Form No. 3396-206 Rev A Groundsmaster® 3500-G Rotary Mower Model No. 30809—Serial No. 315000001 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. The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm. 1 Figure 1 1. Model and serial number location Important: This engine is not equipped with a spark arrester muffler.
Contents Fuses ....................................................................40 Drive System Maintenance .........................................40 Torquing the Wheel Nuts ........................................40 Adjusting the Traction Drive for Neutral....................40 Cooling System Maintenance ......................................41 Cleaning the Engine Cooling System .........................41 Brake Maintenance ....................................................
Safety • Only operate in good light, keeping away from holes and This machine meets or exceeds ANSI B71.4-2012 specifications when equipped with required weight as listed in Rear Ballast section. • Be sure all drives are in neutral and parking brake is Improper use or maintenance by the operator or owner can result in injury.
• Check the safety interlock switches daily for proper • • • • • • • • • • • • • • Any alterations to a ROPS must be approved by the operation. If a switch should fail, replace the switch before operating the machine. When starting the engine, engage the parking brake, put the traction pedal in neutral, and disengage the blade drive. After the engine starts, release the parking brake and keep your foot off of the traction pedal. The machine must not move.
• Carefully release pressure from components with stored • Use full width ramps for loading machine into trailer or energy. truck. • Disconnect the battery or remove spark plug wire before • Tie the machine down securely using straps, chains, cable, making any repairs. Disconnect the negative terminal first and the positive last. Reconnect the positive first and negative last. or ropes. Both front and rear straps should be directed down and outward from the machine. • Use care when checking blades.
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. 106-6755 100-4837 1. Engine coolant under pressure. 3. Warning—do not touch the hot surface. 2. Explosion hazard—read the Operator's Manual. 4. Warning—read the Operator's Manual. 93-7276 1. Explosion hazard—wear eye protection. 2.
Battery Symbols Some or all of these symbols are on your battery 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 1. Thrown object hazard—keep bystanders a safe distance from the machine. 2. Cutting hazard of hand, mower blade—stay away from moving parts, keep all guards and shields in place. 8.
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. Disengage PTO 7. Lock 12. Fast 3. Lower cutting unit 8. Engine—stop 13. Slow 4. Move right 5. Raise cutting unit 9. Engine—run 10. Engine—start 104-1086 1.
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 Description Use Qty. No parts required – Activate, charge, and connect the battery. No parts required – 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 – Check the fluid levels. No parts required – Adjust the optional roller scraper.
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.
If the clearance is not in this range, adjust it as follows: A. Back off the stop bolts (Figure 7). Figure 9 1. Wear bar 2. Bumper strap If the clearance is not in this range, adjust the rear cylinder as follows: Figure 7 1. Stop bolt Note: If the rear lift arm clunks during transport, clearance can be reduced. 3. Clearance 2. Lift arm B. A. Lower the cutting-units and back off the jam nut on the cylinder (Figure 10). Back off the jam nut on the cylinder (Figure 8). Figure 10 1.
same bench setting. It may be necessary to have the rotary-cutting unit bench set 6 mm (1/4 inch) above that of a reel-cutting unit in the same area. 1. For a height of cut in the 2 to 7.6 cm (3/4 to 3 inch) range, mount the front carrier frames in the lower, front mounting holes (Figure 11). Note: This permits more up travel of the cutting unit relative to the traction unit when approaching quick uphill changes in terrain.
Note: Adjustments of more than 3.8 cm (1-1/2 inch) may require temporary assembly to an intermediate height to prevent binding. 2. Slide the scraper up or down until a gap of 0.5 to 1 mm (0.020 to 0.040 inch) is achieved between the rod and the roller. 3. Secure the grease fitting and screw to 41 N-m (30 ft-lb) in an alternating sequence.
Tilt-Steering Lever Product Overview Pull the tilt-steering lever (Figure 16) back to tilt the steering wheel to the desired position. Push the lever forward to lock the steering wheel into position. Controls Indicator Slot The slot in the operator platform (Figure 16) indicates when the cutting-units are in the center position. Angle Indicator The angle indicator (Figure 16) indicates the side-hill angle of the machine in degrees.
Hour Meter Lift-Lever Lock The hour meter (Figure 18) indicates the total hours of machine operation. The hour meter starts to function whenever the key switch is in the On position. Move the lift-lever lock (Figure 18) rearward to prevent the cutting units from dropping. Fuel Gauge Cutting-Unit Lever The fuel gauge (Figure 19) indicates the amount of fuel in the fuel tank. To lower the cutting units to the ground, move the cutting-unit lever (Figure 18) forward.
