Form No. 3354–406 Rev C Groundsmaster) 3500-D Groundsmaster Traction Unit Model No. 30839—Serial No.
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Starting and Stopping the Engine . . . . . . . . . . . . . . Bleeding the Fuel System . . . . . . . . . . . . . . . . . . . . Checking the Interlock System . . . . . . . . . . . . . . . Towing the Traction Unit . . . . . . . . . . . . . . . . . . . . Standard Control Module (SCM) . . . . . . . . . . . . . . Operating Characteristics . . . . . . . . . . .
Introduction CAUTION, WARNING, or DANGER—“personal safety instruction.” Failure to comply with the instruction may result in personal injury or death. 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.
• Thoroughly inspect the area where the equipment is to be used and remove all objects which may be thrown by the machine. – The machine speed should be kept low on slopes and during tight turns. – Stay alert for humps and hollows and other hidden hazards. • Warning—fuel is highly flammable. Take the following precautions: – Never mow across the face of the slope, unless the machine is designed for that purpose. – Store fuel in containers specifically designed for this purpose.
• Carefully release pressure from components with stored energy. • Reduce the throttle setting during engine shut down and, if the engine is provided with a fuel shut-off valve, turn the valve off at the conclusion of mowing. • Disconnect battery or remove spark plug wire before making any repairs. Disconnect the negative terminal first and the positive last. Reconnect positive first and negative last. • Never raise deck with the blades running. • Keep hands and feet away from the cutting units.
Training • For steering control, the cutting units must be lowered when going down slopes. • The operator must be skilled and trained in how to drive on hillsides. Failure to use caution on slopes or hills may cause the vehicle to tip or roll, possibly resulting in personal injury or death. • Avoid sudden stops and starts. • Use the reverse pedal for braking. • Watch for traffic when near or crossing roads. Always yield the right-of-way.
Vibration Level parts and accessories made by other manufacturers could be dangerous, and such use could void the product warranty. 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. Sound Power 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.
93-7818 1. Warning—read the operator’s manual for blade torque instructions. 43-8480 107-7801 (for CE) 93-6681 1. Tipping hazard—do not drive on slopes greater than 15 degrees. 1. Cutting/dismemberment hazard—stay away from moving parts. 99-3444 1. Reel speed—fast 104-0484 104-1086 1. Height of cut 8 2.
106-6753 (for CE) 104-5181 (for CE) 1. Thrown object hazard—keep bystanders a safe distance from the machine. 1. Warning—read the Operator’s Manual. 2. Tipping hazard—do not drive on slopes greater than 15 degrees and, if the roll bar is installed, wear the seat belt. 3. Thrown object hazard—keep bystanders a safe distance from the machine. 4. Cutting hazard of hand or foot—stay away from moving parts. 5.
4–5191 1. Engage the power take off (PTO). 2. Disengage the power take off (PTO). 3. Lower the cutting units. 4. Move the cutting units to the right. 5. Raise the cutting units. 6. Move the cutting units to the left. 7. Move rear ward to lock the lift lever. 8. Engine—stop 107-7800 10 9. 10. 11. 12. 13.
Specifications General Specifications Engine Cooling system Electrical Kubota three-cylinder, 4-cycle liquid-cooled diesel engine. 32 hp @ 2800 RPM, governed to 3050 RPM. 68.5 cu. in. (1124 cc) displacement. Heavy-duty, 2-stage, remote mounted air cleaner. High water temperature shutdown switch. Radiator capacity is approximately 6 qt. of 50/50 mixture of ethylene glycol anti-freeze. Remote mounted 1 qt. expansion tank.
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 Hood lock bracket 1 Screw, 1/4 x 1-1/2 in. 1 Flat washer, 1/4 in. 1 Locknut, 1/4 in.
Activating, Charging, and Connecting the Battery Warning 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. When the battery is charged, disconnect the charger from the electrical outlet and battery posts. Battery posts, terminals, and related accessories contain lead and lead compounds, chemicals known to the State of California to cause cancer and reproductive harm.
Installing the Hood Latch (CE) Important If the battery is ever removed, make sure that battery clamp bolts are reinstalled 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. 1. Unhook the hood latch from the hood latch bracket (Fig. 4). 2. Slide the hood lock bracket onto the latch (Fig. 4). 8.
