweentheinjectionpumpandinjectors;referto BleedingAirfromtheInjectors.
4.Tightenthepipeconnectorsecurely.
5.Repeattheprocedureontheremainingnozzles.
BleedingAirfromtheInjectors
Note:Thisprocedureshouldbeusedonlyifthe
fuelsystemhasbeenpurgedofairthroughnormal primingproceduresandtheenginewillnotstart;refer toBleedingtheFuelSystem.
1.LoosenthepipeconnectiontotheNo.1injector nozzleandholderassemblyattheinjectionpump (Figure40).
Figure40
1.No.1injectornozzle
2.MovethethrottletotheFastposition.
3.TurnthekeyintheignitionswitchtotheStart positionandwatchthefuelowaroundthe connector.TurnthekeytotheOffpositionwhen solidowisobserved.
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ElectricalSystem Maintenance
ChargingandConnectingthe Battery
CALIFORNIA
Proposition65Warning
Batteryposts,terminals,andrelated
accessoriescontainleadandleadcompounds,
chemicalsknowntotheStateofCalifornia
tocausecancerandreproductiveharm.
Washhandsafterhandling.
1.Unlatchandraisethehood.
2.Removethebatterystrapandcover(Figure41).
Chargingthebatteryproducesgassesthatcan explode.
Neversmokenearthebatteryandkeepsparks andamesawayfrombattery.
5.Installthepositivecable(red)tothepositive(+) terminalandthenegativecable(black)tothe negative(-)terminalofthebattery(Figure42). Securecablestopostswithcapscrewsandnuts. Makesurethatthepositive(+)terminalisallof thewayontothepostandthecableispositioned snugtothebattery.Thecablemustnotcontactthe batterycover.Slidetherubberbootoverthepositive terminaltopreventapossibleshortfromoccurring.
Figure41
1.Batterycover2.Batterystrap
Batteryelectrolytecontainssulfuricacidwhich isadeadlypoisonandcausessevereburns.
Donotdrinkelectrolyteandavoidcontact withskin,eyesorclothing.Wearsafety glassestoshieldyoureyesandrubbergloves toprotectyourhands.
Fillthebatterywherecleanwaterisalways availableforushingtheskin.
Figure42
1.Positivebatterycable2.Negativebatterycable
CALIFORNIA
Proposition65Warning
Batteryposts,terminals,andrelated
accessoriescontainleadandleadcompounds,
chemicalsknowntotheStateofCalifornia
tocausecancerandreproductiveharm.
Washhandsafterhandling.
6.CoatbothbatteryconnectionswithGrafo112X (skin-over)grease,ToroPartNo.505-47,petroleum jelly,orlightgreasetopreventcorrosion.Slidethe rubberbootoverthepositiveterminal.
7.Installthebatterycover.
3.Connecta3to4amp.batterychargertothebattery posts.Chargethebatteryatarateof3to4amperes for4to8hours.
4.Whenthebatteryischarged,disconnectthecharger fromtheelectricaloutletandbatteryposts.
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Batteryterminalsormetaltoolscouldshort againstmetalcomponentscausingsparks. Sparkscancausethebatterygassestoexplode, resultinginpersonalinjury.
Whenremovingorinstallingthebattery,do notallowthebatteryterminalstotouchany metalpartsofthemachine.
Donotallowmetaltoolstoshortbetween thebatteryterminalsandmetalpartsofthe machine.
Incorrectbatterycableroutingcoulddamage themachineandcablescausingsparks.Sparks cancausethebatterygassestoexplode, resultinginpersonalinjury.
Alwaysdisconnectthenegative(black) batterycablebeforedisconnectingthe positive(red)cable.
Alwaysconnectthepositive(red)battery cablebeforeconnectingthenegative(black) cable.
Figure43
BatteryCare
ServiceInterval:Every50hours
Important:Beforeweldingonthemachine, disconnectthenegativecablefromthebatteryto preventdamagetotheelectricalsystem.
