Form No. 3354-412 Rev B Groundsmaster® 4500-D Traction Unit Model No. 30856—Serial No. 260000001 and Up Register your product at www.Toro.
Warning the model and serial numbers of your product ready. Figure 1 identifies the location of the model and serial numbers on the product. Write the numbers in the space provided. 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.
Sound Power Level .............................. 7 Vibration Level.................................... 7 Safety and Instructional Decals ............ 8 Setup ................................................................ 14 1 Installing the Seat, Seat Belt, and Manual Tube ..................... 14 2 Greasing the Machine ..................... 15 3 Checking Fluid Levels ..................... 15 4 Reading the Manuals and Viewing the Video........................... 15 Product Overview .......................
Safety of the brake. The main reasons for loss of control are: ◊ insufficient wheel grip; ◊ being driven too fast; ◊ inadequate braking; ◊ the type of machine is unsuitable for the task; ◊ lack of awareness of the effect of ground conditions, especially slopes; • The owner/user can prevent and is responsible for accidents or injuries occurring to himself or herself, other people, or property. This machine meets or exceeds CEN standard EN 836:1997 (when appropriate decals applied), and ANSI B71.
functioning properly. Do not operate unless they are functioning properly. – stop on level ground; – disengage the power take-off and lower the attachments; – change into neutral and set the parking brake; – stop the engine and remove the key. Operation • Do not operate the engine in a confined space where dangerous carbon monoxide fumes can collect. • Mow only in daylight or in good artificial light.
Maintenance and Storage • Keep hands and feet away from moving parts. If possible, do not make adjustments with the engine running. • 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. • Keep all nuts, bolts and screws tight to be sure the equipment is in safe working condition.
– Reduce speed when making sharp turns. Avoid sudden stops and starts. high pressure. Use paper or cardboard, not your hands, to search for leaks. Hydraulic fluid escaping under pressure can have sufficient force to penetrate the skin and cause serious injury. Seek immediate medical attention if fluid is injected into skin. – When near or crossing roads, always yield the right-of-way. – Apply the service brakes when going downhill to keep forward speed slow and to maintain control of the machine.
Safety and Instructional Decals Whole Body 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. Safety decals and instructions are easily visible to the operator and are located near any area of potential danger. Replace any decal that is damaged or lost. 104-0131 1. Read the Operator’s Manual. 105-3888 1. Read the Operator’s Manual. 2.
105-7506 1. Read the Operator’s Manual. 2. Engine—stop 3. On 4. Engine—preheat 5. Engine—start 105-9223 (Afx over part no. 105-38890 for CE) 1. 2. 3. Warning-read the Operator’s Manual. To start the engine (read the Operator’s Manual), sit in the operators’ position, turn the ignition key to the Engine-run position until the Engine-preheat light turns off, turn the ignition key to the Engine-start position, and press the brake pedal.
93-6686 1. Hydraulic oil 2. Read the Operator’s Manual. Battery Symbols Some or all of these symbols are on your battery 1. Explosion hazard 6. 2. No re, open ame, or smoking. 7. 3. Caustic liquid/chemical burn hazard 4. Wear eye protection 8. 5. Read the Operator’s Manual. 105-3889 10 9. 10. Keep bystanders a safe distance from the battery. Wear eye protection; explosive gases can cause blindness and other injuries Battery acid can cause blindness or severe burns.
107-1983 (Afx over part no. 105–3889 for CE) 1. 2. 3. 4. 5. Warning—read the Operator’s Manual. Warning—lock the parking brake, stop the engine, and remove the ignition key before leaving the machine. Thrown object hazard—keep bystanders a safe distance from the machine. Cutting hazard of hand or foot—stay away from moving parts. Tipping hazard—do not drive machine on a slope greater than 15 degrees, wear the seat belt, and lower the cutting unit when driving down slopes. 108-4044 1. 2. 3. 4. 5.
105-8507 1. Input 2. Backlap 3. High temp 4. 5. 6. In seat PTO switch Park brake off 7. Neutral 8. Output 9. PTO 12 10. 11. 12.
105-9895 13
Setup Loose Parts Use the chart below to verify that all parts have been shipped. Step Description 1 Seat Kit, Model 30398 (sold separately) Seat Suspension Kit, Model 30312 (Mechanical) or 30313 (Air) (sold separately) Seat belt Capscrew, 7/16-20 x 1 inch Lockwasher, 7/16 inch Manual Tube R-clamp 2 3 4 Qty. Use 1 1 1 2 2 1 2 Install the seat, seat belt, and manual tube. No parts required – Grease the machine.
