Form No. 3350–569 Groundsmaster 3500-D Groundsmaster Traction Unit Model No. 30821—Serial No.
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Recommended Maintenance Schedule . . . . . . . . . Daily Maintenance Checklist . . . . . . . . . . . . . . . . . Greasing the Bearings and Bushings . . . . . . . . . . . Service Interval Chart . . . . . . . . . . . . . . . . . . . . . . Removing the Hood . . . . . . . . . . . . . . . . . . . . . . . . Servicing the Air Cleaner . . . . . . . . . . . . . . . . . . . . Servicing the Engine Oil and Filter . . . . . . . . . . . .
Safe Operating Practices Introduction The following instructions are from the CEN standard EN 836:1997, ISO standard 5395:1990, and ANSI standard B71.4-1999. Read this manual carefully to learn how to operate and maintain your product properly. The information in this manual can help you and others avoid injury and product damage. Although Toro designs and produces safe products, you are responsible for operating the product properly and safely.
• Warning—fuel is highly flammable. Take the following precautions: – Stay alert for humps and hollows and other hidden hazards. – Never mow across the face of the slope, unless the machine is designed for that purpose. – Store fuel in containers specifically designed for this purpose. – Refuel outdoors only and do not smoke while refuelling. • Stay alert for holes in the terrain and other hidden hazards. – Add fuel before starting the engine.
• Use care when checking blades. Wrap the blades or wear gloves, and use caution when servicing them. Only replace blades. Never straighten or weld them. • Keep hands and feet away from the cutting units. • Look behind and down before backing up to be sure of a clear path. • Keep hands and feet away from moving parts. If possible, do not make adjustments with the engine running. • Slow down and use caution when making turns and crossing roads and sidewalks.
• Do not operate the machine while wearing tennis shoes or sneakers. • Raise the cutting units when driving from one work area to another. • Wearing safety shoes and long pants is advisable and required by some local ordinances and insurance regulations. • Do not touch the engine, muffler, exhaust pipe, or hydraulic tank while the engine is running or soon after it has stopped because these areas could be hot enough to cause burns.
Sound Power Level Vibration Level This unit has a guaranteed sound power level of 105 dBA, based on measurements of identical machines per Directive 2000/14/EC and amendments. This unit does not exceed a vibration level of 2.5 m/s2 at the hands based on measurements of identical machines per ISO 5349 procedures. Sound Pressure Level This unit does not exceed a vibration level of 0.5 m/s2 at the posterior based on measurements of identical machines per ISO 2631 procedures.
93-7818 1. Warning—read the operator’s manual for blade torque instructions. 43-8480 107-7801 (for CE) 1. Tipping hazard—do not drive on slopes greater than 15 degrees. 93-6681 1. Cutting/dismemberment hazard—stay away from moving parts. 99-3444 1. Reel speed—fast 104-0484 104-1086 1. Height of cut 8 2.
106-6753 (for CE) 1. Thrown object hazard—keep bystanders a safe distance from the machine. 104-5181 (for CE) 1. Warning—read the Operator’s Manual. 2. Tipping hazard—do not drive on slopes greater than 15 degrees and, if the roll bar is installed, wear the seat belt. 3. Thrown object hazard—keep bystanders a safe distance from the machine. 4. Cutting hazard of hand or foot—stay away from moving parts. 5.
4–5191 1. Engage the power take off (PTO). 2. Disengage the power take off (PTO). 3. Lower the cutting units. 4. Move the cutting units to the right. 5. Raise the cutting units. 6. Move the cutting units to the left. 7. Move rear ward to lock the lift lever. 8. Engine—stop 107-7800 10 9. 10. 11. 12. 13.
Specifications General Specifications Engine Cooling system Electrical Kubota three-cylinder, 4-cycle liquid-cooled diesel engine. 32 hp @ 2800 RPM, governed to 3050 RPM. 68.5 cu. in. (1124 cc) displacement. Heavy-duty, 2-stage, remote mounted air cleaner. High water temperature shutdown switch. Radiator capacity is approximately 6 qt. of 50/50 mixture of ethylene glycol anti-freeze. Remote mounted 1 qt. expansion tank.
