Form No. 3409-146 Rev B Groundsmaster® 3500-D Rotary Mower Model No. 30807—Serial No. 400000000 and Up Model No. 30839—Serial No. 400000000 and Up Register at www.Toro.com.
This product complies with all relevant European directives; for details, please see the separate product specific Declaration of Conformity (DOC) sheet. You may contact Toro directly at www.Toro.com for product and accessory information, help finding a dealer, or to register your product.
Contents Fuel System Maintenance ................................... 45 Draining the Fuel Tank ...................................... 45 Servicing the Water Separator .......................... 45 Bleeding the Fuel System ................................. 46 Bleeding Air from the Injectors .......................... 46 Electrical System Maintenance ........................... 47 Electrical System Safety ................................... 47 Servicing the Battery.........................................
Safety This machine has been designed in accordance with EN ISO 5395:2013 and ANSI B71.4-2012. General Safety This product is capable of amputating hands and feet and of throwing objects. Always follow all safety instructions to avoid serious personal injury. Using this product for purposes other than its intended use could prove dangerous to you and bystanders. • Read and understand the contents of this Operator’s Manual before starting the engine.
Safety and Instructional 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 missing. decal93-6681 99-3444 93-6681 1. Cutting/dismemberment—hazard, fan-stay away from moving parts. decal99-3444 99-3444 1. Transport speed—fast 2. Mowing speed—slow decal93-7276 93-7276 1. Explosion hazard—wear eye protection. 2. Caustic liquid/chemical burn hazard—to perform first aid, flush with water. 3.
decalbatterysymbols Battery Symbols Some or all of these symbols are on your battery decal117-3270 117-3270 1. Explosion hazard 6. Keep bystanders a safe distance away from the battery. 2. No fire, open flame, or smoking 7. Wear eye protection; explosive gases can cause blindness and other injuries. 3. Caustic liquid/chemical burn hazard 4. Wear eye protection. 8. Battery acid can cause blindness or severe burns. 9. Flush eyes immediately with water and get medical help fast. 1.
decal106-9290 106-9290 1. Inputs 5. In seat 2. Not active 6. Power take-off (PTO) 10. Power take-off (PTO) 3. High-temperature shutdown 4. High-temperature warning 7. Parking brake off 11. Start 8. Neutral 12. Energize to run (ETR) 9. Outputs 13. Start 14. Power decal121-3627 121–3627 1.
decal121-3623 121-3623 1. Warning—read the Operator's Manual; do not operate the machine unless you have received training. 5. Thrown object hazard—keep bystanders away. 2. Warning—read the Operator's Manual before towing the machine. 3. Tipping hazard—slow the machine before turning; when driving on slopes, keep the cutting units lowered and your seatbelt fastened. 4.
decal117-5103 117-5103 (Model 30839) decal121-3532 121-3532 (Model 30807) 1. Read the Operator’s Manual. 4. Optional light—15A 2. SCM-2A 5. System gauges—10A 3. Main—15A 6.
decal121-3620 121-3620 1. PTO—Disengage 7. Lock 2. PTO—Engage 8. Engine—Shut off 3. Move the cutting units right. 9. Engine—Run 4. Move the cutting units left. 10. Engine—Start 5. Lower the cutting units. 11. Fast 6. Raise the cutting units. 12.
Setup Loose Parts Use the chart below to verify that all parts have been shipped. Procedure 1 2 3 4 5 6 7 8 9 10 11 Description Qty. Use No parts required – Activate, charge, and connect the battery. Inclinometer 1 Check the angle indicator. Decal (121-3598) 1 Install the CE decals (if required). Lock bracket Rivet Washer Screw (1/4 x 2 inches) Locknut (1/4 inch) Exhaust guard Self-tapping screw 1 2 1 1 1 1 4 No parts required – Adjust the lift arms.