Step 3 Checking Fluid Levels No Parts Required Procedure 1. Check the rear axle lubricant level before the engine is first started, refer to Checking the Rear Axle Lubricant in Drive System Maintenance, page 39. Figure 3 1. Manual tube 2. R-clamp 3. 4. Seat belt retractor Seat belt buckle 2. Check the hydraulic fluid level before the engine is first started, refer to Checking the Hydraulic Fluid Level in Operation, page 20. 2.
Product Overview Figure 4 1. Steering wheel 2. Brakes 3. Cutting unit 4. 5. 6. Traction pedal Manual tube Hood/engine compartment 7. ROPS (Rollover Protection System) Controls Key Switch Traction Pedal The key switch (Figure 5) has three positions: Off, On/Preheat, and Start. The traction pedal (Figure 5) controls forward and reverse operation. Depress the top of the pedal to move forward and the bottom to move backward. Ground speed depends on how far the pedal is depressed.
Figure 6 1. Forward speed limiter screw 2. Reverse speed limiter screw Brake Pedals Two foot pedals (Figure 7) operate individual wheel brakes for turning assistance, parking, and to aid in obtaining better side hill traction. A latch connects the pedals for parking brake operation and transport. Figure 5 1. Traction pedal 2. Forward speed control 5. 6. 3. Key switch 7. 4.
Throttle Control Power Point Move the control (Figure 8) forward to increase the engine speed and rearward to decrease the speed. The power point (Figure 8) is used to power optional 12 volt electrical accessories. Fuel Gauge The fuel gauge (Figure 9) indicates the level of fuel in the tank. Figure 9 Figure 8 1. 2. 3. 4. Throttle control 5. Lift lever 6. Hour meter 7. Engine temperature gauge 1.
Traction Unit Specications Width of cut 109 in. (2.8 m) Overall width, cutting units down 112.8 in. (286 cm) Overall width, cutting units up (transport) 88.25 in. (224 cm) Overall length 145.8 in. (370 cm) Height with ROPS Ground clearance 6 in. (15 cm) 88.25 in. (224 cm) Track Width, rear 55.5 in. (141 cm) Wheel base 67-1/2 in. (171 cm) Weight (with cutting units and no uids) 4123 lb. (1400 kg) Engine Kubota, four-cycle, four cylinder, 122 in.
Operation The oil level should be up to the FULL mark (Figure 11). Note: Determine the left and right sides of the machine from the normal operating position. This machine produces sound levels in excess of 85 dBA at the operator’s ear and can cause hearing loss through extended periods of exposure. Wear hearing protection when operating this machine. Figure 11 1. Dipstick 4. If the oil is below the FULL mark, remove the fill cap (Figure 12) and add oil until the level reaches the FULL mark.
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. Figure 14 1. Fuel tank cap 2. Fill the tank to about 1 inch (25 mm) below the top of the tank, not the filler neck, with No. 2 diesel fuel. Then install the cap. Under certain conditions, diesel fuel and fuel vapors are highly flammable and explosive.
quality hydraulic fluid. Check the level of the hydraulic fluid before the engine is first started and daily thereafter. The recommended replacement fluid is as follows: 1. Position the machine on a level surface, lower the cutting units, stop the engine, and remove the key. 2. Clean the area around the filler neck and cap of the hydraulic tank (Figure 15). Remove the cap from the filler neck. Toro Premium All Season Hydraulic Fluid (Available in 5 gallon pails or 55 gallon drums.
Stopping the Engine • The engine has ceased running due to lack of fuel. Important: Allow engine to idle for 5 minutes before shutting it off after a full load operation. This allows the turbo charger to cool down before shutting the engine off. Failure to do so may lead to turbo-charger trouble. • Maintenance has been performed upon the fuel system components. Refer to Bleeding the Fuel System in Fuel System Maintenance, page 35. 1.
To check the operation of the interlock switches, perform the following procedure: 1. Drive the machine slowly to a large, relatively open area. Lower the cutting unit, stop the engine, and apply the parking brake. 2. Sit on the seat and depress the traction pedal. Try to start the engine. The engine should not crank. If the engine cranks, there is a malfunction in the interlock system that should be corrected before beginning operation. 3. Sit on the seat and start the engine.
