Form No. 3385-803 Rev A Groundsmaster® 3500-G Rotary Mower Model No. 30809—Serial No. 314000001 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. WARNING 1 CALIFORNIA Proposition 65 Warning This product contains a chemical or chemicals known to the State of California to cause cancer, birth defects, or reproductive harm. The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm. Figure 1 1.
Contents Fuses ....................................................................42 Drive System Maintenance .........................................43 Adjusting the Traction Drive for Neutral....................43 Cooling System Maintenance ......................................43 Cleaning the Engine Cooling System .........................43 Brake Maintenance ....................................................44 Adjusting the Parking Brake .....................................44 Belt Maintenance ....
Preparation Safety • While mowing, always wear substantial footwear, long trousers, hard hat, safety glasses, and hearing protection. Long hair, loose clothing, or jewelry may get tangled in moving parts. Do not operate the equipment when barefoot or wearing open sandals. This machine meets or exceeds CEN standard EN 836:1997 (when appropriate decals applied), and ANSI B71.4-2012 specifications in effect at the time of production when equipped with required weight as listed in Rear Ballast section.
Operation mower for damage and make repairs before restarting and operating the equipment. Torque all the spindle pulley nuts to 176 to 203 N-m (130 to 150 ft-lb). • Do not operate the engine in a confined space where • • • • • • • • • • • • dangerous carbon monoxide fumes can collect. Mow only in daylight or in good artificial light. Before attempting to start the engine, disengage all blade attachment clutches, shift into neutral, and engage the parking brake.
• Do not store fuel near flames. • Park the machine on level ground. Never allow untrained • • • • • • perform a site survey, follow the procedure outlined in the Operation section of the this manual. The maximum side hill angle is detailed on the slope decal affixed near the angle indicator. personnel to service machine. Use jack stands to support components when required. Carefully release pressure from components with stored energy. Disconnect battery before making any repairs.
Sound Power Level • Watch for traffic when near or crossing roads. Always yield the right-of-way. This unit has a guaranteed sound power level of 105 dBA, which includes an Uncertainty Value (K) of 1 dBA. • Raise the cutting units when driving from one work area to another. Sound power level was determined according to the procedures outlined in ISO 11094.
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 lost. 94-3353 1. Crushing hazard of hand—keep your hands a safe distance away. 107-7801 (CE only) *This safety decal includes a slope warning required on the machine for compliance to the European Lawn Mower Safety Standard EN836:1997.
Battery Symbols Some or all of these symbols are on your battery 104-5181 CE only 1. Explosion hazard 6. Keep bystanders a safe distance 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. Warning—read the Operator’s Manual. 2.
6-9290 1. Inputs 5. In seat 2. Not active 6. Power Take-off (PTO) 9. Outputs 13. Start 10. Power Take Off (PTO) 3. High temperature shutdown 7. Parking brake Off 11. Start 4. High temperature warning 12. Energize to Run (ETR) 8. Neutral 14. Power 121–3531 1. Engage PTO 6. Move left 11. Read the Operator’s Manual for information on stopping the engine— 1) Disengage the reel; 2) Move the key to the engine stop position; 3) Remove the key from the ignition; 4) Engage the parking brake. 2.
104-1086 1. Height of cut 121–3533 1. Read the Operator’s Manual for information on maintenance.
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 Description Use Qty. No parts required – Activate, charge, and connect the battery. Inclinometer 1 Check the angle indicator Lock bracket Rivet Washer Screw, 1/4 x 2 inches Locknut, 1/4 inch 1 2 1 1 1 Install the Hood Latch (CE). No parts required – Adjust the lift arms. No parts required – Rear ballast.
3. Remove the filler caps from the battery and slowly fill each cell until electrolyte is just above the plates. 1 4. Install the filler caps and connect a 3 to 4 amp battery charger to the battery posts. Charge the battery at a rate of 3 to 4 amperes for 4 to 8 hours. Activating, Charging, and Connecting the Battery WARNING No Parts Required Charging the battery produces gasses that can explode. Procedure • Keep sparks and flames away from battery. • Never smoke near the battery. WARNING 5.
Figure 5 Figure 4 1. Positive (+) battery cable 1. Angle indicator 2. Negative (–) battery cable 3. If the inclinometer does not read zero degrees, move the machine to a location where a zero degree reading is obtained. The angle indicator, mounted on the machine, should now read zero degrees as well. Important: If the battery is ever removed, make sure that the battery clamp bolts are installed with the bolt heads positioned on the bottom side and the nuts on the top side.
1 2 1 G012630 Figure 8 G012628 1. Hood latch Figure 6 1. Hood latch bracket 2. Rivets 7. Screw the bolt into the other arm of hood lock bracket to lock the latch in position (Figure 9). Tighten bolt securely but do not tighten nut. 3. While aligning the mounting holes, position the CE lock bracket and the hood latch bracket onto the hood. The lock bracket must be against the hood (Figure 7). Do not remove bolt and nut assembly from the lock bracket arm. 3 1 2 2 1 G012631 Figure 9 1. Bolt 2.
