Form No. 3409-200 Rev A Groundsmaster® 3500-G Rotary Mower Model No. 30809—Serial No. 400000000 and Up Register at www.Toro.com.
WARNING 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. Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm.
Contents Inspecting the Fuel Lines and Connections.................40 Electrical System Maintenance ....................................41 Electrical System Safety...........................................41 Servicing the Battery...............................................41 Servicing the Fuses .................................................41 Drive System Maintenance .........................................42 Checking the Tire Pressure ......................................
Safety This machine has been designed in accordance with ANSI B71.4-2012 and meets these standards when the appropriate ballast is added. 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 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. decal117-4764 117-4764 1.
decal121-3627 121–3627 1. Height-of-cut settings 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 from the machine. 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.
decal121-3533 121–3533 1. Read the Operator’s Manual for information on maintenance.
decal121-3620 121-3620 1. Push down to disengage the cutting units 7. Lock 2. Pull up to engage the cutting units. 8. Engine—shut off 3. Right 9. Engine—run 4. 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 Description Use Qty. No parts required – Activate, charge, and connect the battery. Inclinometer 1 Check the angle indicator. No parts required – Adjust the lift arms. No parts required – Adjust the carrier frame. No parts required – Adjust the height of cut. No parts required – Adjust the roller scraper (optional). No parts required – Install the mulching baffle (optional).
2. Remove the filler caps from the battery and slowly fill each cell until the electrolyte is just above the plates. 1 3. Install the filler caps and connect a 3 to 4 A battery charger to the battery posts. Activating, Charging, and Connecting the Battery Note: Charge the battery at a rate of 3 to 4 A for 4 to 8 hours. WARNING No Parts Required Charging the battery produces gasses that can explode. Procedure • Keep sparks and flames away from battery. WARNING • Never smoke near the battery.
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. 3. If the inclinometer does not read 0°, move the machine to a different location to obtain a 0° reading.
B. 3 Back off the jam nut on the cylinder (Figure 8). 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 6. g031573 Figure 8 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.
g031575 Figure 10 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 11 1. Upper, front deck mounting hole Note: Repeat the procedure if required. D. Tighten the clevis jam nut. 3. Rear deck mounting hole 2. Lower, front deck mounting hole Important: Lack of clearance at the front stops or rear wear bar could damage the lift arms. 2.
Note: Adjustments of more than 3.8 cm (1-1/2 inches) may require temporary assembly to an intermediate height to prevent binding (e.g., changing from 3.1 to 7 cm (1-1/4 to 2-3/4 inches) height of cut). Important: Access to the rear cutting units is 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 7 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 15). g031595 Figure 16 1. Tilt-steering lever 4. Forward traction pedal 2. Angle indicator 5. Mow/transport slide 3. Reverse traction pedal 6. Indicator slot g031579 Figure 15 1. Mulching baffle 2.
PTO Switch Note: Allow the pedal to move or move it to the NEUTRAL position to stop the machine. The PTO switch has 2 positions: OUT (start) and IN (stop). Pull the PTO switch out to engage the cutting-unit blades. Push the switch in to disengage the cutting-unit blades (Figure 17). Mow/Transport Slide Using your heel, move the mow/transport slide to the left to transport, and to the right to mow (Figure 16). Hour Meter Note: The cutting units operate only in the mow position.
Fuel Gauge The fuel gauge registers the amount of fuel in the tank (Figure 19). g031598 Figure 19 1. Fuel gauge 2. Seat-adjustment lever 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 19).
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. 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 Distributor or go to www.Toro.
4. To prevent a fire hazard, wipe up any spilled fuel. DANGER In certain conditions during fueling, static electricity can be released causing a spark which can ignite the fuel vapors. A fire or explosion from fuel can burn you and others and can damage property. • Always place the fuel containers on the ground away from your vehicle before filling.
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 • Do not operate the machine when there is the risk of During Operation Safety • • General Safety Rollover Protection System (ROPS) Safety • The owner/operator can prevent and is responsible for • • • • • • • • • • • • • • • • lightning. Do not use the machine as a towing vehicle. Use accessories, attachments, and replacement parts approved by The Toro® Company only. accidents that may cause personal injury or property damage.
Standard-Control Module (SCM) suddenly roll over if a wheel goes over the edge or the edge caves in. Establish a safety area between the machine and any hazard (2 machine widths). 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. Starting the Engine 1.
g031611 Figure 22 1. Backlap (input) 7. PTO (output) 2. High temperature (input) 8. Start (output) 3. In seat (input) 4. PTO switch (input) 9. ETR (output) 10. Start (input) 5. Parking brake—off (input) 11. Power (input) 6. Neutral position (input) Here are the logical troubleshooting steps for the SCM device. 1. Determine the output fault that you are trying to resolve (PTO, START, or ETR). 2. Move key switch to the ON position and ensure that the red, power LED illuminates. 3.
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 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.
Mowing When the Grass Is Dry • Shut off the fuel before storing or transporting the machine. Mow either in the late morning to avoid the dew, which causes grass clumping, or late afternoon to avoid the damage that direct sunlight can cause on the sensitive, freshly mowed grass. • Never store the machine or fuel container where there is an open flame, spark, or pilot light, such as on a water heater or on other appliances.
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. Locate the bypass valve on the pump and rotate it 90° (Figure 24). g031610 Figure 24 1. Bypass valve 2. Before starting the engine, close the bypass valve by rotating it 90° (1/4 turn).
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 oil and oil filter. Before each use or daily • • • • • Check the safety-interlock system.
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. Check the air filter, dust cup, and burp valve. Check for unusual engine noises.1 Check the radiator and screen for debris Check for unusual operating noises. Check the hydraulic-systemoil level.
