Form No. 3374-318 Rev A Groundsmaster® 3500-D Traction Unit Model No. 30839N—Serial No. 313000001 and Up Register at www.Toro.com.
WARNING Model No. 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. Serial No. This manual identifies potential hazards and has safety messages identified by the safety alert symbol (Figure 2), which signals a hazard that may cause serious injury or death if you do not follow the recommended precautions.
Contents Controls System Maintenance .....................................37 Adjusting the Throttle.............................................37 Hydraulic System Maintenance ....................................38 Changing the Hydraulic Filter...................................38 Changing the Hydraulic Fluid...................................38 Checking the Hydraulic Lines and Hoses....................39 Storage ........................................................................
Preparation Safety • While mowing, always wear substantial footwear, long This machine meets or exceeds ANSI B71.4-2004 specifications in effect at the time of production when equipped with required weight as listed in Rear Ballast section. • Improper use or maintenance by the operator or owner can result in injury.
• • • • • • • • • • • • • • Look behind and down before backing up to be sure of – Do not stop or start suddenly when going up or downhill. – Keep machine speeds low on slopes and during tight turns. – Stay alert for humps and hollows and other hidden hazards. – Never mow across the face of the slope, unless the mower is designed for this purpose. Stay alert for holes in the terrain and other hidden hazards. Watch out for traffic when crossing or near roadways.
• When starting the engine, engage the parking brake, put or disconnecting from battery. Wear protective clothing and use insulated tools. the traction pedal in neutral, and disengage the blade drive. After the engine starts, release the parking brake and keep your foot off of the traction pedal. The machine must not move. If movement is evident, refer to the Maintenance section of this manual to adjust the traction drive.
Maintenance and Storage relieved by stopping the engine and lowering the cutting units to the ground. • Before servicing or making adjustments, stop the engine • If the engine must be running to perform a maintenance and remove the ignition key. adjustment, keep hands, feet, clothing, and any parts of the body away from the cutting units, attachments, and any moving parts. Keep everyone away. • Ensure that the entire machine is properly maintained and in good operating condition.
Battery Symbols Some or all of these symbols are on your battery 1. Explosion hazard 6. Keep bystanders a safe distance from the battery. 2. No fire, open flame, or smoking. 7. Wear eye protection; explosive gases can cause blindness and other injuries 3. Caustic liquid/chemical burn hazard 4. Wear eye protection 8. Battery acid can cause blindness or severe burns. 9. Flush eyes immediately with water and get medical help fast. 106-6753 1.
104-5191 1. Engage the power take off (PTO). 5. Raise the cutting units. 2. Disengage the power take off (PTO). 6. Move the cutting units to the left. 3. Lower the cutting units. 7. Move rear ward to lock the 11. Fast lift lever. 8. Engine—stop 12. Continuous variable setting 4. Move the cutting units to the right. 9. Engine—run 10. Engine—start 9 13.
6-9290 1. Inputs 5. In seat 2. Not active 6. Power Take-off (PTO) 9. Outputs 10. Power Take Off (PTO) 3. High temperature shutdown 7. Parking brake Off 11. Start 4. High temperature warning 12. Energize to Run (ETR) 8. Neutral 117-5103 10 13. Start 14.
Setup Loose Parts Use the chart below to verify that all parts have been shipped. Procedure Description 2 3 4 Use Qty. Inclinometer 1 Check the angle indicator No parts required – Adjust the lift arms. No parts required – Rear ballast. Media and Additional Parts Description Use Qty. Ignition keys 2 Start the engine. Operator's Manual Engine Operator's Manual 1 1 Read before operating the machine. Parts Catalog 1 Use to look up and order parts.
Figure 3 Figure 4 1. Battery cover 1. Positive (+) battery cable 3. Remove the filler caps from the battery and slowly fill each cell until electrolyte is just above the plates. 2. Negative (–) battery cable Important: If the battery is ever removed, make sure that the battery clamp bolts are installed 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. 4.