Note:Checkthebatteryconditionweeklyorafter every50hoursofoperation.Keeptheterminalsand theentirebatterycasecleanbecauseadirtybatterywill dischargeslowly.Tocleanthebattery,removeitfrom themachine,washtheentirecasewithasolutionof bakingsodaandwater.Rinsewithclearwater.Coatthe batterypostsandcableconnectorswithGrafo112X (skin-over)grease(ToroPartNo.505-47)orpetroleum jellytopreventcorrosion.
Fuses
Thereare6fusesintheelectricalsystem.Theyare locatedundertheoperatorscontrolpanel.Rotatelatches andremovecontrolpanelcovertoexposethefuseas required.
39
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DriveSystem Maintenance
CheckingtheTorqueofthe WheelNuts
ServiceInterval:Aftertherst8hours
Every200hours
Failuretomaintainpropertorqueofthewheel nutscouldresultinfailureorlossofwheeland mayresultinpersonalinjury.
Torquethefrontandrearwheelnutsto 85-100ft.-lb.(115-136N·m)after1-4hoursof operationandagainafter8hoursofoperation. Torqueevery200hoursthereafter.
Note:Frontwheelnutsare1/2-20UNF .Rearwheel nutsareM12x1.5-6H(Metric).
CheckingthePlanetaryGear DriveOil
ServiceInterval:Every400hours
Checktheoillevelafterevery400hoursofoperation orifexternalleakageisnoted.UsehighqualitySAE 85W-140wt.gearlubeasareplacement.
Thecapacityofthesystemisapproximately16oz. (0.5l).
1.Withthemachineonalevelsurface,positionthe wheelsothatthecheck/drainplug(Figure44)isat eitherthe2or10o’clockposition.
Figure44
1.Check/drainplug
2.Removetheplugontheplanetary(Figure44).Oil shouldbeatthebottomofthecheckplugholeon thebacksideofthebrake.
3.Addgearoiltotheholeintheplanetary,ifnecessary, tobringtheoiluptotheproperlevel.Installthe plug.
4.Repeatsteps1–3ontheoppositegearassembly .
ChangingthePlanetaryGear DriveOil
ServiceInterval:Aftertherst200hours
Every800hours
Yearly
Changetheoilinitiallyafterrst200hoursofoperation. Thereafterchangetheoilevery800hours,oryearly, whicheveroccursrst.UseahighqualitySAE85W -140 wt.gearlube.
1.Withthemachineonalevelsurface,positionthe wheelsothatthecheck/drainplug(Figure45)isat thelowestposition(6o’clock).
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Figure45
1.Check/drainplug
2.Placeadrainpanunderthehub,removetheplug, andallowtheoiltodrain.
3.Placeanotherdrainpanunderthebrakehousingon theothersideofthewheel(Figure46).
CheckingtheRearAxle Lubricant
ServiceInterval:Every400hours
Therearaxleisshippedfromthefactorylledwith SAE85W-140wt.gearlube.Checktheoillevelbefore theengineisrststartedandevery400hoursthereafter. Thecapacityis80oz.(2.4l).Visuallyinspectforleaks daily.
1.Positionthemachineonalevelsurface.
2.Removeacheckplugfromoneendoftheaxle (Figure47)andmakesurethatthelubricantisupto thebottomofthehole.Ifthelevelislow ,remove thellplug(Figure47)andaddenoughlubricantto bringtheleveluptothebottomofthecheckplug holes.
Figure46
1.Brakehousing
2.Drainplug
3.Checkplug
4.Removecheck/drainplugsfromthebrakehousing andallowtheoiltodrain.
5.Whenalloftheoilhasdrained,installthebottom pluginthebrakehousing.
6.Positionthewheelsothattheplugholeisattheten ortwoo’clockpositionontheplanetary.
7.Slowlyaddapproximately16oz.(0.5l)ofhigh qualitySAE85W -140wt.gearlubetotheplanetary llhole(atthetenortwoo’clockposition)untilthe levelisuptothebottomofthebrakehousingcheck hole.Installtheplug.