1 Activating, Charging, and Connecting the Battery No Parts Required Procedure g031567 Figure 3 1. Battery cover WARNING CALIFORNIA Proposition 65 Warning 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. 2. Remove the filler caps from the battery and slowly fill each cell until the electrolyte is just above the plates. 3.
WARNING 2 Incorrect battery cable routing could damage the tractor and cables, causing sparks. Sparks can cause the battery gases to explode, resulting in personal injury. Checking the Angle Indicator • Always disconnect the negative (black) battery cable before disconnecting the positive (red) cable. Parts needed for this procedure: 1 • Always connect the positive (red) battery cable before connecting the negative (black) cable. Inclinometer Procedure 1. Park the machine on a flat, level surface.
3 Installing the CE Decal Parts needed for this procedure: 1 Decal (121-3598) Procedure g031570 Figure 6 If this machine will be used for CE, affix the CE-warning decal over the corresponding English warning decal. 1. Rivets 4 2. Hood-latch bracket 3. Remove the hood-latch bracket from the hood. 4. While aligning the mounting holes, position the lock bracket and the hood-latch bracket onto the hood (Figure 7). Installing the Hood Latch Note: The lock bracket must be against the hood.
5 Installing the Exhaust Guard CE Models Only g012630 Figure 8 Parts needed for this procedure: 1. Hood latch 8. 1 Exhaust guard 4 Self-tapping screw Install the bolt into the other arm of the hood-lock bracket to lock the latch in position (Figure 9). Procedure Note: Tighten the bolt securely, but do not tighten the nut. 1. Position the exhaust guard around the muffler while aligning the mounting holes with the holes in the frame (Figure 10). g012631 Figure 9 1. Bolt 3.
B. 6 Back off the jam nut on the cylinder (Figure 13). Adjusting the Lift Arms No Parts Required Procedure 1. Start the engine, raise the cutting units, and ensure that the clearance between each lift arm and the floor-plate bracket is 5 to 8 mm (0.18 to 0.32 inches) as shown in Figure 11. g031573 Figure 13 1. Jam nut 2. Front cylinder C. Remove the pin from the rod end and rotate the clevis. D. Install the pin and check the clearance. Note: Repeat the procedure if required. E. 2.
g031575 Figure 15 1. Rear cylinder 2. Adjusting nut B. Grasp the cylinder rod close to the nut with a pliers and rag, and rotate the rod. C. Raise the cutting units and check the clearance. g031576 Figure 16 1. Upper, front deck mounting hole Note: Repeat the procedure if required. D. 3. Rear deck mounting hole 2. Lower, front deck mounting hole Tighten the clevis jam nut. Important: Lack of clearance at the front stops or rear wear bar could damage the lift arms. 2.
bench set 6 mm (1/4 inch) above that of the reels cutting in the same area. 8. Repeat steps 4 to 7 for each side adjustment. 9. Tighten the 3 bolts to 41 N∙m (30 ft-lb). Important: Access to the rear cutting units is Note: Tighten the front bolt first. greatly improved by removing the cutting unit from the machine. If the machine is equipped with a Sidewinder® unit, side-wind the cutting units to the right, remove the rear cutting unit, and slide it out to the right side. 1.
10 11 Installing the Mulching Baffle Reading the Manuals and Viewing the Training Materials Optional Parts needed for this procedure: No Parts Required Procedure 1. 2. Thoroughly clean debris from the mounting holes on the rear wall and left wall of the chamber. Install the mulching baffle in the rear opening and secure it with 5 flange-head bolts (Figure 20).
Traction Pedals Product Overview Press the forward traction pedal to move forward. Press reverse traction pedal to move backward or to assist in stopping when moving forward (Figure 21). Controls Note: Allow the pedal to move or move it to the NEUTRAL position to stop the machine. Mow/Transport Slide Using your heel, move the mow/transport slide to the left to transport, and to the right to mow (Figure 21). Note: The cutting units operate only in the mow position.
