Form No. 3352-747 Groundsmaster® 4500-D Traction Unit Model No. 30856—Serial No. 250000001 and Up Register your product at www.Toro.
Warning Specifications ....................................... 17 Operation .......................................................... 19 Checking the Engine Oil Level ................ 19 Checking the Cooling System.................. 19 Filling the Fuel Tank .............................. 20 Checking the Hydraulic Fluid Level..................................... 20 Checking the Tire Pressure ..................... 21 Starting and Stopping the Engine............. 21 Checking the Interlock Switches ...........
Servicing the Engine Cooling System .................................. 41 Brake Maintenance ...................................... 42 Adjusting the Service Brakes ................... 42 Belt Maintenance ......................................... 43 Servicing the Alternator Belt ................... 43 Hydraulic System Maintenance ...................... 43 Changing the Hydraulic Fluid.................. 43 Replacing the Hydraulic Filters ................ 43 Checking the Hydraulic Lines and Hoses ...............
Safety ◊ lack of awareness of the effect of ground conditions, especially slopes; • The owner/user can prevent and is responsible for This machine meets or exceeds CEN standard EN 836:1997 (when appropriate decals applied), and ANSI B71.4-1999 specifications in effect at the time of production when equipped with required weights as listed in the weight chart. accidents or injuries occurring to himself or herself, other people, or property.
• Do not put hands or feet near or under rotating – before making height adjustment unless adjustment can be made from the operator’s position. parts. Keep clear of the discharge opening at all times. • Remember there is no such thing as a safe slope. – before clearing blockages; Travel on grass slopes requires particular care.
• On multi-spindle mowers, take care as rotating one • Wearing safety shoes and long pants is advisable blade can cause other blades to rotate. and required by some local ordinances and insurance regulations. • Disengage drives, lower the cutting units, set • Handle fuel carefully. Wipe up any spills. • Check the safety interlock switches daily for proper parking brake, stop engine and remove key and disconnect spark plug wire (gas engine only).
Sound Pressure Level object injuries. Do not resume mowing until the area is cleared. This unit has an equivalent continuous A-weighted sound pressure level at the operator ear of 89 dBA, based on measurements of identical machines per Directive 98/37/EC and amendments. Maintenance and Storage • Make sure all hydraulic line connectors are tight and all hydraulic hoses and lines are in good condition before applying pressure to the system.
93-6680 93-7272 1. 105-7506 Cutting/dismemberment hazard; fan—stay away fro moving parts. 1. 2. 3. Read the Operator’s Manual. Engine—stop On 105-3888 1. 2. 3. 2. Engine coolant under 3. pressure. Explosion hazard—read the 4. Operator’s Manual. Engine—preheat 5. Engine—start 93-6699 Read the Operator’s Manual. To lock the parking brake, secure the brake pedals with the locking pin, press the brake pedals, and pull out the parking brake knob. To unlock the parking brake, press the brake pedal.
3-6686 1. Hydraulic oil 2. Read the Operator’s Manual. 105-9223 (Afx over part no. 105-38890 for CE) Battery Symbols 1. Warning-read the Operator’s Manual. 2. 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. 3.
5-3889 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. Lower the cutting unit(s). Raise the cutting unit(s). Right cutting unit (GM 4700-D only) Center cutting units Left cutting unit (GM 4700-D only) 6. 7. 8. 9. 10. Fast 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. 5. 6. In seat PTO switch Park brake off 7. Neutral 8. Output 9. PTO 11 10. Start 11. ETR 12.
105-9895 12
Setup Loose Parts Use the chart below to verify that all parts have been shipped. Use Step Description Qty. 1 1 Seat Kit, Model 30398 (sold separately) Seat Suspension Kit, Model 30395 (sold separately) Seat belt Capscrew, 7/16-20 x 1 inch Lockwasher, 7/16 inch Manual Tube R-clamp 1 2 2 1 2 Install the seat, seat belt, and manual tube. No parts required – Grease the machine.
Step Step 2 4 Greasing the Machine Reading the Manuals and Viewing the Video No Parts Required Parts needed for this step: Procedure 1 1 1 1 1 Before the machine is operated, it must be greased to ensure proper lubrication. Refer to Lubrication, page 32. Failure to properly grease the machine will result in premature failure of critical parts. Step Operator’s Manual Engine Operator’s Manual Parts Catalog Operator Video Pre-delivery Inspection Sheet Procedure 3 1. Read the manuals. 2.
