Form No. 3328–558 Rev. D Groundsmaster 3500-D Groundsmaster Traction Unit Model No. 30821—Serial No.
Warning Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Recommended Maintenance Schedule . . . . . . . . . Daily Maintenance Checklist . . . . . . . . . . . . . . . . Greasing the Bearings and Bushings . . . . . . . . . . Removing the Hood . . . . . . . . . . . . . . . . . . . . . . . Servicing the Air Cleaner . . . . . . . . . . . . . . . . . . . Servicing the Engine Oil and Filter . . . . . . . . . . . Servicing the Fuel System . . . . . . . . . . . . . . . . . .
• All drivers and mechanics should seek and obtain professional and practical instruction. The owner is responsible for training the users. Such instruction should emphasize: This manual identifies potential hazards and has special safety messages that help you and others avoid personal injury and even death. Danger, Warning, and Caution are signal words used to identify the level of hazard. However, regardless of the hazard, be extremely careful.
• When using any attachments, never direct discharge of material toward bystanders nor allow anyone near the machine while in operation. • Evaluate the terrain to determine what accessories and attachments are needed to properly and safely perform the job. Only use accessories and attachments approved by the manufacturer. • Never operate the machine with damaged guards, shields, or without safety protective devices in place. Be sure all interlocks are attached, adjusted properly, and functioning properly.
• Charge batteries in an open well ventilated area, away from spark and flames. Unplug charger before connecting or disconnecting from battery. Wear protective clothing and use insulated tools. • The operator shall turn on flashing warning lights, if provided, whenever traveling on a public road, except where such use is prohibited by law. Maintenance and Storage Toro Mower Safety • Keep all nuts, bolts, and screws tight to be sure the equipment is in safe working condition.
• 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. • Wearing safety shoes and long pants is advisable and required by some local ordinances and insurance regulations. • Keep hands, feet, and clothing away from moving parts and the mower discharge area. Maintenance and Storage • Fill fuel tank until level is 1 in. (25 mm) below the bottom of the filler neck. Do not overfill.
Sound Pressure Level Vibration Level This unit has an equivalent continuous A-weighted sound pressure level at the operator ear of 89 dBA based on measurements of identical machines per Directive 98/37/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. 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.
100-4837 93-7276 1. Explosion hazard—wear eye protection. 2. Caustic liquid hazard—flush with water and get medical help fast. 3. Fire hazard—fire, open light, and smoking prohibited. 4. Toxic hazard—keep children away from the battery. 100-6574 1. Hot surface hazard—stay away. 2. Cutting/dismemberment hazard and entanglement hazard—stay away from moving parts. 104-4864 99-3560 (for CE) 1. Warning—read the operator’s manual. 2.
104-1086 1. Height of cut 43-8480 100-6583 (for CE) 1. Thrown object hazard—keep bystanders away. 2. Warning—stay away from rotating blades and moving parts. 93-7818 1. Warning—read the operator’s manual for blade torque instructions. 93-6681 1. Cutting/dismemberment hazard—stay away from moving parts. 99-3444 1. Reel speed—fast 9 2.
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.
2. Remove the battery cover (Fig. 1). Warning Incorrect battery cable routing could damage the tractor and cables causing sparks. Sparks can cause the battery gasses to explode, resulting in personal injury. • Always disconnect the negative (black) battery cable before disconnecting the positive (red) cable. • Always connect the positive (red) battery cable before connecting the negative (black) cable. 1 Figure 1 1. Battery cover 3.
Installing the Seat 6. On the deluxe seat only, route the unused seat switch connector back under the seat strap and secure both wires to the rear-most hole in the seat strap (Fig. 5) with a cable tie (cable tie supplied with seat kit). The machine is shipped without the seat assembly. Deluxe Seat Kit, Model No. 03225 or Standard Seat Kit, Model No. 03224, must be installed as follows: 1. Remove the screws, washers, and spacers securing the seat mounting straps to the traction unit frame (Fig. 3).
Checking the Angle Indicator 2 3 Danger 1 To reduce risk of injury or death due to rollover, do not operate the machine on side hills steeper than 25 . 1. Park the machine on a flat, level surface. Figure 8 2. Verify that the machine is level by placing a hand held inclinometer (supplied with the machine) on the frame cross rail, by the fuel tank (Fig. 7). The inclinometer should read zero degrees when viewed from the operator’s position. 1. Hood latch 2. Hood latch bracket 3.
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.
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. Fri. 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 29
3. Slide the hood to the right side, lift the other side, and pull it out of the brackets. 4. Reverse the procedure to install the hood. Servicing the Air Cleaner Check air cleaner body for damage which could possibly cause an air leak. Replace a damaged air cleaner body. Service the air cleaner filter every 200 hours (more frequently in extreme dusty or dirty conditions). Be sure that cover is sealing around the air cleaner body. Figure 37 1.
Servicing the Engine Oil and Filter 1 Change the oil and filter initially after the first 50 hours of operation; thereafter change the oil every 50 hours and the filter every 100 hours. 1. Remove either drain plug (Fig. 42) and let oil flow into a drain pan. When the oil stops flowing, install the drain plug. Figure 41 1. Filter element 4. Washing Method A.
Servicing the Fuel System Replacing the Fuel Prefilter Fuel Tank Replace the fuel prefilter, located on the inside of the frame rail below the water separator, after every 400 operating hours or yearly, whichever occurs first. Drain and clean the fuel tank every 2 years. Also, drain and clean the tank if the fuel system becomes contaminated or if the machine will be stored for an extended period of time. Use clean fuel to flush out the tank. 1. Remove the screw securing the filter to the frame rail. 2.
Bleeding Air from the Injectors Note: This procedure should be used only if the fuel system has been purged of air through normal priming procedures and the engine will not start; refer to Bleeding the Fuel System, page 21. 3 1. Loosen the pipe connection to the No. 1 nozzle and holder assembly. 2 1 Figure 47 1. Access panel 2. Oil cooler 3. Radiator 1 3. Unlatch the oil cooler and pivot it rearward (Fig. 48). Clean both sides of the oil cooler and radiator area thoroughly with water or compressed air.
Servicing the Engine Belts 2 Check condition and tension of all belts after first day of operation and every 100 operating hours thereafter. Alternator/Fan Belt (Fig. 49) 1 1. Open the hood. 2. Check the tension by depressing the belt midway between the alternator and crankshaft pulleys with 22 lb. (30 N⋅m) of force. The belt should deflect 7/16 in. (11 mm). If the deflection is incorrect, proceed to step 3. If it is correct, continue operation. Figure 50 3.
7. If the throttle does not stay in position during operation, torque the locknut, used to set the friction device on the throttle lever, to 40–55 in.-lb. (5–6 N⋅m). The maximum force required to operate the throttle lever should be 20 lb. (27 N⋅m). 1 Changing the Hydraulic Fluid Change the hydraulic fluid after every 400 operating hours, in normal conditions. If the fluid becomes contaminated, contact your local Toro distributor because the system must be flushed.
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 38
Hydraulic Schematic 39
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 1996 or newer Toro Commercial Product (“Product”) purchased after January 1, 1997, to be free from defects in materials or workmanship for two years or 1500 operational hours*, whichever occurs first.