Adjusting the Lift Arms 1. Start the engine, raise the decks, and check to make sure that the clearance between each lift arm and the floor plate bracket is .18–.32 in. (5–8 mm) (Fig. 6). If the clearance is not in this range, back off the stop bolts (Fig. 7) and adjust the cylinder to attain clearance. To adjust the cylinder, back off the jam nut on the cylinder (Fig. 8), remove the pin from the rod end, and rotate the clevis. Install the pin and check the clearance. Repeat the procedure if required.
Rear Ballast and check the oil level. If the oil level is low, add enough oil to raise the level to the FULL mark on the dipstick. The Groundsmaster 3500 Traction unit with 27” Rotary Cutting decks conforms to the B71.4-1999 standard when 50 lb. of calcium chloride ballast is added to the rear wheels. Important If a puncture occurs in a tire with calcium chloride, remove the machine from the turf as quickly as possible. To prevent possible damage to the turf, immediately soak the affected area with water.
4. To prevent a fire hazard, wipe up any fuel that may have spilled. 1 2 3 1 Figure 13 1. Fuel tank cap Figure 14 1. Access panel 2. Radiator Danger 3. Oil cooler 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. Under certain conditions, diesel fuel and fuel vapors are highly flammable and explosive.
Biodegradable Hydraulic Fluid – Mobil 224H 1 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 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.
Danger Low tire pressure decreases machine side hill stability. This could cause a rollover, which may result in personal injury or death. Do not under-inflate the tires. Checking the Torque of the Wheel Nuts Warning Failure to maintain proper torque of the wheel nuts could result in personal injury. Torque the wheel nuts to 45–65 ft.-lb. (61–88 NVm) after 1–4 hours of operation and again after 10 hours of operation. Torque every 200 hours thereafter.
Operation Note: Determine the left and right sides of the machine from the normal operating position. 1 Caution This machine produces sound levels in excess of 85 dBA at the operators ear and can cause hearing loss through extended periods of exposure. Wear hearing protection when operating this machine. Figure 18 1. Speed stop screw Controls Traction Pedals Tilt Steering Lever Depress the traction forward pedal (Fig. 17) to move forward. Depress traction reverse pedal (Fig.
7 4 3 Danger 2 Shifting the cutting units downhill decreases machine stability. This could cause a rollover, which may result in personal injury or death. 8 6 5 Shift the cutting units uphill while on a side hill. 10 11 9 Engine Coolant Temperature Warning Light 1 The temperature warning light (Fig. 19) glows if the engine coolant temperature is high. If the traction unit is not stopped and the coolant temperature rises another 10°F, the engine will kill. Figure 19 1. 2. 3. 4. 5. 6.
Fuel Gauge Important To prevent overheating of the starter motor, do not engage the starter longer than 15 seconds. After 10 seconds of continuous cranking, wait 60 seconds before engaging the starter motor again. The fuel gauge (Fig. 20) registers the amount of fuel in the tank. 5. When the engine is started for the first time, or after an overhaul of the engine, operate the machine in forward and reverse for one to two minutes.
seat and slowly depress the traction pedal, the engine should stop in one to three seconds. Correct problem if it is not operating properly. 1 Note: The machine is equipped with an interlock switch on the parking brake. The engine will stop if the traction pedal is depressed with the parking brake engaged. Towing the Traction Unit In case of an emergency, the machine can be towed for a short distance; however, we do not recommend this as a standard procedure.
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.
Operating Characteristics 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. Danger The mower has a unique traction system that will allow the machine to move forward on side hills, even if the uphill wheel should come off of the ground.
Mowing Techniques After Mowing To begin cutting, engage the decks, then approach the mowing area slowly. Once the front decks are over the mowing area, lower the cutting units. At the completion of mowing operation, thoroughly wash the machine with a garden hose without a nozzle so that excessive water pressure will not cause contamination and damage to the seals and bearings. Make sure that the radiator and oil cooler are kept free of dirt or grass clippings.
Maintenance Note: Determine the left and right sides of the machine from the normal operating position. Recommended Maintenance Schedule Maintenance Service Interval Maintenance Procedure After first 10 hours • Check the fan and alternator belt tension. • Replace the hydraulic filter. • Torque the wheel lug nuts. After first 50 hours • Change the engine oil and filter. • Check the engine RPM (at idle and full throttle). Inspect the air filter, dust cup, and burp valve. Lubricate all grease fittings.
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 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 the radiator and screen for debris. Check for unusual engine noises.1 Check for unusual operating noises. Check the hydraulic system oil level.