Figure47
1.Checkplug
2.Fillplug
ChangingtheRearAxle Lubricant
ServiceInterval:Aftertherst200hours
Every800hours
Changetheoilinitiallyaftertherst200hoursof operationandevery800hoursofoperationthereafter.
1.Positionthemachineonalevelsurface.
2.Cleantheareaaroundthe3drainplugs,1oneach endand1inthecenter(Figure48).
8.Repeattheprocedureontheopposite planetary/brakeassembly .
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Figure48
1.Drainpluglocation
3.Removethe(3)oillevelcheckplugsandmainaxle ventcaptoeaseindrainingoftheoil.
4.Removethedrainplugsandallowtheoiltodrain intothepans.
5.Installtheplugs.
6.Removeacheckplugandllaxlewithapproximately 80oz.of85W-140gearlubeoruntillubricantisup tobottomofhole.
7.Installcheckplug.
Figure49
1.Pumprod2.Pumpcontroltube
5.Afterwheelrotationceases,tightenjamnutsto secureadjustment.
6.Stoptheengineandreleasetherightbrake.Remove jackstandsandlowerthemachinetotheshopoor. Testdrivethemachinetomakesureitdoesnot creep.
CheckingtheRearWheel Toe-In
AdjustingtheTractionDrive forNeutral
Themachinemustnotcreepwhentractionpedalis released.Ifitdoescreep,anadjustmentisrequired.
1.Parkmachineonalevelsurface,shutengineoff, positionspeedcontrolintoLOWrangeandlower cuttingunitstotheoor.Depressonlytheright brakepedalandengagetheparkingbrake.
2.Jackupleftsideofmachineuntilleftfronttireisoff theshopoor.Supportmachinewithjackstandsto preventitfromfallingaccidentally .
3.Startengineandallowrunatlowidle.
4.Adjustjamnutsonpumprodendtomovepump controltubeforwardtoeliminateforwardcreepor rearwardtoeliminaterearwardcreep(Figure49).
ServiceInterval:Yearly
Every800hours
Afterevery800operatinghoursorannually,checkthe rearwheeltoe-in.
1.Measurethecenter-to-centerdistance(ataxleheight) atthefrontandrearofthesteeringtires.Thefront measurementmustbe1/8in.(3mm)lessthanthe rearmeasurement.
2.Toadjust,removethecotterpinandnutfromeither tierodballjoint(Figure50).Removetierodball jointfromaxlecasesupport.
Figure50
1.Tierodclamp2.Tierodballjoint
3.Loosentheclampsatbothendsofthetierods (Figure50).
4.Rotatethedetachedballjointinwardoroutward one(1)completerevolution.Tightenclampatloose endoftierod.
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5.Rotatetheentiretierodassemblythesamedirection (inwardoroutward)one(1)completerevolution. Tightenclampatconnectedendoftierod.
6.Installtheballjointintheaxlecasesupportand tightenthenutngertight.Measuretoe-in.
7.Repeatprocedureifnecessary.
8.Tightenthenutandinstallanewcotterpinwhen theadjustmentiscorrect.
CoolingSystem Maintenance
ServicingtheEngineCooling System
ServiceInterval:Beforeeachuseordaily
Removedebrisfromtheenginearea,oilcoolerand radiatordaily .Cleanthemmorefrequentlyindirty conditions.
1.Unlatchandswingopenrearscreen(Figure51). Cleanthescreenthoroughlyofalldebris.
Note:Toremovescreen,liftoffhingepins.
Figure51
1.Rearscreenlatch
2.Rotatelatches(Figure52)securingtheoilcoolerto theframe.
Figure52
1.Oilcoolerlatches
3.Pivottheoilcoolerrearward.Cleanbothsidesofthe oilcoolerandradiatorarea(Figure53)thoroughly
43
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withcompressedair.Startfromthefrontandblow thedebrisouttowardstheback.Thencleanfrom thebacksideandblowtowardsthefront.Repeat procedureseveraltimesuntilallchaffanddebrisis removed.
