Form No. 3439-239 Rev B Groundsmaster® 3500-D Rotary Mower Model No. 30807—Serial No. 407170000 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. Visit www.Toro.com for product safety and operation training materials, accessory information, help finding a dealer, or to register your product.
Contents Servicing the Water Separator .......................... 45 Bleeding the Fuel System ................................. 45 Bleeding Air from the Injectors .......................... 46 Electrical System Maintenance ........................... 46 Electrical System Safety ................................... 46 Servicing the Battery......................................... 46 Servicing the Fuses .......................................... 47 Drive System Maintenance ..................................
Safety This machine has been designed in accordance with ANSI B71.4-2017 and with EN ISO 5395 when you complete the setup procedures and install the CE kit, per the Declaration of Conformity. 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. • 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.
decal121-3628 121-3628 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.
decal138-6974 138-6974 1. Read the Operator’s Manual. decal139-6027 139-6027 1. PTO—Disengage 7. Raise the cutting units. 2. PTO—Engage 8. Engine—Shut off 3. Move the cutting units right. 9. Engine—Run 4. Lower the cutting units. 10. Engine—Start 5. Lock 11. Fast 6. Move the cutting units left. 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 Use Qty. Hand-held inclinometer 1 CE warning decal Production year decal CE mark decal Hood-latch bracket Rivet Washer Screw (1/4 x 2 inches) Locknut (1/4 inch) Exhaust guard Self-tapping screw 1 1 1 1 2 1 1 1 1 4 No parts required – Adjust the lift arms. No parts required – Adjust the carrier frame. No parts required – Adjust the height of cut.
1 Checking the Angle Indicator Parts needed for this procedure: 1 Hand-held inclinometer g031569 Figure 4 Procedure 1. Angle indicator 1. Park the machine on a flat, level surface. 2. Verify that the machine is level by placing the handheld inclinometer (supplied with the machine) on the frame cross rail, by the fuel tank (Figure 3). Note: The hand-held inclinometer should read at 0° when viewed from the operating position. g349782 Figure 3 1. Hand-held inclinometer 3.
2 Installing the CE Decals Parts needed for this procedure: 1 CE warning decal 1 Production year decal 1 CE mark decal Procedure g278675 Figure 6 If this machine will be used for CE, affix the CE warning decal (121-3598) over the existing warning decal (121-3628). 1. Serial plate 2. CE mark decal g278676 Figure 5 1. CE warning decal If this machine will be used for CE, affix the production year decal and CE mark decal next to the serial plate (Figure 6). 12 3.
3 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 8 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 7). 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 8). 7.
g012631 Figure 10 1. Bolt 2. Nut 3. Arm of hood-latch bracket 4 g008875 Figure 11 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 11). 14 Secure the exhaust guard to the frame with 4 self-tapping screws (Figure 11).
B. 5 Back off the jam nut on the cylinder (Figure 14). 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 12. g031573 Figure 14 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.
6 Adjusting the Carrier Frame No Parts Required Adjusting the Front Cutting Units g031575 Figure 16 1. Rear cylinder B. C. D. The front and rear cutting units require different mounting positions. The front cutting unit has 2 mounting positions depending on what height of cut and degree of cutting unit rotation you desire. 2. Adjusting nut Grasp the cylinder rod close to the nut with a pliers and rag, and rotate the rod. 1. Raise the cutting units and check the clearance.
Adjusting the Rear Cutting Unit The front and rear cutting units require different mounting positions. The rear cutting unit has 1 mounting position for proper alignment with the Sidewinder® unit under the frame. For all heights of cut, mount the rear cutting unit in the rear mounting holes (Figure 17). 7 Adjusting the Height of Cut g031577 Figure 18 No Parts Required 1. Spacer 3. Height-of-cut bracket 2.
8 9 Adjusting the Roller Scraper Installing the Mulching Baffle Optional Optional No Parts Required No Parts Required Procedure Procedure The optional rear roller scraper functions best when there is an even gap of 0.5 to 1 mm (0.02 to 0.04 inch) between the scraper and the roller. Contact your authorized Toro distributor for the correct mulching baffle. 1. Loosen the grease fitting and the mounting screw (Figure 20). 1.
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 22). Controls 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 22).
maintenance on the cutting unit or when transporting between mowing locations. Mow/Transport Slide Using your heel, move the mow/transport slide to the left to transport, and to the right to mow (Figure 22). Note: The cutting units operate only in the mow position. Important: The mow speed is set at the factory to 9.7 km/h (6 mph). You can increase or decrease the mow speed by adjusting the speed-stop screw (Figure 25). g322579 Figure 24 1. Seat-adjustment lever 2. Fuel gauge g031596 Figure 25 1.
Note: Do this only when the cutting units are raised or if they are on the ground and the machine is moving. Note: The lever does not need to be held in the forward position while you are lowering the cutting units. Alternator Light The alternator light should be off when the engine is running (Figure 23). Note: If it is on, check the charging system and repair it as necessary.
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.