Greasing the Bearings and Bushings The traction unit 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 the bearings and bushings after every 50 hours of operation. The bearings and bushings must be lubricated daily when operating conditions are extremely dusty and dirty. Dusty and dirty operating conditions could cause dirt to get into the bearings and bushings, resulting in accelerated wear.
Figure 29 Figure 26 (2) Figure 30 Figure 27 Figure 31 Figure 28 31
Figure 35 Figure 32 Figure 36 Figure 33 Figure 34 See note 32
Service Interval Chart 33
Removing the Hood force dirt through the filter into the intake tract. This cleaning process prevents debris from migrating into the intake when the primary filter is removed. The hood may be easily removed to ease maintenance procedures in the engine area of the machine. 1. Unlatch and raise the hood. 2 2. Remove the cotter pin securing the hood pivot to the mounting brackets (Fig. 37). 1 1 Figure 38 1. Air cleaner cover Figure 37 2. Air cleaner latch 3. Remove and replace the primary filter (Fig.
Servicing the Engine Oil and Filter Servicing the Fuel System Change the oil and filter initially after the first 50 hours of operation; thereafter change the oil and filter every 150 hours. Drain and clean the fuel tank every 2 years. Also, 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. Fuel Tank 1. Remove either drain plug (Fig. 40) and let oil flow into a drain pan.
Replacing the Fuel Prefilter 4. Remove the clamp from the fuel filter and slide it onto the replacement filter. Push the fuel lines onto the replacement fuel filter and secure them with the hose clamps. Be sure that the arrow on the side of the filter points toward the injection pump. Replace the fuel prefilter, located on the inside of the frame rail below the water separator, after every 400 operating hours or yearly, whichever occurs first. 1. Remove the screw securing the filter to the frame rail. 5.
Alternator/Fan Belt 1. Turn the engine off and raise the hood. Clean the engine area thoroughly of all debris. 1. Open the hood. 2. Remove the access panel (Fig. 45). 2. Check the tension by depressing the belt midway between the alternator and crankshaft pulleys with 22 lb. (30 N⋅m) of force. The belt should deflect 7/16 in. (11 mm). If the deflection is incorrect, proceed to step 3. If it is correct, continue operation. 3 2 1 1 Figure 45 1. Access panel 2. Oil cooler 3. Radiator Figure 47 1.
7. If the throttle does not stay in position during operation, torque the locknut, used to set the friction device on the throttle lever, to 40–55 in.-lb. (5–6 N⋅m). The maximum force required to operate the throttle lever should be 20 lb. (27 N⋅m). 2 Changing the Hydraulic Fluid 1 Change the hydraulic fluid after every 400 operating hours, in normal conditions. If the fluid becomes contaminated, contact your local Toro distributor because the system must be flushed.
6. Start the engine and let it run for about two minutes to purge air from the system. Stop the engine and check for leaks. Important Use only the hydraulic fluids specified. Other fluids could cause system damage. Checking the Hydraulic Lines and Hoses 1 Daily, check hydraulic lines and hoses for leaks, kinked lines, loose mounting supports, wear, loose fittings, weather deterioration, and chemical deterioration. Make all necessary repairs before operating.
3. Loosen the locknut on the traction adjustment cam (Fig. 53). 3 1 2 1 Figure 54 2 1. Parking brake lever 2. Knob Figure 53 1. Traction adjustment cam 3. Set screw 2. Locknut Caring for the Battery Warning The battery electrolyte level must be properly maintained and the top of the battery kept clean. lf the machine is stored in a location where temperatures are extremely high, the battery will run down more rapidly than if the machine is stored in a location where temperatures are cool.
Storing the Battery Warning If the machine will be stored more than 30 days, remove the battery and charge it fully. Either store it on the shelf or on the machine. Leave the cables disconnected if it is stored on the machine. Store 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.
Electrical Schematic 42
Hydraulic Schematic 43
Preparation for Seasonal Storage Engine 1. Drain the engine oil from the oil pan and replace the drain plug. Traction Unit 2. Remove and discard the oil filter. Install a new oil filter. 1. Thoroughly clean the traction unit, cutting units, and engine. 3. Refill the oil pan with approximately 4 U.S. quarts (3.8 l) of SAE15W-40 motor oil. 2. Check the tire pressure. Inflate all tires to 14–18 psi (97–110 kPa). 4. Start the engine and run it at idle speed for approximately two minutes. 3.
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.
