Form No. 3442-584 Rev A Groundsmaster® 3500-G Rotary Mower Model No. 30809—Serial No. 407000000 and Up Register at www.Toro.com.
Whenever you need service, genuine Toro parts, or additional information, contact an Authorized Service Dealer or Toro Customer Service and have the model and serial numbers of your product ready. Figure 1 identifies the location of the model and serial numbers on the product. Write the numbers in the space provided.
Contents Inspecting the Fuel Lines and Connections.................................................. 42 Electrical System Maintenance ........................... 43 Electrical System Safety ................................... 43 Servicing the Battery......................................... 43 Servicing the Fuses .......................................... 43 Drive System Maintenance .................................. 44 Checking the Tire Pressure...............................
Safety This machine has been designed in accordance with ANSI B71.4-2017 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. • 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.
decal117-4764 117-4764 1. Thrown object hazard—keep bystanders away. 2. Cutting hazard of hand, mower blade—stay away from moving parts; keep all guards and shields in place. 3. Cutting hazard of foot, mower blade—stay away from moving parts; keep all guards and shields in place. decal136-3702 136-3702 1. Warning—Read the Operator’s Manual; wear a seatbelt; do not remove the roll bar. decalbatterysymbols Battery Symbols Some or all of these symbols are on your battery. 1. Explosion hazard 6.
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.
decal136-3679 136-3679 1. PTO—Disengage 6. Shift the cutting units to the left. 11. Lights 2. PTO—Engage 7. Lock 12. Fast 3. Lower the cutting units. 8. Engine—Shut off 13. Slow 4. Raise the cutting units. 9. Engine—Run 5. Shift the cutting units to the right. 10.
decal136-3714 136-3714 1. Read the Operator’s Manual for lubrication information. 11. Hydraulic fluid 2. Tire pressure 12. Parking brake 3. Fuel 13. Battery 4. Engine air filter 14. Check every 8 hours. 5. Engine oil 15. Read the Operator’s Manual. 6. Engine-oil level 16. Fluid specification 7. Radiator screen 17. Capacity 8. Engine coolant 18. Fluid change interval (hours) 9. Fuses 19. Filter change interval (hours) 10.
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 Use Qty. No parts required – Charge and connect the battery. No parts required – Add the rear wheel ballast. Hand-held 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).
Note: Charge the battery at a rate of 3 to 4 A for 4 to 8 hours. WARNING Charging the battery produces gasses that can explode. • Keep sparks and flames away from battery. • Never smoke near the battery. 3. g031568 When the battery is charged, disconnect the charger from the electrical outlet and battery posts. 4. Remove the filler caps. 5. Slowly add electrolyte to each cell until the level is up to the fill ring. Figure 4 1. Negative (–) battery cable 2.
3 Checking the Angle Indicator Parts needed for this procedure: 1 Hand-held inclinometer g031569 Figure 6 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 5). Note: The hand-held inclinometer should read at 0° when viewed from the operating position. g349782 Figure 5 1. Hand-held inclinometer 3.
B. 4 Back off the jam nut on the cylinder (Figure 9). 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 7. g031573 Figure 9 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.
g031575 Figure 11 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 12 1. Upper, front cutting unit mounting hole Note: Repeat the procedure if required. D. 3. Rear cutting unit mounting hole 2. Lower, front cutting unit mounting hole Tighten the clevis jam nut. Important: Lack of clearance at the front stops or rear wear bar could damage the lift arms. 2.
bench set 6 mm (1/4 inch) above that of the reels cutting in the same area. 8. Repeat steps 4 to 7 for each side adjustment. 9. Tighten the 3 bolts to 41 N∙m (30 ft-lb). Important: Access to the rear cutting units is Note: Tighten the front bolt first. 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 8 Controls Installing the Mulching Baffle Optional No Parts Required Procedure Contact your authorized Toro distributor for the correct mulching baffle. 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 16). g031595 Figure 17 1. Tilt-steering lever 4. Forward traction pedal 2. Angle indicator 5. Mow/transport slide 3.
Traction Pedals Press the forward traction pedal to move forward. Press reverse traction pedal to move backward or to assist in stopping when moving forward (Figure 17). 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 17).
Lift-Lock Lever Note: The cutting units do not drop unless the engine is running. Use the lift-lock lever to secure the lift switch (Figure 18) to the RAISE-DECK position when performing maintenance on the cutting unit or when transporting between mowing locations. Move the lever to the right or left to move the cutting units in the same direction. Note: Do this only when the cutting units are raised or if they are on the ground and the machine is moving.