ON/PREHEAT position until the glow-plug-indicator light goes out (approximately 7 seconds); then rotate the key to the START position to engage the starter motor. Release the key when the engine starts (Figure 22). Oil-Pressure-Warning Light To shut the engine off, rotate the key to the OFF position. Alternator Light Note: Remove the key from the switch to prevent The alternator light should be off when the engine is running (Figure 22).
Seat-Adjustment Lever Move the seat-adjustment lever on the side of the seat outward, slide the seat to the desired position, and release the lever to lock the seat into position (Figure 24).
Specifications Note: Specifications and design are subject to change without notice.
Overall length in mowing position F 305 cm (120 inches) Overall length in transport position G 295 cm (116 inches) Ground clearance 15 cm (6 inches) Weight of models 30807 and 30839 963 kg (2,124 lb) change without notice. Operation Attachments/Accessories Before Operation Note: Specifications and design are subject to Note: Determine the left and right sides of the machine from the normal operating position.
Filling the Fuel Tank • Never store the machine or fuel container where there is an open flame, spark, or pilot light, such as on a water heater or other appliance. • If you spill fuel, do not attempt to start the engine; avoid creating any source of ignition until the fuel vapors have dissipated. Adding Fuel 1. Clean the area around the fuel-tank cap (Figure 26). 2. Remove the fuel-tank cap. 3. Fill the tank to the bottom of the filler neck. Do not overfill. Install the cap. 4.
Selecting a Blade Using a Standard-Combination Sail Blade This blade provides excellent lift and dispersion in almost any condition. If more or less lift and discharge velocity is required, consider a different blade. Attributes: It has excellent lift and dispersion in most conditions. Using an Angled-Sail Blade The blade generally performs best in lower heights of cut—1.9 to 6.4 cm (3/4 to 2-1/2 inches). Attributes: • The discharge remains more even at lower heights of cut.
Selecting Accessories Optional-Equipment Configurations Angle-Sail Blade High-Lift-Parallel Sail Blade (Do not use with the mulching baffle) Grass cutting: 1.9 to 4.4 cm (0.75 to 1.75 inches) height of cut Recommended in most applications May work well in light or sparse turf Grass cutting: 5 to 6.4 cm (2 to 2.5 inches) height of cut Recommended for thick or lush turf Recommended for light or sparse turf Grass cutting: 7 to 10 cm (2.
During Operation – Disengage the power take-off and lower the attachments. – Engage the parking brake. During Operation Safety – Shut off the engine and remove the key. – Wait for all moving parts to stop. General Safety • Do not operate the machine when there is the risk • The owner/operator can prevent and is responsible • • • • • • • • • • • • • • • • of lightning. for accidents that may cause personal injury or property damage.
• Avoid operating the machine on wet grass. Tires 6. may lose traction; regardless if the brakes are available and functioning. Avoid starting, stopping, or turning the machine on a slope. Keep all movement on slopes slow and gradual. Do not suddenly change the speed or direction of the machine. Do no operate the machine near drop-offs, ditches, embankments, or bodies of water. The machine could suddenly roll over if a wheel goes over the edge or the edge caves in.
Standard-Control Module (SCM) The Standard-Control Module (SCM) is a potted electronic device produced in a 1-size-fits-all configuration. The module uses solid state and mechanical components to monitor and control standard, electrical features required for safe product operation. The module-monitor input includes neutral, parking brake, PTO, start, backlap, and high temperature. The module energizes outputs including PTO, Starter, and ETR (energize to run) solenoid.
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.
Operating Tips • If an obstacle is in the way, shift the cutting units Creating a Site Survey • When transporting the machine from 1 work area to mow around it. to another, raise the cutting units to the fully upward position, move the mow/transport slide to the left to transport, and place the throttle in the FAST position. To perform a site survey, lay a 4 ft 2x4 (1.25 meter plank) on the slope surface and measure the angle of the slope with the inclinometer provide with the machine.