Service-Interval Chart decal121-3533 Figure 25 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. When servicing the cutting decks, use the service latch to prevent injury. 2. Park the machine on a level surface. 1. Center the cutting deck sidewinder with the traction unit. 3. Engage the parking brake. 4. Lower the cutting unit(s) if necessary. 2. Raise the cutting decks to the transport position. 5. Shut off the engine and wait for all moving parts to stop. 3.
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 35 • Mow/transport slide (Figure 36) g008898 Figure 32 • 2 left, front lift-arm pivots and lift cylinder (Figure 33) g008902 Figure 36 • Belt-tension pivot (Figure 37) g008899 Figure 33 • 2 right, front lift-arm pivots and lift cylinder (Figure 34) g008903 Figure 37 • Steering cylinder (Figure 38).
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 g008904 Service Interval: Every 200 hours (More frequently in extreme dusty or dirty conditions) Figure 38 Inspect the air cleaner and hoses periodically to maintain maximum engine protection and to ensure maximum service life. Check the air-cleaner body for damage, which could cause an air leak.
sure that it is seated fully. Remove the dipstick and check the level-of-the-oil. 4. Inspect the new filter for shipping damage, checking the sealing end of the filter and the body. Important: Do not use a damaged filter. 5. Insert the new filter by applying pressure to the outer rim of the element to seat it in the canister. 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. 7.
Changing the Engine Oil and Filter Replacing the Spark Plugs Service Interval: Every 400 hours Service Interval: After the first 50 hours The spark plugs usually last a long time; however, remove and check the plugs whenever the engine malfunctions or every 400 hours. Replace the spark plugs to ensure proper engine performance and reduce exhaust emission level. Every 200 hours 1. Remove the drain plug (Figure 45) and let oil flow into a drain pan. When the oil stops flowing, install the drain plug.
Fuel System Maintenance Replacing the Fuel-Pump Filter Service Interval: Every 400 hours DANGER g021236 In certain conditions, fuel is extremely flammable and highly explosive. A fire or explosion from fuel can burn you and others and can damage property g021236 Figure 49 • Drain fuel from the fuel tank when the engine is cold. Do this outdoors, in an open area. Wipe up any fuel that spills. 1. Fuel pump 3. Fuel line/fuel filter 2.
Electrical System Maintenance The battery cables must be tight on the terminals to provide good electrical contact. Electrical System Safety 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. WARNING • 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 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. Service Interval: Before each use or daily 2. Raise a front wheel and a rear wheel off the floor and place support blocks under the frame.
Cooling System Maintenance 7. 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. Rear Wheel Ballast Cooling System Safety The machine conforms to ANSI standard B71.4-2012 standard when 22.6 kg (50 lb) of calcium-chloride ballast is added to the rear wheel. • 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 1. Turn the engine off and raise the hood. • Do not open the radiator cap when the engine is running. 2. Clean the engine area thoroughly of all debris. 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: Every 200 hours—Check the parking-brake adjustment. Service Interval: After the first 10 hours—Check the condition and tension of all belts. Every 100 hours—Check the condition and tension of all belts. 1. Loosen the set screw securing the knob to the parking-brake lever (Figure 55). Checking the Alternator-Belt Tension 1. Open the hood. 2.
Replacing the Hydrostat-Drive Belt Controls System Maintenance 1. 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. 1. Position the throttle lever rearward so that it stops against the control-panel slot. 2. Loosen the throttle-cable connector on the injection-pump-lever arm (Figure 58).
Hydraulic System Safety Hydraulic System Maintenance • Ensure that all hydraulic-fluid hoses and lines are in 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.
Changing the Hydraulic Filter Changing the Hydraulic Fluid Service Interval: After the first 10 hours 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. Every 200 hours/Yearly (whichever comes first) Use a genuine Toro replacement filter, Part No. 86-3010. Important: Using any other filter may void the warranty on some components. 1. Turn the engine off and raise the hood. 2.
Mower Deck Maintenance 5. Install the reservoir cap. 6. Start the engine. 7. Use all the hydraulic controls to distribute the hydraulic fluid throughout the system, check for leaks, then shut off the engine. Blade Safety 8. Check the fluid level and add enough to raise the level to the FULL mark on the dipstick. 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. Note: Do not overfill.
Mounting the Mower Decks to the Traction Unit 3. Remove the lynch pin or retaining nut securing the deck carrier frame to the lift-arm-pivot pin (Figure 64). 1. Perform the pre-maintenance procedure; refer to Preparing the Machine for Maintenance (page 34). 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 64). 4.
Adjust the other side to within ± 2.2 mm (0.09 inch) of the correct side. 4. Rotate the marked end of the blade to the 3 o’clock and 9 o’clock positions and measure the heights (Figure 65). 5. Compare the 12 o’clock position measured height to the height-of-cut setting. 7. Adjust the right and/or left height-of-cut brackets by repeating steps 1 through 3. 8. Secure the carriage bolts and flange nuts. Note: It should be within 0.7 mm (0.03 inch). The 3 o’clock and 9 o’clock heights should be 3.8 ± 2.
Checking the Blade Stopping Time Note: Because sand and abrasive material can wear away the metal that connects the flat and curved parts of the blade, check the blade before using the machine. If you notice wear, replace the blade; refer to Removing the Blade (page 51). Service Interval: Before each use or daily The blades of the cutting deck should completely stop in 7 seconds after you shut down the cutting deck.
Installing the Front Roller Storage 1. Pressing on the outer race only or equally on the inner and outer race, press the first bearing into the roller housing (Figure 70). 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 replace the drain plug. 2. Remove and discard the oil filter. Install a new oil filter. 3. Refill the oil pan with 3.3 L (3.5 US qt) of motor oil. 4. Start the engine and run it at idle speed for approximately 2 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.
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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).