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 authorized Toro distributor or go to www.Toro.
performance problems and/or engine damage which may not be covered under warranty. DANGER 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. – Do not use gasoline containing methanol. – Do not store fuel either in the fuel tank or fuel containers over the winter unless a fuel stabilizer is used. • Before removing the fuel-tank cap, make sure that the vehicle is positioned on a level surface.
Selecting a Blade 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. Standard Combination Sail This blade was designed to provide excellent lift and dispersion in almost any condition. If more or less lift and discharge velocity is required, consider a different blade.
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 (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 During Operation Safety General Safety • The owner/operator can prevent and is responsible • • • • • • • • • • • • • • • • for accidents that may cause personal injury or property damage. Wear appropriate clothing, including eye protection; long pants; substantial, slip-resistant footwear; and hearing protection. Tie back long hair and do not wear loose clothing or loose jewelry.
surveying the site. Always use common sense and good judgment when performing this survey. continuous cranking, wait 60 seconds before engaging the starter motor again. • Review the slope instructions listed below for 5. operating the machine on slopes and to determine whether you can operate the machine in the conditions on that day and at that site. Changes in the terrain can result in a change in slope operation for the machine. Release the key when the engine starts.
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.
operator’s position. Allow the machine to cool before adjusting, servicing, cleaning, or storing it. 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. • Clean grass and debris from the cutting units, mufflers, and engine compartment to help prevent fires. Clean up oil or fuel spills.
Pushing or Towing the Machine 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. 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. If you must move the machine a considerable distance, transport it on a truck or trailer.
Maintenance or other bystanders. Remove the key from the switch before you perform any maintenance. Note: Determine the left and right sides of the machine from the normal operating position. • Allow machine components to cool before Note: Download a free copy of the electrical or • If the cutting units are in the transport position, use hydraulic schematic by visiting www.Toro.com and searching for your machine from the Manuals link on the home page.
Maintenance Service Interval Maintenance Procedure Every 400 hours • Replace the spark plugs. • Replace the fuel-pump filter. • Inspect the fuel lines and connections. Every 500 hours • Grease the bearings in the rear axle. Every 800 hours • If you are not using the recommended hydraulic fluid or have ever filled the reservoir with an alternative fluid, change the hydraulic fluid.
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. Check the radiator and screen for debris Check for unusual operating noises. Check the hydraulic-systemoil level.
Pre-Maintenance Procedures Using the Cutting Unit Service Latch When servicing the cutting units, use the service latch to prevent injury. Removing the Hood 1. Unlatch and raise the hood. 2. Remove the hairpin cotter securing the hood pivot to the mounting brackets (Figure 26). 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.
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) g008900 Figure 34 • Neutral-adjustment mechanism (Figure 35) 37
Important: Do not lubricate the Sidewinder cross tube. The bearing blocks are self-lubricated. g008904 Figure 38 • 2 (per cutting unit) cutting unit spindle-shaft bearings (Figure 39) 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 Note: Cleaning of the used element is not recommended due to the possibility of damage to the filter media. Engine Safety 4. • Shut off the engine and remove the key before checking the oil or adding oil to the crankcase. Important: Do not use a damaged filter. • Do not change the governor speed or overspeed the engine. Servicing the Air Cleaner 5. Insert the new filter by applying pressure to the outer rim of the element to seat it in the canister. 6.
g016095 Figure 42 1. Position the machine on a level surface and open the hood. 2. Remove the dipstick (Figure 43) and wipe it with a clean rag. Insert the dipstick into the tube and make sure that it is seated fully. Remove the dipstick and check the level-of-the-oil. g002373 Figure 44 1. Note clearance 4. Install the dipstick firmly in place. 5. Install the oil-fill cap and close the hood. Changing the Engine Oil and Filter Service Interval: After the first 50 hours Every 200 hours g008881 1.
g005588 Figure 47 1. Air gap at 0.81 mm (0.032 inch) 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). If you cannot use a torque wrench, tighten the plugs firmly. 6. Install the spark-plug wires. g021414 Figure 46 1. Engine oil filter 3. Add oil to the crankcase; refer to Checking the Engine-Oil Level (page 39).
Fuel System Maintenance Replacing the Fuel-Pump Filter Service Interval: Every 400 hours DANGER 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 1. Fuel pump • Drain fuel from the fuel tank when the engine is cold. Do this outdoors, in an open area. Wipe up any fuel that spills.
Electrical 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. Electrical System Safety • Always disconnect the negative (black) battery cable before disconnecting the positive (red) cable. • 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. 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. 2. Raise a front wheel and a rear wheel off the floor and place support blocks under the frame.
