Form No. 3423-992 Rev B Groundsmaster® 3500-D Rotary Mower Model No. 30807—Serial No. 403207001 and Up Model No. 30839—Serial No. 403207001 and Up Register at www.Toro.com.
Whenever you need service, genuine Toro parts, or additional information, contact an Authorized Service Dealer or Toro Customer Service and have the model and serial numbers of your product ready. Figure 1 identifies the location of the model and serial numbers on the product. Write the numbers in the space provided. This product complies with all relevant European directives; for details, please see the separate product specific Declaration of Conformity (DOC) sheet.
Contents Servicing the Water Separator .......................... 43 Bleeding the Fuel System ................................. 44 Bleeding Air from the Injectors .......................... 44 Electrical System Maintenance ........................... 45 Electrical System Safety ................................... 45 Servicing the Battery......................................... 45 Servicing the Fuses .......................................... 45 Drive System Maintenance ..................................
Safety This machine has been designed in accordance with EN ISO 5395:2017 and ANSI B71.4-2017. 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. • Use your full attention while operating the machine.
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.
decal121-3598 121-3598 Note: This machine complies with the industry standard stability test in the static lateral and longitudinal tests with the maximum recommended slope indicated on the decal. Review the instructions for operating the machine on slopes in the Operator’s Manual as well as the conditions in which you would operate the machine to determine whether you can operate the machine in the conditions on that day and at that site.
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.
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 Description 1 2 3 4 5 6 7 8 9 10 Use Qty. 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). Hood-latch 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.
WARNING 1 Charging the battery produces gasses that can explode. Activating, Charging, and Connecting the Battery • Keep sparks and flames away from battery. • Never smoke near the battery. No Parts Required Procedure Note: If the battery is not filled with electrolyte or activated, purchase bulk electrolyte with 1.26 specific gravity from a local battery-supply outlet and add it to the battery. 4. When the battery is charged, disconnect the charger from the electrical outlet and battery posts. 5.
g031568 g031569 Figure 4 1. Negative (–) battery cable Figure 5 2. Positive (+) battery cable 1. Angle indicator Important: If you ever remove the battery, install the battery-clamp bolts 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. 9. Coat both battery connections with Grafo 112X (skin over) grease (Toro Part No.
4 Installing the Hood Latch CE Machines Only Parts needed for this procedure: 1 Hood-latch bracket 2 Rivet 1 Washer 1 Screw (1/4 x 2 inches) 1 Locknut (1/4 inch) g012629 Figure 7 1. CE lock bracket Procedure 1. Unhook the hood latch from the hood-latch bracket. 2. Remove the 2 rivets securing the hood-latch bracket to the hood (Figure 6). 2. Bolt and nut 5. Align the washers with the holes on the inside of the hood. 6. Rivet the brackets and the washers to the hood (Figure 7). 7.
g012631 Figure 9 1. Bolt 2. Nut 3. Arm of hood-latch bracket 5 g008875 Figure 10 Installing the Exhaust Guard 1. Exhaust guard 2. CE Models Only Parts needed for this procedure: 1 Exhaust guard 4 Self-tapping screw Procedure 1. Position the exhaust guard around the muffler while aligning the mounting holes with the holes in the frame (Figure 10). 14 Secure the exhaust guard to the frame with 4 self-tapping screws (Figure 10).
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 inch) 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.
Product Overview 10 Controls Installing the Mulching Baffle Optional No Parts Required Procedure 1. Thoroughly clean debris from the mounting holes on the rear wall and left wall of the chamber. 2. Install the mulching baffle in the rear opening and secure it with 5 flange-head bolts (Figure 20). g031595 Figure 21 1. Tilt-steering lever 4. Forward traction pedal 2. Angle indicator 5. Mow/transport slide 3. Reverse traction pedal 6. Indicator slot g031579 Figure 20 1. Mulching baffle 3. 2.
Traction Pedals 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). Note: Allow the pedal to move or move it to the NEUTRAL position to stop the machine. Tilt-Steering Lever Pull the tilt-steering lever back to tilt the steering wheel to the desired position, then push the lever forward to tighten (Figure 21).
Mow/Transport Slide Note: The lever does not need to be held in the forward position while you are lowering the cutting units. 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 Alternator Light position. The alternator light should be off when the engine is running (Figure 22). Important: The mow speed is set at the factory to 9.7 km/h (6 mph).