Figure53
1.Oilcooler
2.Radiator
BrakeMaintenance
AdjustingtheServiceBrakes
Adjusttheservicebrakeswhenthereismorethan1in. (25mm)of“freetravel"ofthebrakepedal,orwhenthe brakesdonotworkeffectively.Freetravelisthedistance thebrakepedalmovesbeforebrakingresistanceisfelt.
1.Disengagethelockinglatchfromthebrakepedalsso thatbothpedalsworkindependentlyofeachother.
2.Toreducefreetravelofthebrakepedals,tighten thebrakes:
A.Loosenthefrontnutonthethreadedendofthe
brakecable(Figure54).
Important:Cleaningtheradiatororoilcooler withwaterwillpromoteprematurecorrosion damagetocomponentsandcompactdebris.
4.Pivottheoilcoolerbackintoposition.Secureitto theframewiththelatches,closethescreen.
Figure54
1.Brakecable
B.Tightentherearnuttomovethecablebackward
untilthebrakepedalshave1/2to1in.(13to 25mm)offreetravel.
C.Tightenthefrontnutsafterthebrakesare
adjustedcorrectly.
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BeltMaintenance
ServicingtheAlternatorBelt
HydraulicSystem Maintenance
ServiceInterval:Every100hours
Checktheconditionandtensionofthebelts(Figure55) afterevery100operatinghours.
1.Propertensionwillallow3/8in.(10mm)deection whenaforceof10lb.isappliedonthebeltmidway betweenthepulleys.
2.Ifthedeectionisnot3/8in.(10mm),loosen thealternatormountingbolts(Figure55).Increase ordecreasethealternatorbelttensionandtighten thebolts.Checkthedeectionofthebeltagainto ensurethatthetensioniscorrect.
Figure55
1.Alternator2.Mountingbolt
ChangingtheHydraulicFluid
ServiceInterval:Every800hours
Changethehydraulicuidafterevery800operating hours,innormalconditions.Iftheuidbecomes contaminated,contactyourlocalTorodistributor becausethesystemmustbeushed.Contaminateduid looksmilkyorblackwhencomparedtocleanoil.
1.Turntheengineoffandraisethehood.
2.Disconnectthecasereturnlinefromthebottomof thereservoirandletthehydraulicuidowintoa largedrainpan.Connectthelinewhenthehydraulic uidstopsdraining.
3.Fillthereservoirwithapproximately7.5gallonsof hydraulicuid;refertoCheckingtheHydraulicFluid in,page.
Important:Useonlythehydraulicuids specied.Otheruidscouldcausesystem damage.
4.Installthereservoircap.Starttheengineanduseall ofthehydrauliccontrolstodistributehydraulicuid throughoutthesystem.Alsocheckforleaks;then stoptheengine.
5.Checktheuidlevelandaddenoughtoraiselevel theleveltotheFULLmarkonthedipstick.Donot overll.
ReplacingtheHydraulicFilters
ServiceInterval:Aftertherst200hours
Every800hours
Changethe2hydraulicltersinitiallyaftertherst200 operatinghours.Thereafter,changetheltersafter every800operatinghours,innormalconditions.
UseTororeplacementltersPartNo.94-2621forthe rear(cuttingunit)ofthemachineand75-1310forthe front(charge)ofthemachine.
Important:Useofanyotherltermayvoidthe warrantyonsomecomponents.
1.Positionthemachineonalevelsurface,lowerthe cuttingunits,stoptheengine,engagetheparking brakes,andremovetheignitionkey.
2.Cleantheareaaroundtheltermountingarea.Place adrainpanunderthelterandremovethelter (Figure56andFigure57).
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3.Lubricatethenewltergasketandllthelterwith hydraulicuid.
Hydraulicuidescapingunderpressurecan penetrateskinandcauseinjury.
Makesureallhydraulicuidhosesand linesareingoodconditionandallhydraulic connectionsandttingsaretightbefore applyingpressuretothehydraulicsystem.