5. Tighten the locknut securing the adjustment. 6. Shut off the engine. 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. Cooling System Maintenance Cooling System Safety • Swallowing engine coolant can cause poisoning; keep out of reach from children and pets. • Discharge of hot, pressurized coolant or touching a hot radiator and surrounding parts can cause severe burns.
• Preferred: When mixing coolant from a CAUTION concentrate, mix it with distilled water. If the engine has been running, the pressurized, hot coolant can escape and cause burns. • Preferred option: If distilled water is not available, use a pre-mix coolant instead of a concentrate. • Minimum requirement: If distilled water and • Do not open the radiator cap when the engine is running. pre-mix coolant are not available, mix concentrated coolant with clean drinkable water.
Brake Maintenance Cleaning the Cooling System Adjusting the Parking Brake Service Interval: Before each use or daily 1. Raise the hood. 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. 4. Service Interval: Every 200 hours—Check the parking-brake adjustment. 1. Clean the radiator from the back side and blow toward the front.
Belt Maintenance Replacing the Hydrostat-Drive Belt 1. Servicing the Engine Belts Insert a nut driver or small piece of tubing onto the end of the belt-tensioning spring. CAUTION Service Interval: After the first 10 hours—Check the condition and tension of all belts. The spring that tensions the belt is under a heavy load, and releasing the tension of the spring improperly may cause injury. Every 100 hours—Check the condition and tension of all belts.
Controls System Maintenance Hydraulic System Maintenance Adjusting the Throttle Hydraulic System Safety 1. 2. • Seek immediate medical attention if fluid is injected Position the throttle lever rearward so that it stops against the control-panel slot. into skin. Injected fluid must be surgically removed within a few hours by a doctor. Loosen the throttle-cable connector on the injection-pump-lever arm (Figure 58).
Servicing the Hydraulic Fluid maximum biodegradability and performance, the hydraulic system should be thoroughly flushed of conventional fluid. The oil is available in 19 L (5 US gallons) pails or 208 L (55 US gallons) drums from your authorized Toro distributor. Hydraulic Fluid Specifications The reservoir is filled at the factory with high-quality hydraulic fluid.
filled the reservoir with an alternative fluid, change the hydraulic fluid. Hydraulic Fluid Capacity: 13.2 L (3.5 US gallons) If the fluid becomes contaminated, contact your local Toro distributor to flush the system. Contaminated fluid looks milky or black. 1. Turn the engine off and raise the hood. 2. Disconnect the hydraulic line or remove the hydraulic filter and let the hydraulic fluid flow into a drain pan (Figure 62 and Figure 60). g031641 Figure 61 1. Hydraulic-tank cap g031643 5.
Cutting Unit Maintenance Separating the Cutting Units from the Traction Unit 1. Perform the pre-maintenance procedure; refer to Maintenance Safety (page 32). 2. Remove the hydraulic-motor-mounting screws and disconnect and remove the hydraulic motor from the cutting unit (Figure 63). Important: Cover the top of the spindle to prevent contamination. g195308 Figure 62 1. Hydraulic filter 4. Lubricate the new filter gasket and fill the filter with hydraulic fluid. 5.
3. Inspecting the Blade Plane Remove the lynch pin or retaining nut securing the cutting unit carrier frame to the lift-arm-pivot pin (Figure 64). 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. Remove the roller-mounting bolt (Figure 67). g031649 g031647 Figure 67 Figure 66 1. Height-of-cut bracket 2. Shims 2. Adjust the 1.5 mm (0.06 inch) shims and/or 0.7 mm (0.03 inch) shim between the cutting unit frame and bracket to achieve the desired height of cut (Figure 66). 3. Install the height-of-cut bracket to the cutting unit frame with the remaining shims assembled below the height-of-cut bracket (Figure 66). 4.
Blade Maintenance 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. 6. Blade Safety Torque the mounting bolt to 108 N∙m (80 ft-lb). • 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.
Inspecting and Sharpening the Blade 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. By contrast a 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. Note: Check the blade before using the machine.
Storage To verify the stopping time, have an assistant stand at least 6 m (20 ft) away from the cutting unit and watch the blades on 1 of the cutting units. Shut off the cutting units and record the time that it takes for the blades to come to a complete stop. If the time is longer than 7 seconds, the braking valve needs adjustment; contact your authorized Toro distributor for assistance in making this adjustment.
Note: Do not install the wires on the spark No. 505-47) or petroleum jelly to prevent corrosion. F. plugs. Store the battery on the shelf or on the machine in a cool area. Leave the cables disconnected if you store it on the machine. 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 designated quantity of motor oil. 4.
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).
