Form No. 3359-738 Rev B Groundsmaster® 3500-D Groundsmaster Traction Unit Model No. 30839—Serial No. 280000001 and Up To register your product or download an Operator's Manual or Parts Catalog at no charge, go to www.Toro.com.
Warning Introduction CALIFORNIA Proposition 65 Warning Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm. Read this information carefully to learn how to operate and maintain your product properly and to avoid injury and product damage. You are responsible for operating the product properly and safely. You may contact Toro directly at www.Toro.
Safety Greasing the Bearings And Bushings................... 32 Engine Maintenance............................................... 35 Servicing the Air Cleaner .................................... 35 Changing the Engine Oil and Filter ..................... 35 Fuel System Maintenance ....................................... 36 Servicing the Fuel Tank ...................................... 36 Inspecting the Fuel Lines and Connections...................................................
◊ Inadequate braking ◊ The type of machine is unsuitable for the task ◊ Lack of awareness of the effect of ground conditions, especially slopes ◊ Incorrect hitching and load distribution • Before attempting to start the engine, disengage all blade attachment clutches, shift into neutral, and engage the parking brake. Only start the engine from the operator’s position. Never remove the ROPS and always wear the seat belts during operation. • Do not put hands or feet near or under rotating parts.
• • • • • • • • • • – Before checking, cleaning, or working on the mower – After striking a foreign object or if an abnormal vibration occurs (check immediately). Inspect the mower for damage and make repairs before restarting and operating the equipment. Torque all the spindle pulley nuts to 130 to 150 ft-lb (176 to 203 N-m). Disengage the drive to attachments when transporting or when not machine is not in use.
Preparation Be sure to establish your own special procedures and work rules for unusual operating conditions (e.g., slopes too steep for operation). Survey the complete mowing site to determine which hills can be safely operated on. When performing this site survey, always use common sense and take into consideration the turf condition and the rollover risk. To determine which hills or slopes may be safely operated on, use the inclinometer provided with each machine.
Sound Power Level • If the engine must be running to perform a maintenance adjustment, keep hands, feet, clothing, and any parts of the body away from the cutting units, attachments, and any moving parts. Keep everyone away. This unit has a guaranteed sound power level of 105 dBA, based on measurements of identical machines per ISO 11094. • Do not overspeed the engine by changing governor settings.
107-7801 (CE Only) 100-4837 1. Tipping hazard—do not drive on slopes greater than 15 degrees. 93-7276 1. Explosion hazard—wear eye protection. 2. Caustic liquid/chemical burn hazard—to perform first aid, flush with water. 3. Fire hazard—no fire, open flames, or smoking. 4. Poison hazard—keep children a safe distance from the battery. 104-0484 93-7818 1. Warning—read the Operator’s Manual for instructions on torquing the blade bolt/nut to 115-149 N-m (85-110 ft-lb). 104-1086 1.
Battery Symbols Some or all of these symbols are on your battery 1. Explosion hazard 2. No fire, open flame, or smoking. 43-8480 3. Caustic liquid/chemical burn hazard 4. Wear eye protection 93-6681 5. Read the Operator’s Manual. 99-3444 1. Cutting/dismemberment—hazard, fan-stay away from moving parts. 6. Keep bystanders a safe distance from the battery. 7. Wear eye protection; explosive gases can cause blindness and other injuries 8. Battery acid can cause blindness or severe burns. 9.
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. 9. Engine—run 6. Move the cutting units to 10. Engine—start the left. 7. Move rear ward to lock the 11. Fast lift lever. 8. Engine—stop 12. Continuous variable setting 10 13.
107-7800 11
Setup Loose Parts Use the chart below to verify that all parts have been shipped. Procedure Description 2 3 4 5 6 Use Qty. Inclinometer 1 Hood lock bracket Screw, 1/4 x 1–1/2 inches Flat washer, 1/4 inch Locknut, 1/4 inch Exhaust guard Self-tapping screw 1 1 1 1 1 4 No parts required – Adjust the lift arms. No parts required – Rear ballast. Check the angle indicator. Install the Hood Latch (CE). Install the Exhaust Guard (CE). Media and Additional Parts Description Use Qty.