Keepyourbodyandhandsawayfrompin holeleaksornozzlesthatejecthighpressure hydraulicuid.
Usecardboardorpapertondhydraulic leaks.
Figure56
1.Hydrauliclter
Figure57
1.Hydrauliclter
4.Ensurethattheltermountingareaisclean.Screw thelteronuntilthegasketcontactsthemounting plate;thentightenthelteranadditional1/2turn.
Safelyrelieveallpressureinthehydraulic systembeforeperforminganyworkonthe hydraulicsystem.
Seekimmediatemedicalattentionifuid isinjectedintoskin.
HydraulicSystemTestPorts
Thetestportsareusedtotestthepressureinthe hydrauliccircuits.ContactyourlocalTorodistributor forassistanceorrefertotheServiceManualforthetest specications.
TestPortA(Figure58),locatedonrearoflter manifold,underrighthandframerail.Usedtomeasure thetractionsystemchargepressure.
5.Starttheengineandletitrunforabouttwominutes topurgeairfromthesystem.Stoptheengineand checkforleaks.
CheckingtheHydraulicLines andHoses
ServiceInterval:Beforeeachuseordaily
Inspectthehydrauliclinesandhosesdailyfor leaks,kinkedlines,loosemountingsupports,wear, loosettings,weatherdeterioration,andchemical deterioration.Makeallnecessaryrepairsbefore operating.
Figure58
1.TestportA(Charge)
TestPortB(Figure59),locatedonsideofcounter balancemanifold,underoperatorsseat.Usedtomeasure thecounterbalancepressureappliedtocuttingunitsfor increasedtraction.
TestPortC(Figure59),locatedonfrontof2wheel drive/4wheeldrivemanifoldthroughfrontaccesspanel
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onoperatorplatform.Usedtomeasurethe4wheel drivepressureappliedtotherearaxle(reversemode) andrearaxledynamicbraking.
Figure61
1.TestportF(Decks)2.TestportG(Decks)
TestPortH(Figure62)locatedonreartractioncircuit hardline.Usedtomeasurereversetractionpressure.
Figure59
1.TestportB(Counter balance)
2.TestportC(Fourwheel drive)
TestPortD(Figure60),locatedonfrontofpump assembly,underoperatorsseatplate.Usedtomeasure steeringpressure.
TestPortE(Figure60),locatedonfrontofpump assembly,underoperatorsseatplate.Usedtomeasure liftcircuitpressure.
TestPortI(Figure62)locatedonfronttractioncircuit hardline.Usedtomeasureforwardtractionpressure
Figure62
1.TestportH(Reverse)2.T estportI(Forward)
AdjustingtheCounterbalance
Thecounterbalancedial(Figure63)isusedtoadjustthe pressureinthecounterbalancecircuit.Recommended counterbalancepressureis620psi.Rotatetheadjusting dial(Figure63)clockwisetoincreasethepressureor counterclockwisetodecreasethepressure.
Figure60
1.TestportD(Steering)2.T estportE(Liftcircuit)
TestPortF(Figure61),locatedontopofrighthand deckmanifold.Usedtomeasurecuttingunitcircuit pressureforcuttingunits5,2and3.
TestPortG(Figure61),locatedontopoflefthanddeck manifold.Usedtomeasurecuttingunitcircuitpressure forcuttingunits1and4.
1.Counterbalancedial
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Figure63
2.Tractionassistvalve
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Thetractionassistvalve(Figure63)isusedtoboostthe pressureinthecounterbalancecircuit.Recommended tractionassistcounterbalancepressureis700psi whentractionpressureisabove1800psi.Rotatethe screw(Figure63)clockwisetoincreasethepressureor counterclockwisetodecreasethepressure.
Important:Tractionunitmustbeatoperating temperaturewhenadjustinghydraulicpressure.
Cleaning
ServicingtheSparkArrestor Mufer
ServiceInterval:Every200hours
Every200hoursoperation,clearthemuferofcarbon buildup.
1.Removethepipeplugfromtheclean-outportatthe lowersideofthemufer.