• The cutting units tend to throw grass to the left clippings. After cleaning, inspect the machine for possible hydraulic-fluid leaks, damage, or wear to the hydraulic and mechanical components, and check the cutting-unit blades for sharpness. side of the machine. If you are trimming around bunkers, it is best to mow in a clockwise direction to prevent throwing clippings into the bunker.
Pushing or Towing the Machine Important: In an emergency, you can tow the machine for a short distance. Do not tow the machine at faster than 3 to 4 km/h (2 to 3 mph); otherwise, you may damage the drive system. If you must move the machine a considerable distance, transport it on a truck or trailer. 1. g192121 Locate the bypass valve on the pump and rotate it 90° (Figure 29). g192122 Figure 28 1. Tie-down point g031610 Figure 29 1. Bypass valve 2.
Maintenance Note: Determine the left and right sides of the machine from the normal operating position. Recommended Maintenance Schedule(s) Maintenance Service Interval After the first hour Maintenance Procedure • Torque the wheel-lug nuts. After the first 10 hours • Torque the wheel-lug nuts. • Check the condition and tension of all belts. • Change the hydraulic filter. After the first 50 hours • Change the engine oil and engine-oil filter.
Daily Maintenance Checklist Duplicate this page for routine use. For the week of: Maintenance Check Item Monday Tuesday Wednesday Thursday Friday Saturday Check the safety-interlock operation. Check the 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 for unusual engine noises.2 Check the radiator and screen for debris Check for unusual operating noises.
Service-Interval Chart decal117-5103 Figure 30 Pre-Maintenance Procedures • Use jack stands to support the machine or components when required. • Carefully release pressure from components with stored energy. Pre-Maintenance Safety • Before adjusting, cleaning, repairing, or leaving • • the machine, do the following: – Park the machine on a level surface. – Move the throttle switch to the low-idle position. – Disengage the cutting units. – Lower the cutting units.
Using the Cutting Deck Service Latch Preparing the Machine for Maintenance 1. Ensure that the PTO is disengaged. 2. Park the machine on a level surface. 3. Engage the parking brake. 4. Lower the cutting unit(s) if necessary. 5. Shut off the engine and wait for all moving parts to stop. 6. Turn the ignition key to the STOP position and remove it. 7. Allow machine components to cool before performing maintenance. When servicing the cutting decks, use the service latch to prevent injury. 1.
Lubrication Greasing the Bearings and Bushings Service Interval: Every 50 hours—Lubricate all of the bearings and bushings. Every 500 hours/Yearly (whichever comes first) The machine has grease fittings that you must lubricate regularly with No. 2 lithium grease. Also, lubricate the machine immediately after every washing.
g008901 Figure 40 • Mow/transport slide (Figure 41) g008898 Figure 37 • 2 left, front lift-arm pivots and lift cylinder (Figure 38) g008902 Figure 41 • Belt-tension pivot (Figure 42) g008899 Figure 38 • 2 right, front lift-arm pivots and lift cylinder (Figure 39) g008903 Figure 42 • Steering cylinder (Figure 43).
Important: Do not lubricate the Sidewinder cross tube. The bearing blocks are self-lubricated. g008904 Figure 43 • 2 (per cutting unit) cutting unit spindle-shaft bearings (Figure 44) Note: You can use either fitting, whichever is more accessible. Pump grease into the fitting until a small amount appears at the bottom of the spindle housing (under the deck).
Engine Maintenance Engine Safety • Shut off the engine before checking the oil or adding oil to the crankcase. • Do not change the governor speed or overspeed the engine. Servicing the Air Cleaner Check the air-cleaner body for damage that could cause an air leak and replace it if it is damaged. Check the entire intake system for leaks, damage, or loose hose clamps. Also, inspect the rubber intake-hose connections at the air cleaner and turbocharger to ensure that the connections are complete.
