FORM NO. 3325-238 Rev A MODEL NO.
Foreword The Groundsmaster 3500-D was developed to provide an efficient, reliable and time-saving method of mowing high-quality turf. The latest concepts in engineering and design have been incorporated into this machine along with the highest quality parts and workmanship. Excellent service will be derived if proper operation and maintenance practices are followed. Safety, mechanical and some general information in this manual is emphasized. DANGER, WARNING and CAUTION identify safety messages.
Safety The Groundsmaster 3500-D was tested and certified by TORO for compliance with the B71.4-1999 specifications of the American National Standards Institute. Although hazard control and accident prevention partially are dependent upon the design and configuration of the machine, these factors are also dependent upon the awareness, concern, and proper training of the personnel involved in the operation, transport, maintenance, and storage of the machine.
Safety moderate level. DO NOT EXCEED A 25 DEGREE SIDE HILL ANGLE BECAUSE THE RISK OF A ROLLOVER AND SERIOUS INJURY OR DEATH IS VERY HIGH. The Groundsmaster 3500-D is equipped with an angle indicator, mounted on the steering tube, which indicates the side hill angle the machine is operating on and identifies the recommended maximum limit of 25 degrees. While Operating 12. Always wear your seat belt. 13. Do not run the engine in a confined area without adequate ventilation.
Safety abnormally, stop immediately. Turn engine off, wait for all motion to stop and inspect for damage. 26. Before getting off the seat: A. Move traction pedal to neutral. B. Set the parking brake. C. Disengage the cutting units and wait for the blades to stop spinning. D. Stop the engine and remove key from the ignition switch. 27. Whenever machine is left unattended, make sure, key is removed from ignition switch and parking brake is set. Maintenance 28.
Symbol Glossary Caustic liquids, Poisonous Electrical shock, chemical burns to fumes or toxic electrocution fingers or hand gases, asphyxiation Crushing of whole body, applied from above High pressure fluid, injection into body High pressure High pressure Crushing of Crushing of spray, erosion of spray, erosion of fingers or hand, toes or foot, force flesh flesh force applied from applied from above above Crushing of Crushing of fingers Crushing of leg, Crushing of torso, force or hand/, force force ap
Symbol Glossary Consult technical Fasten seat manual for proper belts service procedures Safety alert triangle Outline safety alert symbol Head protection Hearing Caution, toxic must be worn protection must risk be worn First aid Flush with water Engine Transmission Hydraulic system Exhaust gas Level indicator Liquid level Brake system Filter Oil Temperature Coolant (water) Intake air Failure/ Malfunction Start switch/ mechanism On/start Read operator’s Fire, open light manual and smokin
Symbol Glossary n/min Engine start Engine stop Engine failure/ malfunction Engine rotational Choke speed/frequency Primer (start aid) Electrical preheat Transmission (low temperature oil start aid) NH L F Transmission oil pressure Transmission oil temperature Transmission Clutch failure/malfunction Neutral High Low Forward RP 1 2 3 Reverse Park First gear Hydraulic oil filter Hydraulic oil temperature Hydraulic oil Parking brake failure/malfunction Fuel Unleaded fuel Headlights Unlock
Specifications Engine: Kubota three-cylinder, 4-cycle, liquidcooled diesel engine. 23.9KW @ 2800 rpm. Governed to 3050 rpm. 68.5 cu. in. (1124 cc) displacement. Heavy-duty, 2-stage, remotemounted air cleaner. High water temperature shutdown switch. Frame: Tricycle vehicle with 3-wheel traction drive and rear wheel steering. Frame consists of formed steel, welded steel and steel tubing components. Cooling System: Radiator capacity is approximately 5.7 L of 50/50 mixture of ethylene glycol anti-freeze.
Pre-Operation Checks Adjusting The Lift Arms 1. Start the engine, raise the decks and check to make sure the clearance between each lift arm and the floor plate bracket is 0.46–0.81cm (Fig. 1). If clearance is not in this range, back off the stop bolts (Fig. 3) and adjust the cylinder to attain clearance. To adjust the cylinder, back off the jam nut on the cylinder (Fig. 2), remove the pin from the rod end and rotate the clevis. Install the pin and check clearance. Repeat the procedure if needed.
Pre-Operation Checks CAUTION Before servicing or making adjustments to the machine, stop the engine and remove the key from the switch. 1 Check The Crankcase Oil (Fig. 6–7) The engine is shipped with oil in the crankcase; however, the level of oil must be checked before and after the engine is first started. Crankcase capacity is approximately 4 qts. (3.8 1) with the filter. 1. Position the machine on a level surface. 2. Remove the dipstick and wipe it with a clean cloth.