1 Activating, Charging, and Connecting the Battery No Parts Required Figure 3 Procedure 1. Battery cover Warning 3. Remove the filler caps from the battery and slowly fill each cell until electrolyte is just above the plates. CALIFORNIA Proposition 65 Warning Battery posts, terminals, and related accessories contain lead and lead compounds, chemicals known to the State of California to cause cancer and reproductive harm. Wash hands after handling. 4.
2 Incorrect battery cable routing could damage the tractor and cables causing sparks. Sparks can cause the battery gasses to explode, resulting in personal injury. Checking the Angle Indicator Parts needed for this procedure: • Always disconnect the negative (black) battery cable before disconnecting the positive (red) cable. 1 • Always connect the positive (red) battery cable before connecting the negative (black) cable.
3 4 Installing the Hood Latch (CE Only) Installing the Exhaust Guard (CE Only) Parts needed for this procedure: Parts needed for this procedure: 1 Hood lock bracket 1 Exhaust guard 1 Screw, 1/4 x 1–1/2 inches 4 Self-tapping screw 1 Flat washer, 1/4 inch 1 Locknut, 1/4 inch Procedure 1. Position the exhaust guard around the muffler while aligning the mounting holes with the holes in the frame (Figure 7). Procedure 1. Unhook the hood latch from the hood latch bracket (Figure 6).
5 Adjusting the Lift Arms No Parts Required Procedure Figure 10 1. Start the engine, raise the cutting units, and check to ensure that the clearance between each lift arm and the floor plate bracket is 0.18 to 0.32 inches (5 to 8 mm) (Figure 8). 1. Front cylinder 2. Jam nut C. Remove the pin from the rod end and rotate the clevis. D. Install the pin and check the clearance. Repeat the procedure if required. 2 E. Tighten the clevis jam nut. 3 2.
Product Overview Controls Figure 12 1. Rear cylinder 2. Adjusting nut B. Grasp the cylinder rod close to the nut with a pliers and rag and rotate the rod. C. Raise the cutting units and check the clearance. Repeat the procedure if required. D. Tighten the clevis jam nut. Figure 13 Important: Lack of clearance at the front stops or rear wear bar could damage the lift arms. 1. Forward traction pedal 2. Reverse traction pedal 3. Mow/transport slide 6 4. Tilt steering lever 5. Indicator slot 6.
Tilt Steering Lever Cutting Unit Drive Switch Pull the tilt steering lever (Figure 13) back to tilt the steering wheel to the desired position. Then push the lever forward to tighten. The cutting unit drive switch (Figure 15) has two positions: Engage and Disengage. The rocker switch operates a solenoid valve on the valve bank to drive the cutting units. Indicator Slot Hour Meter The slot in the operator platform (Figure 13) indicates when the cutting units are in the center position.
Glow Plug Indicator Specifications The glow plug indicator light (Figure 15) will glow when the glow plugs are operating. Note: Specifications and design are subject to change without notice. Overall Width - 68 inch width of cut 71.8 inches (182 cm) Whenever the engine is shut off, engage the parking brake (Figure 15) to prevent accidental movement of the machine. To engage the parking brake, pull up on the lever. The engine will stop if you press the traction pedal with the parking brake engaged.
Operation 3. Push the dipstick down into the dipstick tube and make sure that it is seated fully. Pull the dipstick out and check the oil level. 4. If the oil level is low, remove the oil fill cap (Figure 18) and gradually add small quantities of oil, checking the level frequently, until the level reaches the Full mark on the dipstick. Note: Determine the left and right sides of the machine from the normal operating position.
Checking the Cooling System • Painted surfaces may be damaged by biodiesel blends. • Use B5 (biodiesel content of 5%) or lesser blends in cold weather • Monitor seals, hoses, gaskets in contact with fuel as they may be degraded over time. • Fuel filter plugging may be expected for a time after converting to biodiesel blends. • Contact your distributor if you wish for more information on biodiesel 1. Clean the area around the fuel tank cap (Figure 19). 2. Remove the fuel tank cap. 3.
the hydraulic system oil is available in 2/3 oz. (20 ml) bottles. One bottle is sufficient for 4-6 U.S. gallons (15-22 1) of hydraulic oil. Order part no. 44-2500 from your authorized Toro distributor. Biodegradable Hydraulic Fluid—Mobil 224H Toro Biodegradable Hydraulic Fluid (Available in 5 gallon pails or 55 gallon drums. See parts catalog or Toro distributor for part numbers.) Alternate fluid: Mobil EAL 224H This is vegetable–oil based biodegradable oil tested and approved by Toro for this model.
