Form No. 3350–582 Groundsmaster 4500-D Groundsmaster Traction Unit Model No. 30856—Serial No.
Starting and Stopping the Engine . . . . . . . . . . . . . . Bleeding the Fuel System . . . . . . . . . . . . . . . . . . . . Checking the Interlock Switches . . . . . . . . . . . . . . Pushing or Towing the Machine . . . . . . . . . . . . . . Jacking Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tie Downs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Operating Characteristics . . . . . . . . . . . . . . . . . . . . Operating Tips . . . . . . . . . . . . . . . . . . . . .
CAUTION, WARNING, or DANGER—“personal safety instruction.” Failure to comply with the instruction may result in personal injury or death. Introduction 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.
Preparation – machine speeds should be kept low on slopes and during tight turns; • While mowing, always wear substantial footwear, long trousers, hard hat, safety glasses, and hearing protection. Long hair, loose clothing, or jewelry may get tangled in moving parts. Do not operate the equipment when barefoot or wearing open sandals. – 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.
• Reduce the throttle setting during engine run-out and, if the engine is provided with a shut-off valve, turn the fuel off at the conclusion of mowing. • Carefully release pressure from components with stored energy. • Disconnect battery and remove spark plug wire (gas engine only) before making any repairs. Disconnect the negative terminal first and the positive last. Reconnect positive first and negative last. • Keep hands and feet away from the cutting units.
• Before disconnecting or performing any work on the hydraulic system, all pressure in the system must be relieved by stopping the engine and lowering the cutting units and attachments to the ground. – Do not drive close to sand traps, ditches, creeks, embankments, or other hazards. – Reduce speed when making sharp turns. Avoid sudden stops and starts. • Check all fuel lines for tightness and wear on a regular basis. Tighten or repair them as needed.
Whole Body Vibration 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. Hand-Arm 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. Safety and Instruction Decals 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.
105-9223 (Affix over part no. 105–3890 for CE) 105-3888 1. Warning—read the Operator’s Manual. 2. To start the engine (read the Operator’s Manual), sit in the operator’s 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. 3.
106-6754 1. Warning—do not touch the hot surface. 2. Cutting/dismemberment hazard, fan and entanglement hazard, belt—stay away from moving parts 105-9830 (Affix for CE) 1. Lock 2. Unlock 93-6686 1. Hydraulic oil 105-9895 9 2. Read the Operator’s Manual.
5–3889 107-1983 (Affix over part no. 105–3889 for CE) 1. Warning—read the Operator’s Manual. 2. Warning—lock the parking brake, stop the engine, and remove the ignition key before leaving the machine. 3. Thrown object hazard—keep bystanders a safe distance from the machine. 10 4. Cutting hazard of hand or foot—stay away from moving parts. 5. Tipping hazard—do not drive the machine on a slope greater than 15 degrees, wear the seat belt, and lower the cutting unit when driving down slopes.
105-3890 1. Lower the cutting unit(s). 2. Raise the cutting unit(s). 3. Right cutting unit (GM 4700–D only) 4. Center cutting units 5. Left cutting unit (GM 4700–D only) 6. Fast 7. 8. 9. 10. Continuous variable setting Slow Engage Disengage 11. 12. 13. 14. Power Take-off (PTO) High Low Transmission 105-8507 1. Input 2. Backlap 3. High temp 4. In seat 5. PTO switch 6. Park brake off 7. Neutral 8. Output 9. PTO 11 10. Start 11. ETR 12.
Specifications Traction Unit Specifications Engine Cooling system Fuel system Hydraulic system Kubota, four-cycle, four cylinder, 122 in.3 displacement, water-cooled turbo diesel engine. Rated 58 hp @ 2600 RPM, 23:1 compression ratio. Low idle—1300 RPM, high idle—2800 RPM. Oil capacity is 8 qt. (7.6 l) with filter. Capacity is 2-3/4 gallons (10.4 l) of 50/50 mixture of ethylene glycol anti-freeze. Electric fuel pump. Replaceable inline filter and spin-on fuel filter/water separator.
Measurements Width of cut 109 in. (2.8 m) Overall width cutting units down 112.8 in. (286 cm) cutting units up (transport) 88.25 in. (224 cm) Overall length 145.8 in. (370 cm) Height with ROPS 85 in. (216 cm) Ground clearance 6 in. (15 cm) Track Width front 88.25 in. (224 cm) rear 55.5 in. (141 cm) Wheel base 67-1/2 in. (171 cm) Weight (with cutting units and no fluids) 4123 lb. (1400 kg) Optional Equipment 27” Rotary Cutting Unit Model No.
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.
Before Operating Caution If you leave the key in the ignition switch, someone could accidently start the engine and seriously injure you or other bystanders. 1 Remove the key from the ignition before you do any maintenance. Figure 2 1. Oil fill cap Checking the Engine Oil 5. The engine uses any high-quality detergent oil having the American Petroleum Institute (API) “service classification” CD, CE, CF, CF-4, or CG-4.
Caution 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. 1 2. Check the coolant level in the radiator. The radiator should be filled to the top of the filler neck and the expansion tank filled to the FULL mark. Figure 4 1. Fuel tank cap 2.
