Form No. 3327–883 Groundsmaster 4500-D Groundsmaster Traction Unit Model No. 30856—Serial No.
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Recommended Maintenance Schedule . . . . . . . . . Daily Maintenance Checklist . . . . . . . . . . . . . . . . Service Interval Chart . . . . . . . . . . . . . . . . . . . . . . Greasing the Bearings and Bushings . . . . . . . . . . Hood Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . Servicing the Air Cleaner . . . . . . . . . . . . . . . . . . . Servicing the Engine Oil and Filter . . . . . . . . . . .
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.
• Remember there is no such thing as a safe slope. Travel on grass slopes requires particular care. To guard against overturning: Preparation • 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.
• Disengage drives, lower the cutting units, set parking brake, stop engine and remove key and disconnect spark plug wire (gas engine only). Wait for all movement to stop before adjusting, cleaning or repairing. – before checking, cleaning or working on the mower; – after striking a foreign object or if an abnormal vibration occurs. Inspect the mower for damage and make repairs before restarting and operating the equipment.
• Handle fuel carefully. Wipe up any spills. Maintenance and Storage • Check the safety interlock switches daily for proper operation. If a switch should fail, replace the switch before operating the machine. After every two years, replace all interlock switches in the safety system, whether they are working properly or not. • Make sure all hydraulic line connectors are tight and all hydraulic hoses and lines are in good condition before applying pressure to the system.
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.
93-7272 1. Cutting/dismemberment hazard, fan—stay away from moving parts. 105-3888 1. Read the Operator’s Manual. 2. To lock the parking brake, secure the brake pedals with the locking pin, press the brake pedals, and pull out the the parking brake knob. 3. To unlock the parking brake, press the brake pedal. 105-9223 (Affix over part no. 105–3890 for CE) 1. Warning—read the Operator’s Manual. 2.
100-6574 1. Hot surface/burn hazard—stay a safe distance from the hot surface. 2. Cutting/dismemberment hazard, fan and entanglement hazard, belt—stay away from moving parts 105-9830 (Affix for CE) 1. Lock 105-9824 9 2.
5–3889 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. 10 Continuous variable setting Slow Engage Disengage 11. 12. 13. 14.
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 Weight (with cutting units and no fluids) 67-1/2 in. (171 cm) 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. Use Seat belt 1 Capscrew 7/16–20 x 1” 2 Lock washer 7/16 2 Manual tube 1 R-clamp 2 Lift latch 1 Latch bracket –R.H. 1 Latch bracket –L.H.
Install Cutting Unit Lift Latch 3. Hook the latch onto the hood latch bracket (Fig. 2). (For CE Compliance) 4. Insert a bolt (1/4 x 1-1/2 in.) through the hood lock bracket and secure it with a flat washer and locknut (Fig. 2). 1. Rotate latches and remove control panel cover (Fig. 1). 2 3 1 Figure 2 1 1. Hood latch 2. Hood latch bracket 3. Hood lock bracket Install Throttle Stop 2 (For CE Compliance) 4 1. Loosen set screw on throttle stop. 5 2.
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 5 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 7 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.
2. Remove a check plug from one end of the axle (Fig. 11) and make sure that the lubricant is up to the bottom of the hole. If the level is low, remove the fill plug (Fig. 11) and add enough lubricant to bring the level up to the bottom of the check plug holes. 1 2 1 Figure 9 Figure 11 1. Check/drain plug 1. Check plug 2. Remove the plug on the planetary (Fig. 9) and the check plug on the back side of the brake (Fig. 10).
Forward Speed Control Operation Preset the forward speed control (Fig. 12) 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. 12) has three positions: Off, On/Preheat, and Start.
Brake Pedals Engine Temperature Gauge Two foot pedals (Fig. 14) 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. 15) indicates the engine coolant temperature. Pedal Locking Latch The PTO switch (Fig. 15) 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.