Checking the Tire Pressure 3. Move the throttle lever to the 1/2 throttle position. Service Interval: Before each use or daily 4. Insert the key into the switch and rotate it to the On/Preheat position until the glow plug indicator light goes out (approximately 7 seconds); then rotate the key to the Start position to engage the starter motor. Release the key when the engine starts. The key will move automatically to the On/Run position. The tires are over-inflated for shipping.
Checking the Interlock System Service Interval: Before each use or daily 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 safety interlock switches are disconnected or damaged the machine could operate unexpectedly causing personal injury. • Use a funnel and fill the fuel tank outdoors, in an open area, when the engine is off and is cold. Wipe up any fuel that spills.
The module is divided into inputs and outputs. Inputs and outputs are identified by green LED indicators mounted on the printed circuit board. The start circuit input is energized by 12 VDC. All other inputs are energized when the circuit is closed to ground. Each input has a LED that is illuminated when the specific circuit is energized. Use the input LED’s for switch and input circuit troubleshooting. Figure 24 Output circuits are energized by an appropriate set of input conditions.
including: energized to voltage, closed to ground, and open to ground. INPUTS Function Power ON In Neutral Start ON Brake ON OUTPUTS PTO ON In Seat Hi Temp Backlap Start ETR PTO Start — — + O O — O O + + O Run (Off Unit) — — O O O O O O O + O Run (On Unit) — O O — O — O O O + O Mow — O O — — — O O O + + Backlap — — O O — O O — O + + Hi Temp — O O O — O • (–) Indicates a circuit closed to ground.
Operating Tips • Start the engine and run it at half idle until it warms up. Push the throttle lever all the way forward, lift the cutting units, disengage the parking brake, press the forward traction pedal, and carefully drive to an open area. General Tips • 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.
• The Sidewinder offers up to a maximum of 13 inches (33 cm) of overhang, allowing you to trim closer to the edge of sand traps and other obstacles, while at the same time keeping the tractor tires as far away from the edge of traps or water hazards as possible. damage that can be caused by direct sunlight on the sensitive, freshly mowed grass. Select the Proper Height-of-Cut Setting to Suit Conditions Remove approximately one inch or no more than 1/3 of the grass blade when cutting.
Maintenance Note: Determine the left and right sides of the machine from the normal operating position. Recommended Maintenance Schedule(s) Maintenance Service Interval Maintenance Procedure After the first hour • Torque the wheel nuts. After the first 10 hours • Torque the wheel nuts. • Check the condition and tension of all belts. • Change the hydraulic filter. After the first 50 hours • Change the oil and oil filter. Before each use or daily • • • • • • • • Check the engine oil level.
Daily Maintenance Checklist Duplicate this page for routine use. For the week of: Maintenance Check Item Mon. Tues. Wed. Thurs. Fri. Sat. Check the safety interlock operation. Check the 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 for unusual engine noises.2 Check the radiator and screen for debris Check for unusual operating noises. Check the hydraulic system oil level.
Service Interval Chart Figure 26 Premaintenance Procedures Removing the Hood The hood may be easily removed to ease maintenance procedures in the engine area of the machine. 1. Unlatch and raise the hood. Figure 27 2. Remove the hairpin cotter securing the hood pivot to the mounting brackets (Figure 27). 1. Hairpin cotter 3. Slide the hood to the right side, lift the other side, and pull it out of the brackets. Note: Reverse the procedure to install the hood.
Lubrication Greasing the Bearings And Bushings Service Interval: Every 50 hours (Lubricate all bearings and bushings daily when conditions are dusty and dirty.) Yearly Every 500 hours/Yearly (whichever comes first) The machine has grease fittings that must be lubricated regularly with No. 2 General Purpose Lithium Base Grease. Bearings and bushings must be lubricated daily when operating conditions are extremely dusty and dirty.
Figure 35 • Mow/transport slide (Figure 36) Figure 32 • Left front lift arm pivot and lift cylinder (2) (Figure 33) Figure 36 • Belt tension pivot (Figure 37) Figure 33 • Right front lift arm pivot and lift cylinder (2) (Figure 34) Figure 37 • Steering cylinder (Figure 38).