Servicing the Air-Cleaner Filter Service Interval: Every 200 hours (More frequently in extreme dusty or dirty conditions) 1. Before removing the filter, use clean and dry, low-pressure air (275 kPa or 40 psi) to help remove large accumulations of debris packed between the outside of the primary filter and the canister. Important: Avoid using high-pressure air that could force dirt through the filter and into the intake tract, causing damage.
Servicing the Engine Oil Checking the Engine-Oil Level Service Interval: Before each use or daily The engine is shipped with oil in the crankcase; however, check the oil level before and after you start the engine for the first time. The crankcase capacity is approximately 2.8 L (4 US qt) with the filter. Use high-quality engine oil that meets the following specifications: • API Classification Level Required: CH-4, CI-4, or higher.
4. Fuel System Maintenance Change the engine-oil filter as shown in Figure 51. Draining the Fuel Tank Service Interval: Every 1,000 hours—Drain and clean the fuel tank. Every 2 years—Drain and clean the fuel tank. Drain and clean the tank also if the fuel system becomes contaminated or if you are storing the machine for an extended period of time. Use clean fuel to flush out the tank.
Replacing the Fuel Filter Note: The electric fuel pump will operate, 1. Clean the area where the filter mounts (Figure 52). 2. Remove the filter and clean the mounting surface. 3. Lubricate the gasket on the filter with clean oil. 4. Install the filter by hand until the gasket contacts the mounting surface; then rotate an additional 1/2 turn. forcing air out around the air-bleed screw. Leave the key in the ON position until a solid stream of fuel flows out around the screw. 6.
Electrical System Maintenance Keep the top of the battery clean by washing it periodically with a brush dipped in ammonia or a solution of bicarbonate of soda. Flush the top surface with water after cleaning. Do not remove the filler caps while cleaning the battery. Electrical System Safety The battery cables must be tight on the terminals to provide good electrical contact. • Disconnect the battery before repairing the machine. Disconnect the negative terminal first and the positive last.
Adjusting the Traction Drive for Neutral Drive System Maintenance If the machine moves when the traction pedal is in the NEUTRAL position, adjust the traction cam. Checking the Tire Pressure Service Interval: Before each use or daily 1. Park the machine on a level surface, lower the cutting units, engage the parking brake, shut off the engine, and remove the key from the ignition switch. 2. Chock or block the front and rear wheels on one side. 3.
5. Start the engine and rotate the cam hex in both directions to determine the mid position of the neutral span. 6. Tighten the locknut securing the adjustment. 7. Shut off the engine. 8. Remove the support blocks and lower the machine to the shop floor. Test drive the machine to ensure that it does not move when the traction pedal is in neutral. Cooling System Maintenance Cooling System Safety • Swallowing engine coolant can cause poisoning; keep out of reach from children and pets.
Cleaning the Cooling System CAUTION If the engine has been running, the pressurized, hot coolant can escape and cause burns. Service Interval: Before each use or daily • 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. 1. Turn the engine off and raise the hood. 2. Clean the engine area thoroughly of all debris. 3.
Brake Maintenance Belt Maintenance Adjusting the Parking Brake Servicing the Engine Belts Service Interval: After the first 10 hours—Check the condition and tension of all belts. Service Interval: Every 200 hours—Check the parking-brake adjustment. 1. Every 100 hours—Check the condition and tension of all belts. Loosen the set screw securing the knob to the parking-brake lever (Figure 60). Checking the Alternator-Belt Tension 1. Open the hood. 2.
Replacing the Hydrostat-Drive Belt 1. Controls System Maintenance Insert a nut driver or small piece of tubing onto the end of the belt-tensioning spring. CAUTION Adjusting the Throttle The spring that tensions the belt is under a heavy load, and releasing the tension of the spring improperly may cause injury. Use care when de-tensioning the spring and replacing the belt. 2. 1. Position the throttle lever rearward so that it stops against the control-panel slot. 2.