Pre-Operation Checks 2. Check the level of coolant in the expansion tank. With a cold engine, coolant level should be midway between the marks on the side of the tank. DANGER Because diesel fuel is flammable, use caution when storing or handling it. Do not smoke while filling the fuel tank. Do not fill the fuel tank while the engine is running, hot, or when the machine is in an enclosed area. Always fill the fuel tank outside and wipe up any spilled diesel fuel before starting the engine.
Pre-Operation Checks ISO VG 46/68 multi-viscosity, anti-wear hydraulic fluid Mobil Amoco Castro[ Conoco Gulf Kendall Pennzbell Phillips Shell Sunoco Texaco DTE 15M Rykon Premium ISO 46 AWH 46 Hydroclear AW MV46 Harmony HVI 46 AW Hyken Golden MV SAE 5W-20 AWX MV46 Magnus A KV 5W-20 Tellus T 46 Sun Hyd.
Pre-Operation Checks Note: A red dye additive for the hydraulic system fluid is available in 19 ml bottles. One bottle is sufficient for 15–22 liters. of hydraulic fluid. Order Part No. 44-2500 from your Authorized Toro Distributor. Check The Tire Pressure The tires are over-inflated for shipping. Therefore, release some of the air to reduce the pressure. Correct air pressure in tires is 97–124 kPa.
Controls Traction Pedals (Fig. 12)—Depress the traction forward pedal to move forward. Depress the traction reverse pedal to move backward or to assist in stopping when moving forward. Also, allow the pedal to move or move it to the neutral position to stop the machine. Mow/Transport Slide (Fig. 12)—Using your heel, move the slide to the left to transport and to the right to mow. The cutting units will only operate in the mow position. Note: Mow speed is set at the factory to 9.7 kmh.
Controls 3 4 7 rearward to prevent the cutting units from dropping. 2 Fuel Gauge (Fig. 15)—Registers the amount of fuel in the tank. 8 6 Seat Adjustments (Fig. 15)—Fore and Aft Adjustment—Move the 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. 5 10 11 9 1 Deluxe Seat Adjustments Weight Adjustment— Push the lever up or down to adjust to operator’s weight.
Operation Starting/Stopping The Engine CAUTION IMPORTANT: The fuel system may have to be bled if any of the following situations have occurred: Shut the engine off and wait for all moving parts to stop before checking for oil leaks, loose parts and other malfunctions. A. Initial start up of a new engine. B. The engine has ceased running due to lack of fuel. C. Maintenance has been performed upon fuel system components; i.e., filter replaced, etc. Refer to Bleeding The Fuel System 1.
Operation Correct the problem if not operating properly. 4. Turn the key in the ignition switch to the ON position. The electric fuel pump will begin forcing air out around the air bleed screw. Leave the key in the ON position until a solid stream of fuel flows out around the screw. Tighten the screw and turn the key to OFF Note: Normally, the engine should start after above bleeding procedures are followed.
Operation Operating Characteristics DANGER The mower has a unique traction system that will allow the machine to move forward on side hills, even if the uphill wheel should come of the ground. If this should happen, the operator or any bystanders can be seriously injured or killed in a rollover. The slope angle at which the machine will tip depends on many factors.
Operation your next pass. area is cleared. The Groundsmaster is a one-person machine. Never let anyone else ride on the machine with you. This is extremely dangerous and could result in serious injury. Accidents can happen to anyone. The most common causes are excessive speed, sudden turns, terrain (not knowing what slopes and hills can be mowed safely), not stopping the engine before leaving the operator’s seat, and drugs, which impair your alertness.
Maintenance Minimum Recommended Maintenance Intervals Maintenance Procedure Inspect air filter, dust cap and burp valve Lubricate all grease fittings Change engine oil Check battery cable connections ✝ Check fan and alternator belt tension Check battery fluid level Maintenance Interval & Service Every 50 hours Every 100 hours Every 200 hours Every 400 hours Every 800 hours ‡‡ Change engine oil and filter Inspect traction belt Replace the air filter ✝Replace the hydraulic filter ✝Torque wheel lug nuts
Maintenance Greasing Bearings and Bushings The traction unit has grease fittings that must be lubricated regularly with No. 2 General Purpose Lithium Base Grease. If the machine is operated under normal conditions, lubricate bearings and bushings after every 50 hours of operation. Bearings and bushings must be lubricated daily when operating conditions are extremely dusty and dirty. Dusty and dirty operating conditions could cause dirt to get into the bearings and bushings, resulting in accelerated wear.