• Do not add or drain fuel in an enclosed space. • Do not store the machine or fuel container where • Monitor seals, hoses, gaskets in contact with fuel there is an open flame, spark, or pilot light, such as on a water heater or other appliance. • Fuel filter plugging may occur for a time after you as they may degrade over time. convert to biodiesel blends.
Checking the Engine-Oil Level Attributes: • More lift and higher discharge velocity • Sparse or limp turf is picked up significantly at Before you start the engine and use the machine, check the oil level in the engine crankcase; refer to Checking the Engine-Oil Level (page 43). higher heights of cut • Wet or sticky clippings are discharged more efficiently reducing congestion in the cutting unit.
Choosing Accessories Optional Equipment Configurations Angle Sail Blade High-Lift, Parallel-Sail Blade (Do not use with the mulching baffle)(Not CE Compliant) 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 you leave the operator’s position, do the following: – Park the machine on a level surface. During Operation Safety – Disengage the power takeoff and lower the attachments. General Safety – Engage the parking brake. • The owner/operator can prevent and is responsible – Shut off the engine and remove the key. • • • • • • • • • • • • • • • • for accidents that may cause personal injury or property damage.
Starting the Engine • Lower a folding roll bar temporarily only when • • necessary. Do not wear the seat belt when the roll bar is folded down. Be aware that there is no rollover protection when a folded roll bar is in the down position. Check the area that you will be mowing and never fold down a folding roll bar in areas where there are slopes, drop-offs, or water. Slope Safety 1. Ensure that the parking brake is engaged and the cutting-unit-drive switch is in the DISENGAGE position. 2.
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 Changing Mowing Patterns Creating a Site Survey Change mowing patterns often to minimize a poor after-cut appearance from repeatedly mowing in the same direction. 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 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 General Safety Selecting the Proper Height-of-Cut Setting to Suit Conditions • Shut off the engine, remove the key, and wait for all movement to stop before you leave the operator’s position.
Locating the Tie-Down Points Pushing or Towing the Machine There are tie downs located at the front and rear sides of the machine (Figure 29). 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. Note: Use properly-rated DOT-approved straps in 4 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.
Maintenance Note: Download a free copy of the electrical or hydraulic schematic by visiting www.Toro.com and searching for your machine from the Manuals link on the home page. 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.
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 fittings and pivot points. Paint chipped surfaces. Every 2 years • Change the engine coolant. • Drain and flush the hydraulic tank. • Replace moving hoses. Important: Refer to your engine owner’s manual for additional maintenance procedures. Daily Maintenance Checklist Duplicate this page for routine use.
For the week of: Maintenance Check Item Monday Tuesday Wednesday Thursday Friday Saturday Clean and maintain the seat belt. 1Check the glow plug and injector nozzles if starting is hard, there is excess smoke, or rough running is noted. 2Immediately after every washing, regardless of the interval listed. Important: Refer to your engine operator’s manual for additional maintenance procedures.
Pre-Maintenance Procedures Maintenance Safety 6. Turn the ignition key to the STOP position and remove it. 7. Allow machine components to cool before performing maintenance. Removing the Hood • Before you leave the operator’s position, do the following: 1. Unlatch and raise the hood. – Park the machine on a level surface. 2. Remove the hairpin cotter securing the hood pivot to the mounting brackets (Figure 31). – Disengage the power takeoff and lower the attachments. – Engage the parking brake.
Using the Cutting Unit Service Latch When servicing the cutting units, use the service latch to prevent injury. 1. Center the cutting unit sidewinder with the traction unit. 2. Raise the cutting unit to the transport position. 3. Engage the parking brake and shut off the machine. 4. Release the latch rod from the front carrier-frame retainer (Figure 32). g031614 Figure 32 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 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) g008900 Figure 39 • Neutral-adjustment mechanism (Figure 40) 40
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 cutting unit).
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.
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 Toro Premium Engine Oil or another high-quality, low-ash engine oil that meets or exceeds the following specifications: g032050 Figure 47 1. Rubber outlet valve 4.
4. Change the engine-oil filter as shown in Figure 51. g029301 Figure 49 Changing the Engine Oil and Filter Service Interval: After the first 50 hours g027477 Figure 51 Every 200 hours 1. Start the engine and let it run 5 minutes to allow the oil to warm up. 2. With the machine parked on a level surface, shut off the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. 3. Change the engine oil as shown in Figure 50.
Replacing the Fuel Filter Fuel System Maintenance Draining the Fuel Tank Service Interval: Every 800 hours—Drain and clean the fuel tank. Before storage—Drain and clean the fuel tank. In addition to the listed service interval, drain and clean the tank if the fuel system becomes contaminated or if you are storing the machine for an extended period. Use clean fuel to flush out the tank. 1. Clean the area where the filter mounts (Figure 52). 2. Remove the filter and clean the mounting surface. 3.
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. Electrical System Maintenance Tighten the screw and turn the key to the OFF position. Electrical System Safety Note: The electric fuel pump will operate, 6. • Disconnect the battery before repairing the Note: Normally, the engine should start after machine. Disconnect the negative terminal first and the positive last.