Specifications Note: Specifications and design are subject to change without notice.
Overall length in mowing position F 295 cm (116 inches) Overall length in transport position G 295 cm (116 inches) Ground clearance 15 cm (6 inches) Weight 963 kg (2,124 lb) Note: Specifications and design are subject to change without notice. Operation Attachments/Accessories A selection of Toro approved attachments and accessories is available for use with the machine to enhance and expand its capabilities. Contact your Authorized Service Dealer or authorized Toro distributor or go to www.
• Fuel filter plugging may occur for a time after you • Do not store the machine or fuel container where convert to biodiesel blends. there is an open flame, spark, or pilot light, such as on a water heater or other appliance. • For more information on biodiesel, contact your • If you spill fuel, do not attempt to start the engine; authorized Toro distributor. avoid creating any source of ignition until the fuel vapors have dissipated.
Filling the Fuel Tank Selecting a Blade 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. To prevent a fire hazard, wipe up any spilled fuel. Using a Standard Combination Sail This blade provides excellent lift and dispersion in almost any condition. If you require more or less lift and discharge velocity, consider a different blade.
Choosing Accessories Optional Equipment Configurations Angle Sail Blade High-Lift, Parallel-Sail Blade (Do not use with the mulching baffle) Mulching Baffle Roller Scraper Grass Cutting: 1.9 to 4.4 cm (3/4 to 1-3/4 inches) height of cut Recommended in most applications May work well in light or sparse turf Grass Cutting: 5 to 6.
During Operation • Before leaving the operating position (including to empty the catchers or to unclog the chute), do the following: During Operation Safety – Park the machine on level ground. General Safety – Disengage the power takeoff and lower the attachments. • The owner/operator can prevent and is responsible – Engage the parking brake. for accidents that may cause personal injury or property damage. – Shut off the engine and remove the key. – Wait for all moving parts to stop.
• Avoid starting, stopping, or turning the machine on Note: The key automatically moves to the slopes. Avoid making sudden changes in speed or direction. Make turns slowly and gradually. ON/RUN position. 6. • Do not operate a machine under any conditions where traction, steering, or stability is in question. • Remove or mark obstructions such as ditches, holes, ruts, bumps, rocks, or other hidden hazards. Tall grass can hide obstructions. Uneven terrain could overturn the machine.
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 upward position, move the mow/transport slide to the left to transport, and place the throttle in the FAST position. Creating a Site Survey Changing Mowing Patterns To perform a site survey, lay a 1.25 m plank (4 ft long 2 x 4) on the slope surface and measure the angle of the slope with the inclinometer provided with the machine. The plank (2 x 4) will average the slope but will not take into consideration dips or holes which can cause a sudden change in side hill angle.
After Operation when you maintain turf on a regular schedule to avoid removing more than 25 mm (1 inch) of growth per cutting. When you cut too much growth with the mulching baffles installed, the after-cut appearance may deteriorate and the observed power to cut the turf increases. The mulching baffles also perform well for shredding leaves in the fall. After Operation Safety • Clean grass and debris from the cutting units, mufflers, and engine compartment to help prevent fires.
Pushing or Towing the Machine In an emergency, you can move the machine a very short distance by actuating the bypass valve in the hydraulic pump and pushing or towing the machine. Important: Do not push or tow the machine faster than 3 to 4.8 km/h (2 to 3 mph). If you push or tow at a faster speed, internal transmission damage may occur. If you must move the machine a considerable distance, transport it on a truck or trailer.
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.
Pre-Maintenance Procedures Preparing the Machine for Maintenance 1. Ensure that the PTO is disengaged. Maintenance Safety 2. Park the machine on a level surface. • Before adjusting, cleaning, repairing, or leaving 3. Engage the parking brake. the machine, do the following: 4. Lower the cutting unit(s) if necessary. – Park the machine on a level surface. 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.
Using the Cutting Deck Service Latch When servicing the cutting decks, use the service latch to prevent injury. 1. Center the cutting deck sidewinder with the traction unit. 2. Raise the cutting decks to the transport position. 3. Engage the parking brake and turn off the machine. 4. Release the latch rod from the front carrier-frame retainer (Figure 31). g031614 Figure 31 1. Service-latch hook 5.