If the clearance is not in this range, adjust it as follows: A. Back off the stop bolts (Figure 7). Figure 5 1. Angle indicator Figure 7 3. If the inclinometer does not read zero degrees, move the machine to a location where a zero degree reading is obtained. The angle indicator, mounted on the machine, should now read zero degrees as well. 1. Stop bolt 3. Clearance 2. Lift arm B. 4.
Product Overview Controls Figure 9 1. Wear bar 2. Bumper strap If the clearance is not in this range, adjust the rear cylinder as follows: Note: If the rear lift arm clunks during transport, clearance can be reduced. A. Lower the cutting units and back off the jam nut on the cylinder (Figure 10). Figure 11 1. Forward traction pedal 4. Tilt steering lever 2. Reverse traction pedal 5. Indicator slot 3. Mow/transport slide 6. Angle indicator Traction Pedals Figure 10 1.
Tilt Steering Lever Cutting Unit Drive Switch Pull the tilt steering lever (Figure 11) back to tilt the steering wheel to the desired position. Then push the lever forward to tighten. The cutting unit drive switch (Figure 13) 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 11) indicates when the cutting units are in the center position.
Parking Brake Specifications Whenever the engine is shut off, engage the parking brake (Figure 13) 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. Note: Specifications and design are subject to change without notice. Lift Lever Lock Overall Width - 68 inch width of cut 71.8 inches (182 cm) Overall Width - 72 inch width of cut 75.
Operation Note: Determine the left and right sides of the machine from the normal operating position. Checking the Engine Oil Level Service Interval: Before each use or daily The engine is shipped with oil in the crankcase; however, the oil level must be checked before and after the engine is first started. Figure 16 1. Oil fill cap Crankcase capacity is approximately 4 qt (2.8 l) with the filter.
3. Fill the tank to the bottom of the filler neck. Do not overfill. Install the cap. 4. To prevent a fire hazard, wipe up any fuel that may have spilled. Figure 18 Figure 17 1. Access panel 3. Oil cooler 2. Radiator 1. Fuel tank cap The cooling system is filled with a 50/50 solution of water and permanent ethylene glycol anti-freeze. Check the coolant level at the beginning of each day before starting the engine.
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. This fluid is not as resistant to high temperatures as standard fluid, so install an oil cooler if required by the operator manual and follow recommended fluid change intervals with this fluid.
Turn the steering wheel to the left and right to check steering response; then shut the engine off and check for oil leaks, loose parts, and any other noticeable malfunctions. DANGER Low tire pressure decreases machine side hill stability. This could cause a rollover, which may result in personal injury or death. CAUTION Do not under-inflate the tires. Stop the engine and wait for all moving parts to stop before checking for oil leaks, loose parts, and other malfunctions.
Note: The machine is equipped with an interlock switch on the parking brake. The engine will stop if the traction pedal is pressed with the parking brake engaged. Towing the Traction Unit In case of an emergency, the machine can be towed for a short distance; however, Toro does not recommend this as a standard procedure. Important: Do not tow the machine faster than 2 to 3 MPH (3 to 4 km/h) because the drive system may become damaged.
START. Output LED’s monitor relay condition indicating the presence of voltage at one of three specific output terminals. The SCM does not connect to an external computer or hand held device, can not be re–programmed, and does not record intermittent fault troubleshooting data. Output circuits do not determine output device integrity so electrical troubleshooting includes output LED inspection and conventional device and wire harness integrity testing.
Operating Tips • (–) Indicates a circuit closed to ground. – LED ON • (O) Indicates a circuit open to ground or de–energized – LED OFF General Tips • (+) Indicates an energized circuit (clutch coil, solenoid, or DANGER start input) LED ON. To troubleshoot, turn on the key without starting the engine. Identify the specific function that does not work and work across the logic chart. Inspect the condition of each input LED’s to ensure it matches the logic chart.
Mowing Patterns • 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. Change mowing patterns often to minimize aftercut appearance issues induced by repetitive operation in only one direction.
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. In exceptionally lush and dense grass you may have to raise your height–of–cut setting another notch. Always Start Mowing with Sharp Blades A sharp blade cuts cleanly and without tearing or shredding the grass blades like a dull blade.