Standard Control Module (SCM) Therefore, allow the traction pedal to move backward as the engine RPM decreases, and depress the pedal slowly as the RPM increases. By comparison, when driving from one work area to another, with no load and cutting unit raised, have the throttle in the Fast position and depress the traction pedal slowly but fully to attain maximum ground speed. The Standard Control Module is a "potted" electronic device produced in a "one size fits all" configuration.
Figure 17 Here are the logical troubleshooting steps for the SCM device. 1. Determine the output fault you are trying to resolve (PTO, START, or ETR). 2. Move key switch to "ON" and ensure the red "power" LED is illuminated. 3. Move all input switches to ensure all LED’s change state. 4. Position input devices at appropriate position to achieve the appropriate output. Use the following logic chart to determine the appropriate input condition. 5.
After Operating input LED’s to ensure it matches the logic chart. To ensure optimum performance, clean the underside of the mower housing after each use. If residue is allowed to build up in the mower housing, cutting performance will decrease. If the input LED’s are correct, check the output LED.
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 rst 8 operating hours • Torque the wheel nuts. After the rst 50 operating hours • Change the engine oil and lter. After the rst 200 operating hours • Change the planetary gear drive oil. • Change the rear axle lubricant. • Change the hydraulic lters.
Maintenance Service Interval Yearly Every 2 years Maintenance Procedure • • • • Check the fuel lines and connections. Replace the fuel pre-lter. Change the planetary gear drive oil. Check the rear wheel toe-in. • Replace the interlock switches. Important: Refer to your engine Operator’s Manual and cutting unit Operator’s Manual for additional maintenance procedures.
Daily Maintenance Checklist Duplicate this page for routine use. Maintenance Check Item For the week of: Mon. Tues. Wed. Thurs. Fri. Check the safety interlock operation. Check the brake operation. Check the engine oil and fuel level. Check the cooling system uid level. Drain the water/fuel separator. Check the air lter restriction indicator. Check the radiator, oil cooler, and screen for debris. Check unusual engine noises.1 Check unusual operating noises. Check the hydraulic system oil level.
Service Interval Chart Figure 19 If you leave the key in the ignition switch, someone could accidently start the engine and seriously injure you or other bystanders. Remove the key from the ignition before you do any maintenance.
Premaintenance Procedures Lubrication Greasing the Bearings and Bushings Removing the Hood The machine 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 all bearings and bushings after every 50 hours of operation or immediately after every washing. To gain additional access to engine compartment, the hood may be removed from traction unit. 1. Release hood latches (Figure 20) and raise hood.
Figure 26 • Cutting unit carrier arm bushings (1 per cutting unit) (Figure 26) • Rear roller bearings (2 per cutting unit) (Figure 27) Figure 24 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. 1. Top tting on king pin • Tie rod ball joints (2) (Figure 24) • King pin bushings (2) (Figure 24). The top fitting on the king pin should only be lubricated annually (2 pumps).
for shipping damage, checking the sealing end of the filter and the body. Do not use a damaged element. 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. Figure 28 1. Air cleaner indicator Important: Be sure the cover is seated correctly and seals with the air cleaner body. 1. Pull the latch outward and rotate the air cleaner cover counterclockwise (Figure 29). Figure 30 1.
Adjusting the Throttle approximately 5:00 to 7:00 when viewed from the end. Adjust the throttle cable (Figure 34) so that the governor lever on the engine contacts the low and high speed set bolts before the throttle lever contacts the slot in the seat base. 6. Reset the indicator (Figure 28) if it shows red. Servicing the Engine Oil and Filter Change the oil and filter initially after the first 50 hours of operation; thereafter change the oil and filter every 150 hours. 1.
Fuel Tank Replacing the Fuel Pre-Filter Drain and clean the fuel tank every 800 hours. Also, drain and clean the tank if 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. Replace the fuel pre-filter (Figure 36), located between fuel the tank and fuel pump, after every 400 operating hours or yearly, whichever occurs first. 1.
Note: Normally the engine should start after the above bleeding procedures are followed. However, if the engine does not start, air may be trapped between the injection pump and injectors; refer to Bleeding Air from the Injectors. 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.
Electrical System Maintenance 4. When the battery is charged, disconnect the charger from the electrical outlet and battery posts. Charging and Connecting the Battery 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. Install the positive cable (red) to the positive (+) terminal and the negative cable (black) to the negative (-) terminal of the battery (Figure 40).