Figure 41 Note: The flush fittings on the rollers (Figure 27) require a grease gun nozzle adapter. Order Toro Part No. 107-1998 from your Authorized Toro Distributor. Figure 38 Note: If desired, an additional grease fitting may be installed in the other end of the steering cylinder. Remove the tire, install the fitting, grease the fitting, remove the fitting, and install the plug (Figure 39). Important: Do not lubricate the Sidewinder cross tube. The bearing blocks are self-lubricated.
Engine Maintenance Servicing the Air Cleaner Service Interval: Every 200 hours (More frequently in extreme dusty or dirty conditions) • Check the air cleaner body for damage which could cause an air leak. Replace if damaged. Check the whole intake system for leaks, damage, or loose hose clamps. • Service at the recommended service interval or earlier if engine performance suffers due to extremely dusty, dirty conditions.
Fuel System Maintenance Servicing the Fuel Tank Service Interval: Every 2 years—Drain and clean the fuel tank. ( 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. Figure 44 1. Engine oil drain plug Inspecting the Fuel Lines and Connections 2. Remove the oil filter (Figure 45). Apply a light coat of clean oil to the new filter seal before screwing it on. Do not overtighten.
Electrical System Maintenance 2. Remove the filter canister and clean the mounting surface. 3. Lubricate the gasket on the filter canister with clean oil. Caring for the Battery 4. Install the filter canister by hand until the gasket contacts the mounting surface; then rotate an additional 1/2 turn. Service Interval: Every 25 hours—Check the electrolyte level. (If machine is in storage, check every 30 days.
Drive System Maintenance Incorrect battery cable routing could damage the tractor and cables causing sparks. Sparks can cause the battery gasses to explode, resulting in personal injury. Adjusting the Traction Drive for Neutral • Always disconnect the negative (black) battery cable before disconnecting the positive (red) cable. If the machine moves when the traction pedal is in the neutral position, the traction cam must be adjusted.
Cooling System Maintenance Brake Maintenance Cleaning the Engine Cooling System Service Interval: Every 200 hours—Check the parking brake adjustment. Adjusting the Parking Brake 1. Loosen the set screw securing the knob to the parking brake lever (Figure 51). Service Interval: Before each use or daily Remove debris from the oil cooler and radiator daily. Clean them more frequently in dirty conditions. 1. Turn the engine off and raise the hood. Clean the engine area thoroughly of all debris. 2.
Belt Maintenance Servicing the Engine Belts Service Interval: After the first 10 hours—Check the condition and tension of all belts. Every 100 hours—Check the condition and tension of all belts. Tensioning the Alternator/Fan Belt 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 inch (11 mm). Figure 53 1. Hydrostat drive belt 2. Spring end 3. Replace the belt. 4.
Controls System Maintenance Hydraulic System Maintenance Adjusting the Throttle Changing the Hydraulic Filter 1. Position the throttle lever rearward so it stops against the control panel slot. Service Interval: After the first 10 hours Every 200 hours/Yearly (whichever comes first) 2. Loosen the throttle cable connector on the injection pump lever arm (Figure 54). Use a genuine Toro replacement filter, Part No. 86-3010. Important: Use of any other filter may void the warranty on some components. 1.
Checking the Hydraulic Lines and Hoses 2. Disconnect the hydraulic line (Figure 56) or remove the hydraulic filter (Figure 55) and let the hydraulic fluid flow into a drain pan. Install the hydraulic line when hydraulic fluid stops draining. Service Interval: Before each use or 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.
Engine Storage 1. Drain the engine oil from the oil pan and replace the drain plug. Storing the Battery 2. Remove and discard the oil filter. Install a new oil filter. If the machine will be stored more than 30 days, remove the battery and charge it fullyStore the battery in a cool atmosphere to avoid quick deterioration of the charge in the battery.. To prevent the battery from freezing, make sure it is fully charged. The specific gravity of a fully charged battery is 1.265–1.299. 3.
Schematics G008924 Electrical Schematic (Rev.
G008925 Hydraulic Schematic (Rev.
Notes: 46
Notes: 47
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. This warranty is applicable to all products with the exception of Aerators (refer to separate warranty statements for these products).