E. Tighten the clevis jam nut. 2. Check to make sure that the clearance between each lift arm and stop bolt is 0.005 to 0.040 inches (0.13 to 1.02 mm) (Figure 11). If the clearance is not in this range, adjust the stop bolts to attain clearance. 3. Start the engine, raise the cutting units, and check to make sure that the clearance between the wear strap on the top of the rear cutting unit wear bar and the bumper strap is 0.02 to 0.10 inches (0.51 to 2.54 mm) (Figure 13).
5 Rear Ballast No Parts Required Procedure The machine conforms to CEN standard EN 836:1997 and ANSI standard B71.4-2012 standard when 22.6 kg (50 lbs.) of calcium chloride ballast is added to the rear wheels. Figure 15 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. 1. Front deck mounting hole (upper) 3. Rear deck mounting hole 2.
cutting units to the right, remove the rear cutting unit, and slide it out to the right side. 8 1. Lower the cutting deck to the ground, stop the engine, and remove the key from ignition switch. Adjusting the Roller Scraper (Optional) 2. Loosen the bolt securing each height-of-cut bracket to the height-of-cut plate (front and each side) (Figure 16). 3. Beginning with front adjustment, remove the bolt.
Product Overview Controls 1 G011347 Figure 19 1. Mulching baffle 3. Verify that mulching baffle does not interfere with the tip of the blade and does not protrude inside the surface of the rear chamber wall. Figure 20 1. Forward traction pedal WARNING Do not use the high lift blade with the mulching baffle. The blade could break, resulting in personal injury or death. 4. Tilt steering lever 2. Reverse traction pedal 5. Indicator slot 3. Mow/transport slide 6.
Tilt Steering Lever Hour Meter Pull the tilt steering lever (Figure 20) back to tilt the steering wheel to the desired position. Then push the lever forward to tighten. The hour meter (Figure 22) indicates the total hours of machine operation. The hour meter starts to function whenever the key switch is On. Indicator Slot Cutting Unit Shift Lever The slot in the operator platform (Figure 20) indicates when the cutting units are in the center position.
Lift Lever Lock Specifications Move the lift lever lock (Figure 22) rearward to prevent the cutting units from dropping. Note: Specifications and design are subject to change without notice. Overall Width Fuel Gauge 182 cm (71.8 inches) Width of Cut The fuel gauge (Figure 23) registers the amount of fuel in the tank. 173 cm (68 inches) Length 295 cm (116 inches) Height to top of ROPS 180 cm (70.8 inches) Wheel Base 149 cm (58.5 inches) Track Width 145 cm (57 inches) Ground Clearance 15.
Operation Note: Determine the left and right sides of the machine from the normal operating position. 1 Checking the Engine Oil Level Service Interval: Before each use or daily 2 The engine is shipped with oil in the crankcase; however, the oil level must be checked before and after the engine is first started. g021401 Crankcase capacity is approximately 3.3 liters (3.5 quarts) with the filter. Figure 25 1.
Filling the Fuel Tank DANGER • Fuel tank capacity: 38 liters (10 US gallons) In certain conditions, gasoline is extremely flammable and highly explosive. A fire or explosion from gasoline can burn you and others and can damage property. • Recommended Fuel: – For best results, use only clean, fresh (less than 30 days old), unleaded gasoline with an octane rating of 87 or higher ((R+M)/2 rating method). • Before removing the fuel tank cap, make sure the vehicle is positioned on a level surface.
DANGER In certain conditions during fueling, static electricity can be released causing a spark which can ignite the gasoline vapors. A fire or explosion from gasoline can burn you and others and can damage property. • Always place gasoline containers on the ground away from your vehicle before filling. • Do not fill gasoline containers inside a vehicle or on a truck or trailer bed because interior carpets or plastic truck bed liners may insulate the container and slow the loss of any static charge.
hydraulic systems and is suitable for a wide-range of temperature conditions. This fluid is compatible with conventional mineral oils, but for maximum biodegradability and performance the hydraulic system should be thoroughly flushed of conventional fluid. The oil is available in 19 liters (5 gallon) containers or 55 gallon drums from your Mobil Distributor. Important: Many hydraulic fluids are almost colorless, making it difficult to spot leaks.
Checking the Interlock System DANGER Low tire pressure decreases machine side hill stability. This could cause a rollover, which may result in personal injury or death. Service Interval: Before each use or daily Do not under-inflate the tires. If safety interlock switches are disconnected or damaged the machine could operate unexpectedly causing personal injury. CAUTION Torquing the Wheel Nuts • Do not tamper with the interlock switches.