Setup Note: Determine the left and right sides of the machine from the normal operating position. Loose Parts Note: Use this chart as a checklist to ensure that all parts necessary for assembly have been received. Without these parts, total setup cannot be completed. Some parts may have already been assembled at the factory. Description Qty. Use Hood lock bracket 1 Screw, 1/4 x 1-1/2 in. 1 Flat washer, 1/4 in. 1 Locknut, 1/4 in.
Activating, Charging, and Connecting the Battery Warning Charging the battery produces gasses that can explode. Warning Never smoke near the battery and keep sparks and flames away from battery. CALIFORNIA Proposition 65 Warning 5. When the battery is charged, disconnect the charger from the electrical outlet and battery posts. Battery posts, terminals, and related accessories contain lead and lead compounds, chemicals known to the State of California to cause cancer and reproductive harm.
Important If the battery is ever removed, make sure that battery clamp bolts are reinstalled with the bolt heads positioned on the bottom side and the nuts on the top side. If the clamp bolts are reversed, they may interfere with the hydraulic tubes when shifting the cutting units. 1 2 3 8. Coat both battery connections with Grafo 112X (skin over) grease, Toro Part No. 505-47, petroleum jelly, or light grease to prevent corrosion. Slide the rubber boot over the positive terminal. 9.
8. Mount the seat straps to the frame with the fasteners and spacers removed in step 1. 4. Insert a bolt (1/4 x 1-1/2 in.) through the hood lock bracket and secure it with a flat washer and locknut (Fig. 8). 9. Slide the seat completely forward and backward to ensure proper operation and that the seat switch wires and connectors are not pinched or do no contact any moving parts.
Adjusting the Lift Arms 1. Start the engine, raise the decks, and check to make sure that the clearance between each lift arm and the floor plate bracket is .18–.32 in. (5–8 mm) (Fig. 10). If the clearance is not in this range, back off the stop bolts (Fig. 11) and adjust the cylinder to attain clearance. To adjust the cylinder, back off the jam nut on the cylinder (Fig. 12), remove the pin from the rod end, and rotate the clevis. Install the pin and check the clearance. Repeat the procedure if required.
Rear Ballast 3. If the oil level is low, remove the oil fill cap (Fig. 16) and gradually add small quantities of oil, checking the level frequently, until the level reaches the FULL mark on the dipstick. The Groundsmaster 3500 Traction unit with 27” Rotary Cutting decks conforms to the B71.4-1999 standard when 50 lb. of calcium chloride ballast is added to the rear wheels. 1 Important If a puncture occurs in a tire with calcium chloride, remove the machine from the turf as quickly as possible.
Danger Caution Under certain conditions, diesel fuel and fuel vapors are highly flammable and explosive. A fire or explosion from fuel can burn you and others and can cause property damage. If the engine has been running, the pressurized, hot coolant can escape and cause burns. • Do not open the radiator cap when the engine is running. • Use a rag when opening the radiator cap, and open the cap slowly to allow steam to escape.
Multigrade Hydraulic Fluid – ISO VG 46 3. Remove the dipstick from the filler neck and wipe it with a clean rag. Insert the dipstick into the filler neck; then remove it and check the fluid level. The fluid level should be within 1/4 inch (6 mm) of the mark on the dipstick. Normal Climate: 0 F (–18 C) to 110 F (43 C) Mobil DTE 15M Amoco Rykon Premium ISO 46 Chevron 4. If the level is low, add the appropriate fluid to raise the level to the full mark.
Operation Note: Determine the left and right sides of the machine from the normal operating position. 1 Caution This machine produces sound levels in excess of 85 dBA at the operators ear and can cause hearing loss through extended periods of exposure. Wear hearing protection when operating this machine. Figure 22 1. Speed stop screw Controls Traction Pedals Tilt Steering Lever Depress the traction forward pedal (Fig. 21) to move forward. Depress traction reverse pedal (Fig.