Specifications Operation Note: Specifications and design are subject to change without notice. Overall Width Note: Determine the left and right sides of the machine from the normal operating position. 182 cm (71.8 inch) Width of Cut Think Safety First 173 cm (68 inch) Length 295 cm (116 inch) Height to top of ROPS 180 cm (70.8 inch) Wheel base 149 cm (58.5 inch) Track width 145 cm (57 inch) Ground clearance 15.
The engine is shipped with oil in the crankcase; however, the oil level must be checked before and after the engine is first started. 3. If the oil level is low, remove the filler cap (Figure 22) and add enough oil to raise the level-of-the-oil to the Full mark on the dipstick. Note: When adding oil, remove dipstick to allow proper venting. Pour oil slowly and check the level-of-the-oil often during this process. Do not overfill. Crankcase capacity is approximately 3.3 L (3.5 US qt) with the filter.
– Do not use gasoline containing methanol. DANGER – Do not store fuel either in the fuel tank or fuel containers over the winter unless a fuel stabilizer is used. 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. – Do not add oil to gasoline. Important: Do not use fuel additives other than a fuel stabilizer/conditioner.
Clean the radiator/oil hourly if conditions are extremely dusty or dirty; refer to Cleaning the Engine Cooling System (page 41). 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 the gasoline containers on the ground away from your vehicle before filling.
Alternate fluids: If the Toro fluid is not available, you may use other fluids provided that they meet all the following material properties and industry specifications. Toro does not recommend the use of synthetic fluid. Consult with your lubricant distributor to identify a satisfactory product. Note: Toro will not assume responsibility for damage caused by improper substitutions, so use only products from reputable manufacturers who will stand behind their recommendation.
Starting and Stopping the Engine Checking the Interlock System Service Interval: Before each use or daily 1. Make sure that all bystanders are away from the area of operation. Starting the Engine 1. Be sure that the parking brake is set and the cutting unit drive switch is in the Disengage position. Note: Keep hands and feet away from the cutting units. 2. Remove your foot from the traction pedal and make sure that the pedal is in the Neutral position.
Standard Control Module (SCM) circuit is energized. Use the input LEDs to troubleshoot switches and input circuits. Output circuits are energized by an appropriate set of input conditions. The 3 outputs are PTO, ETR, and START. The output LED indicates the presence of voltage at the relay. The Standard Control Module is a potted electronic device produced in a one size fits all configuration.
INPUTS Function Power ON In Neutral Start ON Brake ON OUTPUTS PTO ON In Seat Hi Temp 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 To troubleshoot, turn the key to the On position. Identify the specific function that is not operating properly and work across the logic chart.
Choosing Accessories Optional Equipment Configurations Angle Sail Blade High Lift Parallel Sail Blade Do not use with the mulching baffle Mulching Baffle Roller Scraper Height of Cut 1.9 to 4.4 cm (0.75 to 1.75 inches) Recommended in most applications May work well in light or sparse turf Height of Cut 5 to 6.4 cm (2.00 to 2.
• Requires more horsepower to run. • Tends to discharge further left and can tend to windrow The machine is designed for 1 person. Never let anyone else ride on the machine with you. This is extremely dangerous and could result in serious injury. at a lower height of cut. • Accidents can happen to anyone.
• As soon as the front cutting units reach the edge of kept free of dirt or grass clippings. After cleaning, inspect the machine for possible hydraulic-fluid leaks, damage, or wear to the hydraulic and mechanical components, and check the cutting-unit blades for sharpness. the mowing area, lift the cutting units and perform a teardrop-shaped turn to quickly line you up for your next pass.
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 30 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 31 2. Remove the hairpin cotter securing the hood pivot to the mounting brackets (Figure 31). 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.
Lubrication Using the Cutting-Unit Service Latch Greasing the Bearings And Bushings 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 units to the transport position. Service Interval: Every 50 hours (Lubricate all bearings and bushings daily when conditions are dusty and dirty.) 3. Set the parking brake and turn off the machine. Every 500 hours/Yearly (whichever comes first) 4.
• SideWinder cylinder ends 2 (Figure 35) • Rear lift-arm pivot and lift cylinder 2 (Figure 37) Figure 37 • Left front lift-arm pivot and lift cylinder 2 (Figure 38) Figure 35 • Steering pivot (Figure 36) Figure 38 • Right front lift-arm pivot and lift cylinder 2 (Figure 39) Figure 36 Figure 39 • Neutral-adjust mechanism (Figure 40) 34
• Steering cylinder (Figure 43). Figure 40 • Mow/Transport slide (Figure 41) Figure 43 Note: If desired, install an additional grease fitting in the other end of the steering cylinder. Remove the tire, install the fitting, grease the fitting, remove the fitting, and install the plug (Figure 44). Figure 41 • Belt-tension pivot (Figure 42) Figure 44 • Cutting unit spindle-shaft bearings (2 per cutting unit) (Figure 45) Note: Either fitting can be used, which ever is more accessible.