Checking the Hydraulic Fluid Mobil. Contact your local Toro Distributor for details. This oil is available in 5 gallon (19 l) containers from your Toro Distributor, order part no. 100–7674. The machines reservoir is filled at the factory with approximately 7.5 gallons of high quality hydraulic fluid. Check the level of hydraulic fluid before the engine is first started and daily thereafter. Appropriate hydraulic oils are listed below. 1.
Check Tire Pressure The tires are over-inflated for shipping. Therefore, release some of the air to reduce the pressure. The correct air pressure in the tires is 20 psi (138 kPa). 1 Important Maintain the recommended pressure in all tires to ensure a good quality-of-cut and proper machine performance. Do not under-inflate. Checking the Torque of the Wheel Nuts Warning Figure 6 Failure to maintain proper torque of the wheel nuts could result in failure or loss of wheel and may result in personal injury.
Forward Speed Control Operation Preset the forward speed control (Fig. 8) to limit the amount the traction pedal can be depressed in the forward direction to maintain a constant mowing speed. Note: Determine the left and right sides of the machine from the normal operating position. Caution Key Switch The key switch (Fig. 8) has three positions: Off, On/Preheat, and Start.
Brake Pedals Engine Temperature Gauge Two foot pedals (Fig. 10) 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. This gauge (Fig. 11) indicates the engine coolant temperature. Pedal Locking Latch The PTO switch (Fig. 11) has two positions: On (engage) and Off (disengage). Push the PTO switch forward to the On position to start the implement or cutting unit blades.
2. Move the throttle control to the low idle position. 3. Turn the ignition key to the Run position. The glow indicator will light. 4. When the glow indicator dims, turn the ignition key to the Start position. Release the key immediately when the engine starts and allow it to return to the Run position. Move the throttle control to the desired position. 1 Figure 12 Important Do not run the starter motor more than 15 seconds at a time or premature starter failure may result.
Checking the Interlock Switches Danger 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. Caution 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.
Pushing or Towing the Machine Tie Downs In an emergency, the machine can be moved forward by actuating the bypass valve in the variable displacement hydraulic pump and pushing or towing the machine. Do not push or tow the machine for more than 1/4 mile (0.4 km). • On each side of the frame under the front steps • The rear bumper Operating Characteristics Important Do not push or tow the machine faster than 2–3 MPH (3–4.8 km/h) because internal transmission damage may occur.
High Lift Parallel Sail 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. The blade generally performs better in the higher heights of cut (2 to 4 inch). Attributes: Before stopping the engine, disengage all controls and move the throttle to Slow. Moving the throttle to Slow reduces high engine RPM, noise, and vibration.
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.
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.
Maintenance Note: Determine the left and right sides of the machine from the normal operating position. Recommended Maintenance Schedule Maintenance Service Interval After first 10 hours • Check the alternator belt tension. • 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 • Lubricate all grease fittings. • Inspect the air cleaner indicator.1 • Check the battery level and cable connections.
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 the brake operation. Check the engine oil and fuel level. Check the cooling system fluid level. Drain the water/fuel separator. Check the air filter 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 Caution 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.
Greasing the Bearings and Bushings 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. The grease fitting locations and quantities are: Traction Unit • Brake shaft pivot bearings (5) (Fig. 16) • Rear axle pivot bushings (2) (Fig. 17) Figure 17 • Steering cylinder ball joints (2) (Fig.
Hood Removal To gain additional access to engine compartment, the hood may be removed from traction unit. 1. Release hood latches (Fig. 21) and raise hood. 1 Figure 19 Figure 21 1. Hood latch 2. Unhook lanyard from hood pin, remove pin and slide hood tubes rearward off guides (Fig. 22). Figure 20 1 Figure 22 1.
Servicing the Air Cleaner Check the air cleaner body for damage which could possibly cause an air leak. Replace a damaged air cleaner body. Service the air cleaner filters when the air cleaner indicator (Fig. 24) shows red or every 400 hours (more frequently in extremely dusty or dirty conditions). Do not over-service the air filter. 1 1 Figure 25 1. Air cleaner primary filter 3. Inspect the primary filter and discard it if it is damaged. Do not wash or reuse a damaged filter. Figure 23 1.
5. Inspect the new filter for shipping damage. Check the sealing end of the filter. Do not install a damaged filter. 6. 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. 7. Install the cover and secure the latch. Make sure that the cover is positioned with the TOP side up. 1 8. Reset the indicator (Fig. 24) if it shows red.
Fuel Lines and Connections 2. Loosen the hose clamps at both ends of the filter and pull the fuel lines off of the filter. Check the fuel lines and connections every 400 hours or yearly, whichever comes first. Inspect them for deterioration, damage, or loose connections. 1 Water Separator Drain water or other contaminants from the water separator (Fig. 29) daily. 1. Place a clean container under the fuel filter. 2. Loosen the drain plug on the bottom of the filter canister (Fig. 29).