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. 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 24 Premaintenance Procedures 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. 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. 2. Remove the hairpin cotter securing the hood pivot to the mounting brackets (Figure 25). Figure 25 1.
Lubrication Greasing the Bearings And Bushings Service Interval: Every 50 hours (Lubricate all bearings and bushings daily when conditions are dusty and dirty.) 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.
• Left front lift arm pivot and lift cylinder (2) (Figure 31) Figure 34 • Belt tension pivot (Figure 35) Figure 31 • Right front lift arm pivot and lift cylinder (2) (Figure 32) Figure 35 • Steering cylinder (Figure 36). Figure 32 • Neutral adjust mechanism (Figure 33) Figure 36 Figure 33 Note: If desired, an additional grease fitting may be installed in the other end of the steering cylinder.
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. Figure 37 • Service at the recommended service interval or earlier if engine performance suffers due to extremely dusty, dirty conditions.
Figure 42 1. Engine oil drain plug Figure 41 2. Remove the oil filter (Figure 43). Apply a light coat of clean oil to the new filter seal before screwing it on. Do not overtighten. 1. Primary filter 5. Inspect the new filter for shipping damage, checking the sealing end of the filter and the body. Do not use a damaged element. 6. Insert the new filter by applying pressure to the outer rim of the element to seat it in the canister. Do not apply pressure to the flexible center of the filter. 7.
Changing the Fuel Filter Canister Fuel System Maintenance Service Interval: Every 400 hours Servicing the Fuel Tank 1. Clean the area where the filter canister mounts (Figure 44). Service Interval: Every 2 years—Drain and clean the fuel tank. 2. Remove the filter canister and clean the mounting surface. 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. 3.
Electrical System Maintenance WARNING 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. Caring for the Battery Service Interval: Every 25 hours—Check the electrolyte level. (If machine is in storage, check every 30 days.) The battery electrolyte level must be properly maintained and the top of the battery kept clean.
Drive System Maintenance Cooling System Maintenance Adjusting the Traction Drive for Neutral Cleaning the Engine Cooling System If the machine moves when the traction pedal is in the neutral position, the traction cam must be adjusted. Service Interval: Before each use or daily Remove debris from the oil cooler and radiator daily. Clean them more frequently in dirty conditions. 1. Position the throttle lever rearward so it stops against the control panel slot. 1.
Brake Maintenance Belt Maintenance Adjusting the Parking Brake Servicing the Engine Belts Service Interval: Every 200 hours—Check the parking brake adjustment. 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. 1. Loosen the set screw securing the knob to the parking brake lever (Figure 49). Tensioning the Alternator/Fan Belt 1. Open the hood. 2.
Controls System Maintenance 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 (Figure 52). Figure 51 1. Hydrostat drive belt 2. Spring end 3. Replace the belt. 4. Reverse the procedure to tension the spring. Figure 52 1. Injection pump lever arm 3. Hold the injection pump lever arm against the low idle stop and tighten the cable connector. 4.
Hydraulic System Maintenance 2. Disconnect the hydraulic line (Figure 54) or remove the hydraulic filter (Figure 53) and let the hydraulic fluid flow into a drain pan. Install the hydraulic line when hydraulic fluid stops draining. Changing the Hydraulic Filter Service Interval: After the first 10 hours Every 200 hours/Yearly (whichever comes first) 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 Storage Storing the Battery Service Interval: Before each use or daily 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. Refill the oil pan with approximately 4 qt (3.8 l) of SAE15W-40 motor oil. 4. Start the engine and run it at idle speed for approximately two minutes. 5. Stop the engine. 6. Thoroughly drain all fuel from the fuel tank, fuel lines, fuel filter, and water separator assembly. 7. Flush the fuel tank with fresh, clean diesel fuel. 8. Secure all fuel system fittings. 9. Thoroughly clean and service the air cleaner assembly. 10. Seal the air cleaner inlet and the exhaust outlet with weatherproof tape. 11.
Schematics G008924 Electrical Schematic (Rev.
G008925 Hydraulic Schematic (Rev.
Notes: 43
The Toro Total Coverage Guarantee A 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).
