Form No. 3376-468 Rev A Groundsmaster® 3500-G Traction Unit Model No. 30809—Serial No. 313000001 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 Brake Maintenance ....................................................40 Adjusting the Parking Brake .....................................40 Belt Maintenance ......................................................40 Servicing the Engine Belts .......................................40 Hydraulic System Maintenance ....................................41 Changing the Hydraulic Filter...................................41 Changing the Hydraulic Fluid...................................
Preparation Safety • While mowing, always wear substantial footwear, long 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. • Improper use or maintenance by the operator or owner can result in injury.
• • • • • • • • • • • • • • Look behind and down before backing up to be sure of – Do not stop or start suddenly when going up or downhill. – Keep machine speeds low on slopes and during tight turns. – Stay alert for humps and hollows and other hidden hazards. – Never mow across the face of the slope, unless the mower is designed for this purpose. Stay alert for holes in the terrain and other hidden hazards. Watch out for traffic when crossing or near roadways.
• When starting the engine, engage the parking brake, put or disconnecting from battery. Wear protective clothing and use insulated tools. Toro Mower Safety The following list contains safety information specific to Toro products or other safety information that you must know that is not included in the CEN, ISO, or ANSI standards. • This product is capable of amputating hands and feet and throwing objects. Always follow all safety instructions to avoid serious injury or death.
Sound Power Level Use paper or cardboard, not your hands, to search for leaks. Hydraulic fluid escaping under pressure can have sufficient force to penetrate the skin and cause serious injury. If fluid is injected into the skin it must be surgically removed within a few hours by a doctor familiar with this form of injury or gangrene may result. This unit has a guaranteed sound power level of 105 dBA, which includes an Uncertainty Value (K) of 1 dBA.
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 2 3 4 5 6 Description Use Qty. Inclinometer 1 Check the angle indicator Warning decal (104–5181) 1 Install CE decals, if required. 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. Media and Additional Parts Description Use Qty.
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 4 2 Installing the Hood Latch (CE Only) Parts needed for this procedure: 1 Lock bracket 2 Rivet 1 Washer 1 Screw, 1/4 x 2 inches 1 Locknut, 1/4 inch G012629 Figure 7 2. Bolt and nut assembly 1. CE lock bracket 4. Align the washers with the holes on the inside of the hood. Procedure 5. Rivet the brackets and the washers to the hood (Figure 7). 1. Unhook the hood latch from the hood latch bracket. 6. Hook the latch onto the hood latch bracket (Figure 8). 2.
5 Adjusting the Lift Arms No Parts Required Procedure Figure 12 1. Start the engine, raise the cutting units, and check to ensure that the clearance between each lift arm and the floor plate bracket is 0.18 to 0.32 inches (5 to 8 mm) (Figure 10). 1. Front cylinder 2. Jam nut C. Remove the pin from the rod end and rotate the clevis. D. Install the pin and check the clearance. Repeat the procedure if required. E. Tighten the clevis jam nut. 2.
Product Overview Controls Figure 14 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. Repeat the procedure if required. D. Tighten the clevis jam nut. Figure 15 Important: Lack of clearance at the front stops or rear wear bar could damage the lift arms. 6 1. Forward traction pedal 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 15) back to tilt the steering wheel to the desired position. Then push the lever forward to tighten. The hour meter (Figure 17) 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 15) indicates when the cutting units are in the center position.
Lift Lever Lock Attachments/Accessories Move the lift lever lock (Figure 17) rearward to prevent the cutting units from dropping. 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.com for a list of all approved attachments and accessories. Fuel Gauge The fuel gauge (Figure 18) registers the amount of fuel in the tank. 1 2 g021400 Figure 18 1.
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 3.5 qt (3.3 l) with the filter. Figure 20 1.
Filling the Fuel Tank DANGER 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. The Toro® Company strongly recommends the use of fresh, clean, unleaded regular grade gasoline in Toro gasoline powered products. Unleaded gasoline burns cleaner, extends engine life, and promotes good starting by reducing the build–up of combustion chamber deposits. Use a minimum octane rating of 87.
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.
Biodegradable Hydraulic Fluid—Mobil 224H Toro Biodegradable Hydraulic Fluid (Available in 5 gallon pails or 55 gallon drums. See parts catalog or Toro distributor for part numbers.) Alternate fluid: Mobil EAL 224H This is vegetable–oil based biodegradable oil tested and approved by Toro for this model. This fluid is not as resistant to high temperatures as standard fluid, so install an oil cooler if required by the operator manual and follow recommended fluid change intervals with this fluid.
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 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 • (–) Indicates a circuit closed to ground.
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. 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. Check the hydraulic hoses for damage.
Service Interval Chart Figure 28 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 29 2. Remove the hairpin cotter securing the hood pivot to the mounting brackets (Figure 29). 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 • SideWinder cylinder ends (2) (Figure 32) 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 34) • Neutral adjust mechanism (Figure 37) Figure 37 • Mow/transport slide (Figure 38) Figure 34 • Left front lift arm pivot and lift cylinder (2) (Figure 35) Figure 38 • Belt tension pivot (Figure 39) Figure 35 • Right front lift arm pivot and lift cylinder (2) (Figure 36) Figure 39 Figure 36 33
• Steering cylinder (Figure 40). • Rear roller bearings (2 per cutting unit) (Figure 43) G011349 Figure 43 Note: The flush fittings on the rollers (Figure 43) require a grease gun nozzle adapter. Order Toro Part No. 107-1998 from your Authorized Toro Distributor. Figure 40 Important: Do not lubricate the Sidewinder cross tube. The bearing blocks are self-lubricated. 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 1. Clean the area around the spark plugs so foreign matter cannot fall into the cylinder when you remove the spark plug.
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 50 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 53). 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 55 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.
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 it is fully charged. The specific gravity of a fully charged battery is 1.265–1.299. 3.
Schematics g021399 Hydraulic Schematic (Rev.
Notes: 45
Notes: 46
Notes: 47
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).