Engine Maintenance • Rear roller bearings (2 per cutting unit) (Figure 46) Servicing the Air Cleaner Service Interval: Every 200 hours (More frequently in extreme dusty or dirty conditions) 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. Replace a damaged air-cleaner body.
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. Install the cover orienting the rubber, outlet valve in a downward position, between approximately 5 o'clock to 7 o'clock when viewed from the end (Figure 47). 8. Secure the cover latches. Changing the Engine Oil and Filter Service Interval: After the first 50 hours Every 200 hours 1 1.
Fuel System Maintenance Replacing the Fuel-Pump Filter Service Interval: Every 400 hours Figure 50 DANGER 1. Air gap at 0.81 mm (0.032 inch) 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 4. Set the air gap on each plug between the center and side electrodes to 0.81 mm (0.032 inch). 5. Install the correctly-gapped spark plugs and tighten them to 24.5 to 29 N-m (18 to 22 ft-lb).
Electrical System Maintenance 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. If the machine is stored in a location where temperatures are extremely high, the battery will run down more rapidly than if the machine is stored in a location where temperatures are cool. g021236 Figure 52 1. Fuel pump 3.
Drive 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. Torquing the Wheel Nuts Service Interval: After the first hour After the first 10 hours Every 200 hours Torque the wheel nuts to 61 to 88 N-m (45 to 65 ft-lb).
Cooling System Maintenance maximum force required to operate the throttle lever should not exceed 27 N-m (20 ft-lb). Cleaning the Engine Cooling System Service Interval: Before each use or daily Every 2 years Remove debris from the radiator/oil cooler daily. Clean the radiator/oil more frequently in dirty conditions. 1. Turn the engine off and allow it to cool. 2. Raise the hood. 3. Remove debris from the engine. 4.
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 55). 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) WARNING Hydraulic fluid escaping under pressure can penetrate skin and cause injury. • Make sure that all hydraulic fluid hoses and lines are in good condition and all hydraulic connections and fittings are tight before applying pressure to the hydraulic system.
5. Ensure that the filter mounting area is clean. Screw the filter on until the gasket contacts the mounting plate; then tighten the filter 1/2 turn. 6. Release the hose to the filter mounting plate. 7. Start the engine and let it run for about 2 minutes to purge air from the system. Stop the engine and check for leaks. Changing the Hydraulic Fluid Service Interval: Every 400 hours Figure 60 If the fluid becomes contaminated, contact your local Toro distributor because the system must be flushed.
Mounting the Cutting Units to the Traction Unit Maintaining the Cutting Unit 1. Position the traction unit on a level surface and shut off the engine. Separating the Cutting Unit from the Traction Unit 2. Move the cutting unit into position in front of the traction unit. 3. Slide the cutting unit carrier frame onto the lift-arm pivot pin. Secure with the lynch pin (Figure 62). 1.
Servicing the Cutter Blade 6. Compare the 12 o’clock measured height to the height of cut setting. It should be within 0.7 mm (0.030 inch). The 3 and 9 o’clock heights should be 3.8 +/- 2.2 mm (0.150 +/- 0.090 inch) higher than the 12 o’clock setting and within 2.2 mm (0.090 inch) of each other. Removing the Cutter Blade The blade must be replaced if a solid object is hit, the blade is out-of-balance, or if the blade is bent.
meet (Figure 66). Since 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 (Figure 66), replace the blade; refer to Removing the Cutter Blade (page 46). blade that is higher at the ends than the center, or if cutting edge is higher than the heel, the blade is bent or warped and must be replaced. 5.
Assembling the Front Roller 3. Push the second bearing out in a press. 4. Inspect the roller housing, bearings, and bearing spacer for damage (Figure 68). Replace damaged components and assemble. 1. Press the first bearing into the roller housing (Figure 68). Press on the outer race only or equally on the inner and outer race. 2. Insert the spacer (Figure 68). 3. Press the second bearing into the roller housing (Figure 68).
Engine Storage 1. Drain the engine oil from the oil pan and replace the drain plug. Storing the Battery 2. Remove and discard the oil filter. Install a new oil filter. 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 that it is fully charged. The specific gravity of a fully charged battery is 1.265–1.299. 3.
Notes: 50
Notes: 51
Toro General Commercial Product 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).