Maintenance Figure 23 Figure 27 Figure 24 Figure 28 Figure 25 Figure 29 (See note on previous page) Figure 26 – 23 –
Maintenance CAUTION Before servicing or making adjustments to the machine, stop the engine and remove the key from the switch. Servicing The Air Cleaner 1. Release the latches securing the air cleaner cover to the air cleaner body. Separate cover from body Clean inside of the air cleaner cover. Hood Removal 2 The hood may be easily removed to ease maintenance procedures in the engine area of the machine. 1. Unlatch and raise the hood. 2.
Maintenance cleaner carton for complete information. B. After soaking the filter for 15 minutes, rinse it with clear water. Maximum water pressure must not exceed 276 kPa to prevent damage to the filter element. Rinse the filter from clean side to dirty side. C. Dry the filter element using warm, flowing air (71°C) max), or allow element to air dry. Do not use a light bulb to dry the filter element because damage could result. 1 Figure 33 1. Engine oil drain plug Compressed Air Method A.
Maintenance 2. Clamp both fuel lines that connect to the fuel filter so fuel cannot drain when lines are removed. Water Separator Drain water or other contaminants from water separator (Fig. 35) daily. 3. Loosen the hose clamps at both ends of the filter and pull the fuel lines off the filter. 1. Place a clean container under the fuel filter. 2. Loosen the drain plug on the bottom of the filter canister. Tighten the plug after draining. 1 Figure 36 1. Fuel pre filter 2. Hose clamps 4.
Maintenance 3 1 2 1 Figure 38 Figure 37 1. Access panel 2. Oil cooler 3. Radiator 1. Fuel Injectors (3) 2. Move the throttle to the FAST position. C. Remove access panel. Unlatch the oil cooler and pivot rearward. Clean both sides of the oil cooler and radiator area thoroughly with water or compressed air. Pivot the oil cooler back into position. 3. Turn the key in the key switch to the START position and watch fuel flow around the connector.
Maintenance 3. Loosen the bolt securing the brace to the engine and the bolt securing the alternator to the brace. 4. Insert a pry bar between the alternator and the engine and pry out on the alternator. 2 5. When proper tension is achieved, tighten the alternator and brace bolts to secure adjustment. 1 Figure 41 1. Hydrostat Drive Belt 2. Spring end 1 Adjusting The Throttle 1. Position the throttle lever rearward so it stops against control panel slot. 2.
Maintenance the friction device on the throttle lever. The maximum force required to operate the throttle lever should be 27 Nm. CAUTION 1 Before servicing or making adjustments to the machine, stop the engine and remove the key from the switch. Figure 44 1. Hydraulic filter Changing Hydraulic Fluid Change hydraulic fluid after every400 operating hours, in normal conditions. If fluid becomes contaminated, contact your local TORO distributor because the system must be flushed.
Maintenance whichever comes first. Adjusting The Traction Drive For Neutral Use the Toro replacement filter (Part No. 54-0110). If the machine “creeps” when the traction pedal is in the neutral position, the traction cam must be adjusted. IMPORTANT: Use of any other filter may void the warranty on some components. 1. Position the machine on a level surface, lower the cutting units, stop the engine, engage the parking brake and remove the key from ignition switch. 2.
Maintenance days. 4. Start the engine and rotate the cam hex in both directions to determine the mid position of the neutral span. 3. Maintain cell level with distilled or demineralized water. Do not fill cells above the bottom of the split ring inside each cell. Install the filler caps with vents pointing to the rear (toward the fuel tank). 5. Tighten the locknut to secure adjustment. 6. Stop the engine. 7. Remove the support blocks and lower the machine to the shop floor.
Maintenance Battery Storage If the machine will be stored more than 30 days, remove the battery and charge it fully. Either store it on the shelf on the machine. Leave the cables disconnected if stored on the machine. Store the battery in a cool atmosphere to avoid quick deterioration of the charge in the battery. To prevent battery from freezing, make sure it is fully charged. The specific gravity of a fully charged battery is 1.265–1.299.
Maintenance Preparation for Seasonal Storage 4. Start the engine and run at idle speed for approximately two minutes. 5. Stop the engine. 6. Thoroughly drain all fuel from the fuel tank, lines and the fuel filter/water separator assembly. Traction Unit 1. Thoroughly clean the traction unit, cutting units and the engine. 2. Check the tire pressure. Inflate all traction unit tires to 97–124 kPa. 7. Flush the fuel tank with fresh, clean diesel fuel. 3.