Drive 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. Checking the Tire Pressure • Always disconnect the negative (black) battery cable before disconnecting the positive (red) cable. Service Interval: Before each use or daily • Always connect the positive (red) battery cable before connecting the negative (black) cable.
Adjusting the Traction Drive for Neutral 5. Start the engine and rotate the cam hex in both directions to determine the mid position of the neutral span. If the machine moves when the traction pedal is in the NEUTRAL position, adjust the traction cam. 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. 1.
Cooling System Maintenance • Preferred: When mixing coolant from a concentrate, mix it with distilled water. • Preferred option: If distilled water is not available, use a pre-mix coolant instead of a concentrate. • Minimum requirement: If distilled water and Cooling System Safety pre-mix coolant are not available, mix concentrated coolant with clean drinkable water. • 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. 1. Raise the hood. 2. Clean the engine area thoroughly of all debris. • Use a rag when opening the radiator cap, and open the cap slowly to allow steam to escape. 3. With compressed air, start from the front of the radiator and blow the debris out toward the back. 4.
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 High Viscosity Index/Low Pour Point Anti-wear Hydraulic Fluid, ISO VG 46 (cont'd.) Material Properties: Hydraulic System Safety Viscosity, ASTM D445 • Seek immediate medical attention if fluid is injected into skin. Injected fluid must be surgically removed within a few hours by a doctor.
g031643 Figure 65 g031641 Figure 64 1. Hydraulic line 1. Hydraulic-tank cap 3. 3. Remove the hydraulic-tank cap (Figure 64). 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. 4. Important: Use only the hydraulic fluids specified. Other fluids could damage the system. Note: The fluid level should be within 6 mm (1/4 inch) of the mark on the dipstick. 6.
Changing the Hydraulic Filter Checking the Hydraulic Lines and Hoses Service Interval: Every 1,000 hours—If you are using the recommended hydraulic fluid, replace the hydraulic filter (sooner if the service interval indicator is in the red zone). Service Interval: Before each use or daily Every 2 years—Replace moving hoses. Check the hydraulic lines and hoses for leaks, kinked lines, loose mounting supports, wear, loose fittings, weather deterioration, and chemical deterioration.
Cutting Unit Maintenance 3. Remove the lynch pin or retaining nut securing the cutting unit carrier frame to the lift-arm-pivot pin (Figure 69). Separating the Cutting Units from the Traction Unit 1. Perform the pre-maintenance procedure; refer to Preparing the Machine for Maintenance (page 37). 2. Remove the hydraulic-motor-mounting screws and disconnect and remove the hydraulic motor from the cutting unit (Figure 68). Important: Cover the top of the spindle to prevent contamination.
Inspecting the Blade Plane 1. Remove the hydraulic motor from the cutting unit and remove the cutting unit from the traction unit. Note: Use a hoist (or a minimum of 2 people) and place the cutting unit on a flat table. 2. Mark an end of the blade with a paint pen or marker. Note: Use this end of the blade to check all heights. 3.
Removing the Front Roller 1. Note: If there is a gap over 1.5 mm (0.06 inch), install enough 5/8-inch diameter washers to take up the slop. Remove the roller-mounting bolt (Figure 72). 6. g031649 Figure 72 1. Bearing 3. Front roller 2. Mounting bolt 4. Bearing spacer 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. Note: There should be a 1.5 mm (0.06 inch) lip of inner race exposed. 3.
Blade Maintenance Note: After striking a foreign object, torque all spindle-pulley nuts to 115 to 149 N∙m (85 to 110 ft-lb). Blade Safety Inspecting and Sharpening the Blade • 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. Only replace or sharpen the blades; never straighten or weld them. On multi-bladed machines, take care as rotating one blade can cause other blades to rotate.
5. Lay the blade on a level surface and check its ends to ensure that the blade is straight and parallel. Note: Ensure that the cutting units are lowered onto a clean section of turf or hard surface to avoid thrown dust and debris. Note: Position the ends of the blade slightly lower than the center, and the cutting edge lower than the heel of the blade. This blade produces a good quality of cut and requires minimal power from the engine.
Storage 2. Remove and discard the oil filter. Install a new oil filter. Storage Safety 3. Refill the oil pan with designated quantity of motor oil. • Shut off the engine, remove the key, and wait 4. Turn the key in the switch to the ON position, start the engine, and run it at idle speed for approximately 2 minutes. 5. Turn the key in the switch to the OFF position. 6. Thoroughly drain all fuel from the fuel tank, lines, and the fuel filter/water separator assembly. 7.
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California Proposition 65 Warning Information What is this warning? You may see a product for sale that has a warning label like the following: WARNING: Cancer and Reproductive Harm—www.p65Warnings.ca.gov. What is Prop 65? Prop 65 applies to any company operating in California, selling products in California, or manufacturing products that may be sold in or brought into California.
The Toro Warranty Two-Year or 1,500 Hours Limited Warranty Parts Conditions and Products Covered The Toro Company warrants your Toro Commercial product (“Product”) to be free from defects in materials or workmanship for 2 years or 1,500 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).