2. Before starting the engine, close the bypass valve by rotating it 90° (1/4 turn). Do not start the engine when the valve is open. Each input has a LED that is illuminated when the specific circuit is energized. Use the input LED’s for switch and input circuit troubleshooting. Output circuits are energized by an appropriate set of input conditions. The three outputs include PTO, ETR, and START.
INPUTS Function Power ON In Neutral Start ON Brake ON OUTPUTS PTO ON In Seat • Backlap Start ETR PTO Start — — + O O — O O + + O Run (Off Unit) — — O O O O O O O + O Run (On Unit) — O O — O — O O O + O Mow — O O — — — O O O + + Backlap — — O O — O O — O + + Hi Temp — O O O — O • (–) Indicates a circuit closed to ground.
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 (0.75 to 1.75 inch) Height-of-Cut Recommended in most applications May work well in light or sparse turf Grass Cutting: 5 to 6.4 cm (2.00 to 2.50 inch) Height-of-Cut Recommended for thick or lush turf Recommended for light or sparse turf Grass Cutting: 7 to 10 cm (2.75 to 4.
Operating Tips • 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.
Mowing Patterns Mow When Grass is Dry Change mowing patterns often to minimize aftercut appearance issues induced by repetitive operation in only one direction. Mow either in the late morning to avoid the dew, which causes grass clumping, or in late afternoon to avoid the damage that can be caused by direct sunlight on the sensitive, freshly mowed grass.
Maintenance Note: Determine the left and right sides of the machine from the normal operating position. Recommended Maintenance Schedule(s) Maintenance Service Interval Maintenance Procedure After the first hour • Torque the wheel nuts. After the first 8 hours • Check the condition and tension of all belts. After the first 10 hours • Torque the wheel nuts. • Change the hydraulic filter. After the first 50 hours • Change the oil and oil filter.
Daily Maintenance Checklist Duplicate this page for routine use. For the week of: Maintenance Check Item Mon. Tues. Wed. Thurs. Fri. Sat. Sun. Check the safety interlock operation. Check the brake operation. Check the engine oil level. Check the cooling system fluid level. 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. Check the hydraulic system oil level.
Service Interval Chart Figure 33 Premaintenance Procedures Removing the Hood The hood may be easily removed to ease maintenance procedures in the engine area of the machine. 1. Unlatch and raise the hood. Figure 34 2. Remove the hairpin cotter securing the hood pivot to the mounting brackets (Figure 34). 1. Hairpin cotter 3. Slide the hood to the right side, lift the other side, and pull it out of the brackets. Note: Reverse the procedure to install the hood.
2. Raise the cutting decks to the transport position. 3. Set the parking brake and turn off the machine. 4. Release the latch rod (Figure 35) from front carrier frame retainer. Figure 35 1. Service latch hook 5. Lift the outside of the front cutting decks and place the latch over the frame pin mounted on the front of the operator's platform (Figure 35). 6. Sit on the operator seat and start the traction unit. 7. Lower the cutting decks to the mow position. 8. Turn off the machine and remove the key. 9.
Lubrication • SideWinder cylinder ends (2) (Figure 38) Greasing the Bearings And Bushings Service Interval: Every 50 hours (Lubricate all bearings and bushings daily when conditions are dusty and dirty.) Every 500 hours/Yearly (whichever comes first) The machine has grease fittings that must be lubricated regularly with No. 2 General Purpose Lithium Base Grease. Bearings and bushings must be lubricated daily when operating conditions are extremely dusty and dirty.
• Rear lift arm pivot and lift cylinder (2) (Figure 40) • Neutral adjust mechanism (Figure 43) Figure 43 • Mow/transport slide (Figure 44) Figure 40 • Left front lift arm pivot and lift cylinder (2) (Figure 41) Figure 44 • Belt tension pivot (Figure 45) Figure 41 • Right front lift arm pivot and lift cylinder (2) (Figure 42) Figure 45 Figure 42 37
• Steering cylinder (Figure 46). • Rear roller bearings (2 per cutting unit) (Figure 49) G011349 Figure 49 Note: Make sure the grease groove in each roller mount aligns with the grease hole in each end of the roller shaft. To help align the groove and hole, there is also an alignment mark on one end of the roller shaft. Figure 46 Note: If desired, an additional grease fitting may be installed in the other end of the steering cylinder.
Engine Maintenance 6. Clean the dirt ejection port located in the removable cover. Remove the rubber outlet valve from the cover, clean the cavity, and replace the outlet valve. Servicing the Air Cleaner 7. Install the cover orienting the rubber outlet valve in a downward position—between approximately 5:00 to 7:00 when viewed from the end. Service Interval: Every 200 hours (More frequently in extreme dusty or dirty conditions) 8. Secure the cover latches.