7 4 3 Engine Coolant Temperature Warning Light 2 The temperature warning light (Fig. 23) glows if the engine coolant temperature is high. If the traction unit is not stopped and the coolant temperature rises another 10°F, the engine will kill. 8 6 5 10 Oil Pressure Warning Light 11 9 The oil pressure warning light (Fig. 23) glows if the engine oil pressure drops below a safe level. 1 Alternator Light Figure 23 1. 2. 3. 4. 5. 6.
Deluxe Seat Adjustments Important To prevent overheating of the starter motor, do not engage the starter longer than 15 seconds. After 10 seconds of continuous cranking, wait 60 seconds before engaging the starter motor again. Weight Adjustment—Push the lever up or down to adjust to the operator’s weight: lever up—light operator, lever in middle position—medium weight operator, or lever down—heavy operator. 5.
seat and slowly depress the traction pedal, the engine should stop in one to three seconds. Correct problem if it is not operating properly. 1 Note: The machine is equipped with an interlock switch on the parking brake. The engine will stop if the traction pedal is depressed with the parking brake engaged. Towing the Traction Unit In case of an emergency, the machine can be towed for a short distance; however, we do not recommend this as a standard procedure.
Standard Control Module (SCM) Output circuits are energized by an appropriate set of input conditions. The three outputs include PTO, ETR, and START. Output LED’s monitor relay condition indicating the presence of voltage at one of three specific output terminals. The Standard Control Module is a ”potted” electronic device produced in a ”one size fits all” configuration.
Each row (across) in the logic chart below identifies input and output requirements for each specific product function. Product functions are listed in the left column. Symbols identify specific circuit condition including: energized to voltage, closed to ground, and open to ground. – Indicates a circuit closed to ground. – LED ON O Indicates a circuit open to ground or de–energized – LED OFF + Indicates an energized circuit (clutch coil, solenoid, or start input) LED ON.
Operating Characteristics Practice moving forward and reverse, and starting and stopping the machine. To stop, take your foot off of the traction pedal and let it return to neutral or press down on the reverse pedal to stop. Going down a hill, you may need to use the reverse pedal to stop. 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 off of the ground.
• Requires more horsepower to run. Mowing Techniques • Tends to discharge further left and can tend to windrow at lower heights of cut. To begin cutting, engage the decks, then approach the mowing area slowly. Once the front decks are over the mowing area, lower the cutting units. Warning To achieve the professional straight-line cut and striping that is desirable for some applications, find a tree or other object in the distance and drive straight toward it.
Optional Equipment Configuration Cons Pros Applicatio tion High Lift Parallel Sail Blade Standard Angle Sail DO NOT USE Blade WITH MULCHING BAFFLE Grass Cutting: .75 to 1.75 inch Height of Cut Recommended in most applications May work well in light or sparse turf Grass Cutting: 2.00 to 2.50 inch Height of Cut Recommended for thick or lush turf Recommended for light or sparse turf Grass Cutting: 2.75 to 4.
Maintenance Note: Determine the left and right sides of the machine from the normal operating position. Recommended Maintenance Schedule Maintenance Service Interval Maintenance Procedure After first 10 hours • Check the fan and alternator belt tension. • Replace the hydraulic filter. • Torque the wheel lug nuts. After first 50 hours • Change the engine oil and filter. • Check the engine RPM (at idle and full throttle). Every 50 hours • • • • • • Every 100 hours • Change the engine oil filter.
Daily Maintenance Checklist Duplicate this page for routine use. For the week of: Maintenance Check Item Mon. Tues. Wed. Thurs. Check the safety interlock operation. Check brake operation. Check the engine oil level. Check the cooling system fluid level. Drain the water/fuel separator. Check the air filter, dust cup, and burp valve. Check the radiator and screen for debris. Check for unusual engine noises.1 Check for unusual operating noises. Check the hydraulic system oil level.
Greasing the 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 the bearings and bushings after every 50 hours of operation. The 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.