Themufermaybehotandcouldcauseinjury.
Becarefulwhileworkingaroundthemufer.
2.Starttheengine.Plugthenormalmuferexitwitha blockofwoodormetalplatesothattheexhaustow willbeforcedoutoftheclean-outport.Continueto blocktheexituntilcarbondepositsceasecoming outoftheport.
Donotstandinlinewiththeclean-outport.
Alwayswearsafetyglasses.
3.Stoptheengineandreplacethepipeplug.
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Storage
TractionUnit
1.Thoroughlycleanthetractionunit,cuttingunits,and theengine.
2.Checkthetirepressure;refertoCheckingtheTire Pressure.
3.Checkallfastenersforlooseness;tightenas necessary.
4.Greaseoroilallgreasettingsandpivotpoints. Wipeupanyexcesslubricant.
5.Lightlysandandusetouch-uppaintonpaintedareas thatarescratched,chipped,orrusted.Repairany dentsinthemetalbody .
6.Servicethebatteryandcablesasfollows:
A.Removethebatteryterminalsfromthebattery
posts.
B.Cleanthebattery,terminals,andpostswitha
wirebrushandbakingsodasolution.
C.Coatthecableterminalsandbatterypostswith
Grafo112Xskin-overgrease(ToroPartNo. 505-47)orpetroleumjellytopreventcorrosion.
D.Slowlyrechargethebatteryevery60daysfor24
hourstopreventleadsulfationofthebattery.
7.Engagethetransportlatches(Groundsmaster 4700–Donly).
Engine
1.Draintheengineoilfromtheoilpanandinstallthe drainplug.
2.Removeanddiscardtheoillter.Installanewoil lter.
3.Relltheoilpanwith8qt.(7.6l)ofSAE15W -40 CH-4,CI-4,highermotoroil.
4.Starttheengineandrunitatidlespeedfor approximatelytwominutes.
5.Stoptheengine.
6.Flushthefueltankwithfresh,cleandieselfuel.
7.Secureallofthefuelsystemttings.
8.Thoroughlycleanandservicetheaircleaner assembly.
9.Sealtheaircleanerinletandtheexhaustoutletwith weatherprooftape.
10.Checktheantifreezeprotectionandadda50/50 solutionofwaterandethyleneglycolanti-freezeas neededfortheexpectedminimumtemperaturein yourarea.
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Schematics
ElectricalSchematic-GM4500(Rev.C)
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ElectricalSchematic-GM4700(Rev.C)
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HydraulicSchematic(Rev.E)
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HydraulicSchematic(Rev.E)
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Notes:
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Notes:
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Toro General Commercial Products Warranty
A Two-Year Limited Warranty
Conditions and Products Covered
The Toro Company and its affi liate, Toro Warranty Company, pursuant to an agreement between them, jointly warrant your Toro Commercial Product (“Product”) to be free from defects in materials or workman­ship for two years or 1500 operational hours*, whichever occurs rst. This warranty is applicable to all products with the exception of Aerators (refer to separate warranty statements for these products). Where a warrantable condition exists, we will repair the Product at no cost to you including diagnosis, labor, parts, and transportation. This warranty begins on the date the Product is delivered to the original retail purchaser.
* Product equipped with hour meter
Instructions for Obtaining Warranty Service
You are responsible for notifying the Commercial Products Distributor or Authorized Commercial Products Dealer from whom you pur­chased the Product as soon as you believe a warrantable condition exists. If you need help locating a Commercial Products Distributor or Authorized Dealer, or if you have questions regarding your warranty rights or responsibilities, you may contact us at:
Toro Commercial Products Service Department Toro Warranty Company 8111 Lyndale Avenue South Bloomington, MN 55420-1196 952-888-8801 or 800-952-2740 E-mail: commercial.warranty@toro.com
Owner Responsibilities
As the Product owner, you are responsible for required maintenance and adjustments stated in your Operator’s Manual. Failure to perform required maintenance and adjustments can be grounds for disallow­ing a warranty claim.