Product Overview Figure 3 1. Steering wheel 2. Brakes 3. Cutting unit 4. Traction pedal 5. Manual tube 6. Hood/engine compartment 7. ROPS (Rollover Protection System) Controls Engine Oil Pressure Warning Light Traction Pedal The light (Figure 4 ) illuminates when the engine oil pressure is dangerously low. The traction pedal (Figure 4 ) controls forward and reverse operation. Depress the top of the pedal to move forward and the bottom to move backward.
Figure 5 1. Forward speed limiter screw 2. Reverse speed limiter screw Brake Pedals Two foot pedals (Figure 6 ) 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 4 1. 2. Traction pedal Forward speed control 5. 6. 3. 4. Key switch 7.
Figure 8 1. Fuel gauge Cutting Unit Lift Latch (CE) Figure 7 1. 2. 3. 4. Throttle control 5. Lift lever 6. Hour meter 7. Engine temperature gauge The cutting unit lift latch (Figure 9 ) locks the center five cutting unit lift levers when the cutting units are in the raised position. PTO switch Hi-Lo speed control Power point Lift Lever The lever (Figure 7 ) raises and lowers the cutting units. Hour Meter The hour meter (Figure 7 ) shows the total hours that the machine has been operated.
Height with ROPS Ground clearance 85 in. (216 cm) 6 in. (15 cm) Track Width, front 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. 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 lter.
Operation 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. Figure 10 1. Wear hearing protection when operating this machine. Dipstick 4. If the oil is below the FULL mark, remove the fill cap (Figure 11 ) and add oil until the level reaches the FULL mark. Do not overfill.
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 13 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.
Toro Premium All Season Hydraulic Fluid (Available in 5 gallon pails or 55 gallon drums. See parts catalog or Toro distributor for part numbers.) Alternate fluids: If the Toro fluid is not available, other fluids may be used provided they meet all the following material properties and industry specifications. We do not recommend the use of synthetic fluid.
Checking the Interlock Switches 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. If safety interlock switches are disconnected or damaged the machine could operate unexpectedly causing personal injury.
Operating Characteristics hydraulic pump and pushing or towing the machine. Do not push or tow the machine for more than 1/4 mile (0.4 km). Practice driving the machine because it has a hydrostatic transmission and its characteristics are different than many turf maintenance machines. Some points to consider when operating the traction unit, cutting units, or other implements are the transmission, engine speed, load on the cutting blades or other implement components, and the importance of the brakes.
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 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.
6. If specific output LED is not illuminated, check both fuses. 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. 7. If specific output LED is not illuminated and inputs are in appropriate condition, install new SCM and determine if fault disappears.
• More lift and higher discharge velocity. • Sparse or limp turf is picked up significantly at higher heights of cut. • Wet or sticky clippings are discharged more efficiently reducing congestion in deck. • Requires more horsepower to run. • Tends to discharge further left and can tend to windrow at lower heights of cut. Do not use the high lift blade with the mulching baffle. The blade could break, resulting in personal injury or death.
Cutting Unit Pitch We recommend a blade pitch of 5/16 in. (7.9 mm). A pitch larger than 5/16 in. (7.9 mm) will result in less power required, larger clippings, and a poorer quality of cut. A pitch less than 5/16 in. (7.9 mm) will result in more power required, smaller clippings and a better quality of cut.
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 use • 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 Maintenance Procedure Before storage • • • • • Drain and clean the fuel tank. Check the tire pressure. Check all fasteners. Grease or oil all grease ttings and pivot points. Paint chipped surfaces. Yearly • • • • Check the fuel lines and connections. Replace the fuel pre-lter. Change the planetary gear drive oil. Check the rear wheel toe-in. Every 2 years • Replace the interlock switches.
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 18 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 19 ) and raise hood.
Figure 25 • Cutting unit carrier arm bushings (1 per cutting unit) (Figure 25 ) • Rear roller bearings (2 per cutting unit) (Figure 26 ) Note: The flush fittings on the rollers (Figure 26 ) require a grease gun nozzle adapter. Order Toro Part No. 107-1998 from your Authorized Toro Distributor. Figure 23 1. Top tting on king pin • Tie rod ball joints (2) (Figure 23 ) • King pin bushings (2) (Figure 23 ). The top fitting on the king pin should only be lubricated annually (2 pumps).
Figure 27 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 28 ). Figure 29 1. Air cleaner primary lter Important: Never attempt to clean the safety filter (Figure 30 ). Replace the safety filter with a new one after every three primary filter services. Figure 28 1. Air cleaner latch 2. Air cleaner cover 2. Remove the cover from the air cleaner body.