Replacing the Spark Plugs Service Interval: Every 400 hours The spark plugs usually last a long time; however, the plugs should be removed and checked whenever the engine malfunctions or every 400 hours. Replace the spark plugs to ensure proper engine performance and reduce exhaust emission level. The correct spark plug to use is a Champion RC 14YC or NGK BPR 4ES. 1. Clean the area around the spark plugs so foreign matter cannot fall into the cylinder when you remove the spark plug. 2.
Fuel System Maintenance Replacing the Fuel Pump Filter Service Interval: Every 400 hours DANGER g021236 In certain conditions, gasoline is extremely flammable and highly explosive. A fire or explosion from gasoline can burn you and others and can damage property Figure 55 1. Fuel pump 3. Fuel line/fuel filter 2. Hose clamp • Drain gasoline from the fuel tank when the engine is cold. Do this outdoors in an open area. Wipe up any gasoline that spills. 5.
Electrical System Maintenance 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. Caring for the Battery Service Interval: Every 25 hours—Check the electrolyte level. (If machine is in storage, check every 30 days.) The battery electrolyte level must be properly maintained and the top of the battery kept clean.
Drive System Maintenance Cooling System Maintenance Adjusting the Traction Drive for Neutral Cleaning the Engine Cooling System If the machine moves when the traction pedal is in the neutral position, the traction cam must be adjusted. Service Interval: Before each use or daily Every 2 years 1. Position the throttle lever rearward so it stops against the control panel slot. Remove debris from the radiator/oil cooler daily. Clean them more frequently in dirty conditions. 2.
Brake Maintenance Belt Maintenance Adjusting the Parking Brake Servicing the Engine Belts Service Interval: Every 200 hours—Check the parking brake adjustment. Service Interval: After the first 8 hours—Check the condition and tension of all belts. 1. Loosen the set screw securing the knob to the parking brake lever (Figure 58). Every 200 hours—Check the condition and tension of all belts. Tensioning the Alternator/Fan Belt 1. Open the hood. 2.
Hydraulic System Maintenance Changing the Hydraulic Filter Service Interval: After the first 10 hours Every 200 hours/Yearly (whichever comes first) Use a genuine Toro replacement filter, Part No. 86-3010. Important: Use of any other filter may void the warranty on some components. Figure 60 1. Hydrostat drive belt 1. Position the machine on a level surface, lower the cutting units, stop the engine, engage the parking brake, and remove the key from the ignition switch. 2. Spring end 3. Replace the belt.
Checking the Hydraulic Lines and Hoses flow into a drain pan. Install the hydraulic line when hydraulic fluid stops draining. Service Interval: Before each use or 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. WARNING Hydraulic fluid escaping under pressure can penetrate skin and cause injury.
Cutting Deck Maintenance 3. Slide deck carrier frame onto lift arm pivot pin. Secure with lynch pin (Figure 65). 4. Install the hydraulic motor to the deck (Figure 64). Make sure that the O-ring is in position and not damaged. Separating the Cutting Decks from the Traction Unit 5. Grease the spindle. 1. Position the machine on a level surface, lower the cutting decks to the floor, shut the engine off, and engage the parking brake. 2. Disconnect and remove the hydraulic motor from the deck (Figure 64).
Adjusting the Blade Plane performance. Never use replacement blades made by other manufacturers because they could be dangerous. Start with the front adjustment (change one bracket at a time). 1. Remove the height-of-cut bracket, (front, left, or right) from the deck frame (Figure 67). 1. Raise the cutting deck to the highest position, shut the engine off, and engage the parking brake. Block the cutting deck to prevent it from falling accidentally. 2. Adjust 1.5 mm (0.060 inch) shims and/or 0.7 mm (0.
Checking the Blade Stopping Time DANGER Service Interval: Before each use or daily If the blade is allowed to wear, a slot will form between the sail and flat part of the blade (Figure 69). Eventually a piece of the blade may break off and be thrown from under the housing, possibly resulting in serious injury to yourself or bystanders. The blades of the cutting deck should come to a complete stop in approximately 5 seconds after you shut down the cutting deck engagement switch.
Storage 2. Insert the spacer (Figure 71). 3. Press the second bearing into the roller housing (Figure 71) pressing equally on the inner and outer race until the inner race comes in contact with the spacer. Storing the Battery If the machine will be stored 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 it is fully charged.
Engine 1. Drain the engine oil from the oil pan and replace the drain plug. 2. Remove and discard the oil filter. Install a new oil filter. 3. Refill the oil pan with 3.3 liters (3.5 quarts) of motor oil. 4. Start the engine and run it at idle speed for approximately two minutes. 5. Stop the engine. 6. For storage over 30 days, prepare the fuel system as follows: • Add a petroleum based stabilizer/conditioner to fuel in the tank. Follow the mixing instructions from stabilizer manufacturer.
The Toro Total Coverage Guarantee A 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).