Items and Conditions Not Covered
Not all product failures or malfunctions that occur during the warranty period are defects in materials or workmanship. This warranty does not cover the following:
Product failures which result from the use of non-Toro replace­ment parts, or from installation and use of add-on, or modifi ed non-Toro branded accessories and products. A separate waranty may be provided by the manufacturer of these items.
Product failures which result from failure to perform recomended maintenance and/or adjustments. Failure to properly maintain your Toro product per the Recommended Maintenance listed in the Operator’s Manual can result in claims for warranty being denied.
Product failures which result from operating the Product in an abusive, negligent or reckless manner. Parts subject to consumption through use unless found to be
defective. Examples of parts which are consumed, or used up, during normal Product operation include, but are not limited to, brake pads and linings, clutch linings, blades, reels, rollers and bearings (sealed or greasable), bed knives, aerator crankshaft and stomper arm bearings, tines, spark plugs, castor wheels and bearings, tires, fi lters, belts, and certain sprayer components such as diaphragms, nozzles, and check valves, etc.
Failures caused by outside infl uence. Conditions considered to be
outside infl uence include, but are not limited to, weather, storage practices, contamination, use of unapproved coolants, lubricants, additives, fertilizers, water, or chemicals, etc.
Normal noise, vibration, wear and tear, and deterioration.
Normal “wear and tear” includes, but is not limited to, damage to seats due to wear or abrasion, worn painted surfaces, scratched decals or windows, etc.
Parts
Parts scheduled for replacement as required maintenance are war­ranted for the period of time up to the scheduled replacement time for that part. Parts replaced under this warranty are covered for the duration of the original product warranty and become the property of Toro. Toro will make the fi nal decision whether to repair any existing part or assembly or replace it. Toro may use remanufactured parts for warranty repairs.
Note Regarding Deep Cycle Battery Warranty:
Deep cycle batteries have a specifi ed total number of kilowatt-hours they can deliver during their lifetime. Operating, recharging, and ainte­nance techniques can extend or reduce total battery life. As the batter­ies in this product are consumed, the amount of useful work between charging intervals will slowly decrease until the battery is completely worn out. Replacement of worn out batteries, due to normal consump­tion, is the responsibility of the product owner. Battery replacement may be required during the normal product warranty period at owner’s expense.
Maintenance is at Owner’s Expense
Engine tune-up, lubrication cleaning and polishing, replacement of lters, coolant, and completing recommended maintenance are some of the normal services Toro products require that are at the owner’s expense.
General Conditions
Repair by an Authorized Toro Distributor or Dealer is your sole remedy under this warranty.
Neither The Toro Company nor Toro Warranty Company is liable for indirect, incidental or consequential damages in connetion with the use of the Toro Products covered by this warranty, including any cost or expense of providing substitute equipment or service during reasonable periods of malfunction or non-use pending completion of repairs under this warranty. Except for the Emissions warranty referenced below, if applicable, there is no other express warranty. All implied warranties of merchantability and f tness for use are limited to the duration of this express war­ranty.
Some states do not allow exclusions of incidental or consequential damages, or limitations on how long an implied warranty lasts, so the above exclusions and limitations may not apply to you. This warranty gives you specifi c legal rights, and you may also have other rights which vary from state to state.
Note regarding engine warranty:
The Emissions Control System on your Product may be covered by a separate warranty meeting requirements established by the U.S. Envi­ronmental Protection Agency (EPA) and/or the California Air Resourc­es Board (CARB). The hour limitations set forth above do not apply to the Emissions Control System Warranty. Refer to the Engine Emission Control Warranty Statement supplied with your product or contained in the engine manufacturer’s documentation for details.
Countries Other than the United States or Canada Customers who have purchased Toro products exported from the United States or Canada should contact their Toro Distributor (Dealer) to obtain guarantee policies for your country, province, or state. If for any reason you are dissatisfi ed with your Distributor’s service or have diffi culty ob- taining guarantee information, contact the Toro importer.
Part No. 374-0031 Rev. E
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