Hydraulic System Maintenance is sufficient for 15 to 22 L (4 to 6 US gallons) of hydraulic oil. Order Part No. 44-2500 from your authorized Toro distributor. The reservoir is filled at the factory with approximately 13.2 L (3.5 US gallons) of high-quality hydraulic fluid. Check the level of the hydraulic fluid before the engine is first started and daily thereafter. The recommended replacement fluid is Toro Premium All-Season Hydraulic Fluid (Available in 19 L (5 US gallons) pails or 55-gallon drums.
4. Remove the dipstick from the filler neck and wipe it with a clean rag. 5. Insert the dipstick into the filler neck, then remove it and check the fluid level. Note: The fluid level should be within 6 mm (1/4 inch) of the mark on the dipstick. 6. If the level is low, add the appropriate fluid to raise the level to the FULL mark. 7. Install the dipstick and cap onto the filler neck.
Changing the Hydraulic Fluid Service Interval: Every 400 hours If the fluid becomes contaminated, contact your local Toro distributor to flush the system. Contaminated fluid looks milky or black. 1. Turn the engine off and raise the hood. 2. Disconnect the hydraulic line or remove the hydraulic filter and let the hydraulic fluid flow into a drain pan (Figure 65 and Figure 66). g031641 Figure 67 1. Hydraulic-tank cap g031643 Figure 66 5. Install the reservoir cap. 6. Start the engine. 7.
Mower Deck Maintenance 3. Remove the lynch pin or retaining nut securing the deck carrier frame to the lift-arm-pivot pin (Figure 69). Blade Safety A worn or damaged blade can break, and a piece of the blade could be thrown toward you or bystanders, resulting in serious personal injury or death. • Inspect the blade periodically for wear or damage. • Use care when checking the blades. Wrap the blades or wear gloves, and use caution when servicing the blades.
Mounting the Mower Decks to the Traction Unit 1. Perform the pre-maintenance procedure; refer to Preparing the Machine for Maintenance (page 38). 2. Move the cutting deck into position in front of the traction unit. 3. Slide the deck-carrier frame onto the lift-arm-pivot pin and secure it with the lynch pin or retaining nut (Figure 69). 4. g011353 Figure 70 Using the hydraulic-motor-mounting screws, install the hydraulic motor to the deck (Figure 68). 4.
2. Adjust the 1.5 mm (0.06 inch) shims and/or 0.7 mm (0.03 inch) shim between the deck frame and bracket to achieve the desired height of cut (Figure 71). 3. Install the height-of-cut bracket to the deck frame with the remaining shims assembled below the height-of-cut bracket (Figure 71). 4. Secure the socket-head bolt and spacer and flange nut. Note: The socket-head bolt and spacer are held together with Loctite to prevent the spacer from falling inside the deck frame. g011355 Figure 72 5.
4. Inspect the cutting edges of all the blades, sharpen the cutting edges if they are dull or nicked, sharpen only the top of the cutting edge, and maintain the original cutting angle to ensure sharpness (Figure 74). Checking the Blade Stopping Time Note: The blade remains balanced if the same amount of metal is removed from both cutting edges.
Installing the Front Roller 1. Storage Pressing on the outer race only or equally on the inner and outer race, press the first bearing into the roller housing (Figure 75). Storing the Battery If you are storing the machine for more than 30 days, remove the battery and charge it fully. 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 that it is fully charged.
Preparing the Engine 1. Drain the engine oil from the oil pan and install the drain plug. 2. Remove and install a new oil filter. 3. Fill the engine with approximately 3.8 L (4 US qt) of SAE 15W-40 motor oil. 4. Start the engine and run it at idle speed for approximately 2 minutes. 5. Shut off the engine. 6. Thoroughly drain all fuel from the fuel tank, fuel lines, fuel filter, and water separator assembly. 7. Flush the fuel tank with fresh, clean diesel fuel. 8.
Notes:
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The Toro 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. This warranty is applicable to all products with the exception of Aerators (refer to separate warranty statements for these products).