1. Remove the rear drain plug (Figure 31 ) and let the oil flow into a drain pan. When the oil stops, install the drain plug. Figure 33 Figure 31 1. 1. Engine oil drain plug 2. Remove the oil filter (Figure 32 ). Apply a light coat of clean oil to the new filter seal before screwing it on. Do not overtighten. Throttle cable Fuel System Maintenance Under certain conditions, diesel fuel and fuel vapors are highly flammable and explosive.
Fuel Lines and Connections Check the fuel lines and connections every 400 hours or yearly, whichever comes first. Inspect them for deterioration, damage, or loose connections. Water Separator Drain water or other contaminants from the water separator (Figure 34 ) daily. 1. Place a clean container under the fuel filter. 2. Loosen the drain plug on the bottom of the filter canister (Figure 34 ). Tighten the plug after draining. Figure 35 1. Fuel pre-lter 3.
3. Open the air bleed screw on the fuel injection pump (Figure 36 ). 3. Turn the key in the ignition switch to the Start position and watch the fuel flow around the connector. Turn the key to the Off position when solid flow is observed. 4. Tighten the pipe connector securely. 5. Repeat the procedure on the remaining nozzles. Electrical System Maintenance Charging and Connecting the Battery Figure 36 1. Fuel injection pump bleed screw Warning 4. Turn the key in the ignition switch to the On position.
Warning CALIFORNIA Proposition 65 Warning Battery electrolyte contains sulfuric acid which is a deadly poison and causes severe burns. 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. • Do not drink electrolyte and avoid contact with skin, eyes or clothing. Wear safety glasses to shield your eyes and rubber gloves to protect your hands. 6.
the machine, wash the entire case with a solution of baking soda and water. Rinse with clear water. Coat the battery posts and cable connectors with Grafo 112X (skin-over) grease (Toro Part No. 505-47) or petroleum jelly to prevent corrosion. 1. With the machine on a level surface, position the wheel so that the check/drain plug (Figure 41 ) is at either the 2 or 10 o’clock position. Fuses There are 6 fuses in the electrical system. They are located under the operators control panel.
Checking the Rear Axle Lubricant 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. Position the machine on a level surface. 2. Remove a check plug from one end of the axle (Figure 44 ) and make sure that the lubricant is up to the bottom of the hole.
4. Remove the drain plugs and allow the oil to drain into the pans. 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. 5. Install the plugs. 6. Remove a check plug and fill axle with approximately 80 oz. of 85W-90 gear lube or until lubricant is up to bottom of hole. 2. To adjust, remove the cotter pin and nut from either tie rod ball joint (Figure 47 ).
Figure 48 1. Figure 50 Rear screen latch 1. Oil cooler 2. Radiator Important: Cleaning the radiator or oil cooler with water will promote premature corrosion damage to components and compact debris. 4. Pivot the oil cooler back into position. Secure it to the frame with the latches, close the screen. 2. Rotate latches (Figure 49 ) securing the oil cooler to the frame. Brake Maintenance Adjusting the Service Brakes Adjust the service brakes when there is more than 1 in.
B. Tighten the rear nut to move the cable backward until the brake pedals have 1/2 to 1 in. (13 to 25 mm) of free travel. into a large drain pan. Connect the line when the hydraulic fluid stops draining. 3. Fill the reservoir with approximately 7.5 gallons of hydraulic fluid; refer to Checking the Hydraulic Fluid in Operation, page 19. C. Tighten the front nuts after the brakes are adjusted correctly. Important: Use only the hydraulic fluids specified. Other fluids could cause system damage.
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. • Use cardboard or paper to find hydraulic Figure 53 1. leaks.
Figure 58 1. Figure 56 1. Test port B (Counter balance) 2. Test port F (Decks) 2. Test port G (Decks) Test Port H (Figure 59 ) located on rear traction circuit hard line. Used to measure reverse traction pressure. Test port C ( Four wheel drive) Test Port I (Figure 59 ) located on front traction circuit hard line. Used to measure forward traction pressure Test Port D (Figure 57 ), located on front of pump assembly, under operators seat plate. Used to measure steering pressure.
Figure 60 1. Counterbalance dial 2. Traction assist valve The traction assist valve (Figure 60 ) 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 60 ) clockwise to increase the pressure or counterclockwise to decrease the pressure. Important: Traction unit must be at operating temperature when adjusting hydraulic pressure.
Storage 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 19. 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. Repair any dents in the metal body. 6. Service the battery and cables as follows: A.
Schematics Electrical Schematic (Rev.
Hydraulic Schematic (Rev.
Notes:
Notes:
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.