5. Repeat the procedure on the remaining nozzles. Servicing the Engine Cooling System 2 Remove debris from the engine area, oil cooler and radiator daily. Clean them more frequently in dirty conditions. 1 1. Unlatch and swing open rear screen (Fig. 32). Clean the screen thoroughly of all debris. Note: To remove screen, lift off hinge pins. Figure 34 1. Oil cooler 2.
Adjusting the Throttle Caution A djust the throttle cable (Fig. 36) 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. Do not stand in line with the clean-out port. Always wear safety glasses. 3. Stop the engine and replace the pipe plug. Changing the Hydraulic Fluid Change the hydraulic fluid after every 800 operating hours, in normal conditions.
2. Clean the area around the filter mounting area. Place a drain pan under the filter and remove the filter (Fig. 37 & 38). Checking the Hydraulic Lines and Hoses 3. Lubricate the new filter gasket and fill the filter with hydraulic fluid. Inspect the hydraulic lines and hoses daily for leaks, kinked lines, loose mounting supports, wear, loose fittings, weather deterioration, and chemical deterioration. Make all necessary repairs before operating.
Test Port “B” (Fig. 40), located on side of counter balance manifold, under operators seat. Used to measure the counter balance pressure applied to cutting units for increased traction. Test Port “F” (Fig. 42), located on top of right hand deck manifold. Used to measure cutting unit circuit pressure for cutting units 5, 2 and 3. Test Port “G” (Fig. 42), located on top of left hand deck manifold. Used to measure cutting unit circuit pressure for cutting units 1 and 4. Test Port “C” (Fig.
Adjusting Counterbalance The counterbalance dial (Fig. 44) is used to adjust the pressure in the counterbalance circuit. Recommended counterbalance pressure is 620 psi. Rotate the adjusting dial (Fig. 44) clockwise to increase the pressure or counterclockwise to decrease the pressure. 1 2 Adjust Length 2 1 2 1 Figure 45 1. Pump rod 2. Pump control tube 5. After wheel rotation ceases, tighten jam nuts to secure adjustment. 6. Stop the engine and release the right brake.
Changing the Planetary Gear Drive Oil 1 Change the oil initially after first 200 hours of operation. Thereafter change the oil every 800 hours, or yearly, whichever occurs first. Use a high quality SAE 85W-140 wt. gear lube. 3 1. With the machine on a level surface, position the wheel so that the check/drain plug (Fig. 47) is at the lowest position (6 o’clock). 2 1 Figure 48 1. Brake housing 2. Drain plug 3.
Checking the Rear Wheel Toe-In Charging and Connecting the Battery After every 800 operating hours or annually, check the rear wheel toe-in. Warning 1. Measure the center-to-center distance (at axle height) at the front and rear of the steering tires. The front measurement must be 1/8 in. (3 mm) less than the rear measurement.
Warning Warning Charging the battery produces gasses that can explode. Battery terminals or metal tools could short against metal components causing sparks. Sparks can cause the battery gasses to explode, resulting in personal injury. Never smoke near the battery and keep sparks and flames away from battery. • When removing or installing the battery, do not allow the battery terminals to touch any metal parts of the machine.
Fuses There are 4 fuses in the electrical system. They are located under the operators control panel (Fig. 53). 1. Rotate latches and remove control panel cover. 1 Figure 53 1.
R R 45 F 3 10 A F 2 10 A F 1 15 A F8 F7 P23–A2 PK W L R W R R I B S BU/W R/BK X A Y P23–D1 X B RUN Y A S I START IGNITION SW STOP –––– NONE RUN –––– B+I+A; X+Y START ––– B+I+S OFF OR Y (+) P4–G P4–C P4–A P4–D P4–F P4–B W T P23–D3 P23–A5 BATTERY (–) ENGINE GROUND FRAME GROUND ENGINE SP FUSIBLE LINK P23–D2 BU B+ G Start R P5–A 110 C ENGINE OVER TEMP.
G2 G1 G1 P1 T1 T2 P1 T1 OIL COOLER T 40 PSI 50 / 50 PROPORTIONAL FLOW DIVIDER G 5 PSI P3 G P1 FILTER P2 P2 P1 CD2 180 PSI TOW VALVE LH PORT P4 11.96:1 MF FORWARD G FRONT MF FNT PORTS G 11.96:1 FILTRATION AND CHARGE CONTROL MANIFO LD G RV CD1 5000 PSI 5000 PSI B .094 A P2 CHG P1 C4 3 M1 PRV1 PRV2 T2 1500 PSI C1 C3 CB PP G RV PR1 CV B .052 PD2 RV5 SV G 1.16 M4 2.48 6.1 MR V1 700 450 3500 PR1 PRV1 T GAGE M2 CS 2.00 1.50 1.
Preparing for Seasonal Storage Engine Traction Unit 1. Drain the engine oil from the oil pan and install the drain plug. 1. Thoroughly clean the traction unit, cutting units, and the engine. 2. Remove and discard the oil filter. Install a new oil filter. 3. Refill the oil pan with 8 qt. (7.6 l) of SAE 10W-30 CD, CE, CF, CF-4, or CG-4 motor oil. 2. Check the tire pressure; refer to Checking the Tire Pressure. 3. Check all fasteners for looseness; tighten as necessary. 4.
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.