(2) Figure 34 Figure 31 Figure 35 Figure 32 Figure 36 Figure 33 32
Figure 38 Figure 37 See note Service Interval Chart 33
Removing the Hood 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. Remove the cotter pin securing the hood pivot to the mounting brackets (Fig. 39). 1 1 Figure 40 1. Air cleaner dust cup 2. Air cleaner latch 2. Gently slide the filter out of the air cleaner body to reduce the amount of dust dislodged. Avoid knocking the filter against the air cleaner body. Figure 39 1. Cotter pin 3. Inspect the filter (Fig.
7. Insert the new filter properly into the air cleaner body. Make sure that the filter is sealed properly by applying pressure to the outer rim of the filter when installing it. Do not press on the flexible center of the filter. 8. Install the cover and secure the latches. Make sure that the cover is positioned with the TOP side up.
4. Remove the clamp from the fuel filter and slide it onto the replacement filter. Push the fuel lines onto the replacement fuel filter and secure them with the hose clamps. Be sure that the arrow on the side of the filter points toward the injection pump. 5. Secure the filter to the frame rail with the previously removed screw. 1 Danger 2 Under certain conditions, diesel fuel and fuel vapors are highly flammable and explosive.
2. Move the throttle to the Fast position. 3. Turn the key in the key switch to the Start position and watch the fuel flow around the connector. Turn the key to the Off position when solid flow is observed. 4. Tighten the pipe connector securely. 5. Repeat the procedure on the remaining nozzles. Cleaning the Engine Cooling System Remove debris from the oil cooler and radiator daily. Clean them more frequently in dirty conditions. Figure 48 1. Turn the engine off and raise the hood.
Adjusting the Throttle 1. Position the throttle lever rearward so it stops against the control panel slot. 2. Loosen the throttle cable connector on the injection pump lever arm (Fig. 51). 1 Figure 49 1 1. Alternator/fan belt Replacing the Hydrostat Drive Belt 1. Insert a nut driver or small piece of tubing onto the end of the belt tensioning spring. Figure 51 Warning 1. Injection pump lever arm Use caution when de-tensioning the spring, as it is under a heavy load. 3.
4. Install the reservoir cap. Start the engine and use all of the hydraulic controls to distribute the hydraulic fluid throughout the system. Also check for leaks; then stop the engine. 5. Check the fluid level and add enough to raise the level to FULL mark on the dipstick. Do not overfill. Replacing the Hydraulic Filter 1 The hydraulic system filter must be changed initially, after the first 10 hours of operation, and thereafter every 200 hours of operation or yearly, whichever comes first.
Checking the Hydraulic Lines and Hoses Daily, check hydraulic lines and hoses for leaks, kinked lines, loose mounting supports, wear, loose fittings, weather deterioration, and chemical deterioration. Make all necessary repairs before operating. Warning Hydraulic fluid escaping under pressure can penetrate skin and cause injury. 1 • Make sure all hydraulic fluid hoses and lines are in good condition and all hydraulic connections and fittings are tight before applying pressure to the hydraulic system.
Adjusting the Parking Brake Keep the top of the battery clean by washing it periodically with a brush dipped in ammonia or bicarbonate of soda solution. Flush the top surface with water after cleaning. Do not remove the filler caps while cleaning. Check the adjustment of the parking brake every 200 hours. 1. Loosen the set screw securing the knob to the parking brake lever (Fig. 56). The battery cables must be tight on the terminals to provide good electrical contact. 2.
Electrical Schematic 42
Hydraulic Schematic 43
Engine Preparation for Seasonal Storage 1. Drain the engine oil from the oil pan and replace the drain plug. Traction Unit 2. Remove and discard the oil filter. Install a new oil filter. 1. Thoroughly clean the traction unit, cutting units, and engine. 3. Refill the oil pan with approximately 4 U.S. quarts (3.8 l) of SAE10W-30 motor oil. 2. Check the tire pressure. Inflate all tires to 14–18 psi (97–110 kPa). 4. Start the engine and run it at idle speed for approximately two minutes. 3.
The Toro General Commercial Products Warranty A Two-Year Limited Warranty Conditions and Products Covered The Toro Company and its affiliate, 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 first.