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 39 • Mow/transport slide (Figure 40) g008898 Figure 36 • 2 left, front lift-arm pivots and lift cylinder (Figure 37) g008902 Figure 40 • Belt-tension pivot (Figure 41) g008899 Figure 37 • 2 right, front lift-arm pivots and lift cylinder (Figure 38) g008903 Figure 41 • Steering cylinder (Figure 42) g008900 Figure 38 • Neutral-adjustment mechanism (Figure 39) 38
Important: Do not lubricate the Sidewinder cross tube. The bearing blocks are self-lubricated. g008904 Figure 42 • 2 (per cutting unit) cutting unit spindle-shaft bearings (Figure 43) 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 and remove the key 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.
g032050 Figure 46 1. Rubber outlet valve 4. Air-cleaner body 2. Air-cleaner latch 5. Air-cleaner-restriction sending unit 3. Air cleaner primary filter 6. Rubber intake hose g008861 Figure 47 1. Safety filter 3. Replace the primary filter (Figure 46). 4. Insert the new filter by applying pressure to the outer rim of the element to seat it in the canister. Note: Do not apply pressure to the flexible center of the filter. 5. Clean the dirt-ejection port located in the removable cover. 6.
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 50. 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 51). 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 WARNING Incorrectly routing the battery cable could damage the tractor and cables, causing sparks. Sparks can cause the battery gases to explode, resulting in personal injury. Electrical System Safety • Always disconnect the negative (black) battery cable before disconnecting the positive (red) cable. • Disconnect the battery before repairing the machine. Disconnect the negative terminal first and the positive last. Connect the positive terminal first and the negative 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.
Cooling System Maintenance 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. Cooling System Safety 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. • Swallowing engine coolant can cause poisoning; • • • • keep out of reach from children and pets.
Cleaning the Cooling System The capacity of the cooling system is approximately 5.7 L (6 US qt). CAUTION Service Interval: Before each use or daily If the engine has been running, the pressurized, hot coolant can escape and cause burns. 1. Raise the hood. 2. Clean the engine area thoroughly of all debris. • Do not open the radiator cap when the engine is running. 3. With compressed air, start from the front of the radiator and blow the debris out toward the back.
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 59). 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.
5. 6. 7. Changing the Hydraulic Fluid 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. If the level is low, add the appropriate fluid to raise the level to the FULL mark. Install the dipstick and cap onto the filler neck. 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.
Cutting Unit Maintenance Separating the Mower Decks from the Traction Unit 1. Perform the pre-maintenance procedure; refer to Preparing the Machine for Maintenance (page 35). 2. Remove the hydraulic-motor-mounting screws and disconnect and remove the hydraulic motor from the deck (Figure 67). g031641 Important: Cover the top of the spindle to prevent contamination. Figure 66 1. Hydraulic-tank cap 5. Install the reservoir cap. 6. Start the engine. 7.
3. Mounting the Mower Decks to the Traction Unit Remove the lynch pin or retaining nut securing the deck carrier frame to the lift-arm-pivot pin (Figure 68). 1. Perform the pre-maintenance procedure; refer to Preparing the Machine for Maintenance (page 35). 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 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 70). 3. Install the height-of-cut bracket to the deck frame with the remaining shims assembled below the height-of-cut bracket (Figure 70). 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. g011353 Figure 69 4. 5.
2. Insert a punch through the end of the roller housing and drive the opposite bearing out by alternating taps to the opposite side of inner-bearing race. Servicing the Blade Note: There should be a 1.5 mm (0.06 inch) lip of inner race exposed. Replace the blade if it hits a solid object, if it is out of balance, or if it is bent. Always use genuine Toro replacement blades to ensure safety and optimum performance. Never use replacement blades made by other manufacturers, because they could be dangerous.
3. 7. Examine the cutting ends of the blade carefully, especially where the flat and curved parts of the blade meet (Figure 73). Tighten the blade bolt to 115 to 149 N∙m (85 to 110 ft-lb). Checking the Blade Stopping Time Service Interval: Before each use or daily The cutting-deck blades should stop within 7 seconds after you shut off the cutting units. Note: Ensure that the decks are lowered onto a clean section of turf or hard surface to avoid thrown dust and debris.
Preparing the Engine Storage Follow these procedures whenever you store the machine for more than 30 days. 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. The specific gravity of a fully charged battery is 1.265 to 1.299. Preparing the Traction Unit 1. 2. 1.
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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).