Fuses There are 6 fuses in the electrical system. They are located under the operators control panel. Rotate latches and remove control panel cover. Battery terminals or metal tools could short against metal components causing sparks. Sparks can cause the battery gasses to explode, resulting in personal injury. • When removing or installing the battery, do not allow the battery terminals to touch any metal parts of the machine.
Figure 42 Figure 43 1. Check/drain plug 1. Check/drain plug 2. Remove the plug on the planetary (Figure 42). Oil should be at the bottom of the check plug hole. 2. Place a drain pan under the hub, remove the plug, and allow the oil to drain. 3. Place another drain pan under the brake housing on the other side of the wheel (Figure 44). 3. Add gear oil to the hole in the planetary, if necessary, to bring the oil up to the proper level. Install the plug. 4. Repeat steps 1–3 on the opposite gear assembly.
position) until the level is up to the bottom of the brake housing check hole. Install the plug. 8. Repeat the procedure on the opposite planetary/brake assembly. Checking the Rear Axle Lubricant Figure 46 The rear axle is shipped from the factory filled with SAE 85W-140 wt. gear lube. Check the oil level before the engine is first started and every 400 hours thereafter. The capacity is 80 oz. (2.4 l). Visually inspect for leaks daily. 1. Drain plug location 3.
5. Rotate the entire tie rod assembly the same direction (inward or outward) one (1) complete revolution. Tighten clamp at connected end of tie rod. 6. Install the ball joint in the axle case support and tighten the nut finger tight. Measure toe-in. 7. Repeat procedure if necessary. 8. Tighten the nut and install a new cotter pin when the adjustment is correct. Figure 47 1. Pump rod 2. Pump control tube Cooling System Maintenance 5. After wheel rotation ceases, tighten jam nuts to secure adjustment. 6.
or when the brakes do not work effectively. Free travel is the distance the brake pedal moves before braking resistance is felt. 1. Disengage the locking latch from the brake pedals so that both pedals work independently of each other. 2. To reduce free travel of the brake pedals, tighten the brakes: A. Loosen the front nut on the threaded end of the brake cable (Figure 52). Figure 50 1. Oil cooler latches 3. Pivot the oil cooler rearward.
Replacing the Hydraulic Filters Change the 2 hydraulic filters initially after the first 200 operating hours. Thereafter, change the filters after every 800 operating hours, in normal conditions. Use Toro replacement filters Part No. 94-2621 for the rear (cutting unit) of the machine and 75-1310 for the front (charge) of the machine. Figure 53 1. Alternator 2. Important: Use of any other filter may void the warranty on some components. Mounting bolt 1.
Hydraulic fluid escaping under pressure can penetrate skin and cause injury. • 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. • Keep your body and hands away from pin hole leaks or nozzles that eject high pressure hydraulic fluid. Figure 55 • Use cardboard or paper to find hydraulic leaks. 1.
Test Port C (Figure 57), located on front of 2 wheel drive/4 wheel drive manifold through front access panel on operator platform. Used to measure the 4 wheel drive pressure applied to the rear axle (reverse mode) and rear axle dynamic braking. Test Port G (Figure 59), located on top of left hand deck manifold. Used to measure cutting unit circuit pressure for cutting units 1 and 4. Figure 59 1. Test port F (Decks) 2.
Do not stand in line with the clean-out port. Always wear safety glasses. 3. Stop the engine and replace the pipe plug. Figure 61 1. Counterbalance dial 2. Traction assist valve The traction assist valve (Figure 61) is used to boost the pressure in the counterbalance circuit. Recommended traction assist counterbalance pressure is 700 psi when traction pressure is above 1800 psi. Rotate the screw (Figure 61) clockwise to increase the pressure or counterclockwise to decrease the pressure.
Storage glycol anti-freeze as needed for the expected minimum temperature in your area. Traction Unit 1. Thoroughly clean the traction unit, cutting units, and the engine. 2. Check the tire pressure; refer to Checking the Tire Pressure in Operation, page 20. 3. Check all fasteners for looseness; tighten as necessary. 4. Grease or oil all grease fittings and pivot points. Wipe up any excess lubricant. 5. Lightly sand and use touch-up paint on painted areas that are scratched, chipped, or rusted.
Schematics Electrical Schematic (Rev.
Hydraulic Schematic (Rev.
The Toro General Commercial Products Warranty A Two-Year Limited Warranty Conditions and Products Covered The Toro Company and its afliate, 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 rst.