1. Remove your foot from the traction pedal and ensure that it is in neutral. Ensure that the parking brake is set. 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 16 1.
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.
The blade generally performs better in the higher heights of cut (2 to 4 inch). Important Allow engine to idle for 5 minutes before shutting it off after a full load operation. Failure to do so may lead to turbo–charger trouble. 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. Turn the key to Off to stop the engine. • More lift and higher discharge velocity.
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. 20) • Rear axle pivot bushings (2) (Fig. 21) Figure 21 • 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. 25) and raise hood. 1 Figure 23 Figure 25 1. Hood latch 2. Unhook lanyard from hood pin, remove pin and slide hood tubes rearward off guides (Fig. 26). Figure 24 1 Figure 26 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. 28) shows red or every 400 hours (more frequently in extremely dusty or dirty conditions). Do not over-service the air filter. 1 1 Figure 29 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 27 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. 28) 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. 33) daily. 1. Place a clean container under the fuel filter. 2. Loosen the drain plug on the bottom of the filter canister (Fig. 33).
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. 36). Clean the screen thoroughly of all debris. Note: To remove screen, if desired, lift off hinge pins. Figure 38 1. Oil cooler 2.
Adjusting the Throttle Caution A djust the throttle cable (Fig. 40) 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. 41 & 42). 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. 44), 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. 46), 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. 46), 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 test port (Fig. 48) is used to adjust the pressure in the counterbalance circuit. Recommended counterbalance pressure is 620 psi. Rotate the adjusting dial (Fig. 48) clockwise to increase the pressure or counterclockwise to decrease the pressure. 1 2 Adjust Length 2 1 2 1 Figure 49 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. 51) is at the lowest position. 2 1 Figure 52 1. Brake housing 2. Drain plug 3.
Checking the Rear Wheel Toe-In 1. Unlatch and raise the hood. 2. Remove the battery strap and cover (Fig. 55). After every 800 operating hours or annually, check the rear wheel toe-in. 2 1 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. 2. To adjust, remove the cotter pin and nut from either tie rod ball joint. Remove tie rod ball joint from axle case support. 3.
Battery Care must not contact the battery cover. Slide the rubber boot over the positive terminal to prevent a possible short from occurring. 2 Important Before welding on the machine, disconnect the terminal connector from the alternator to prevent damage to the electrical system. 1 Note: Check the battery condition weekly or after every 50 hours of operation. Keep the terminals and the entire battery case clean because a dirty battery will discharge slowly.
R Y R W F 3 10 A F 2 10 A F 1 15 A W R BU BU BK X A Y X B RUN Y A S I 30 W VIO BK PK VIO 88–9830 START F 4 10 A GN IGNITION SW STOP ––– NONE RUN ––– B+I+A; X+Y START––– B+I+S OFF (+) BATTERY (–) 86 85 K5 START RELAY 87a 87 FRAME GROUND 99–7411 99–7416 POWER POINT GY OR I B S OR ENGINE ENGINE GROUND FUSIBLE LINK SP R OPTIONAL FUSE BLOCK D2 B+ G Start 99–3441 GLOW PLUGS (4) R/BK BU/W ENGINE OVER TEMP.
G1 P1 T1 OIL COOLER T 40 PSI 50 / 50 PROPORTIONAL FLOW DIVIDER G 5 PSI P3 G P1 180 PSI TOW VALVE P4 LH PORT CD2 P1 FILTER P2 P2 11.96:1 MF G FRONT MF FNT PORTS FORWARD 11.96:1 P2 CHG P1 C2 C1 G C3 PP CB PR1 B CV .052 PD2 RV5 SV 450 3500 PRV1 T GAGE M2 REAR MR 11.9:1 CS C5 C4 C3 2.00 1.50 1.50 1.50 1.50 C2 4.20 7.00 7.00 3.50 3.50 .625 .625 .625 .625 .625 .625 1.50 C1 4.00 BORE STROKE ROD 1100 1100 550 COMP.
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 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.
