Form No. 3426-651 Rev C Groundsmaster® 3500-D Rotary Mower Model No. 30807—Serial No. 403440001 and Up Model No. 30839—Serial No. 403440001 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. Visit www.Toro.com for product safety and operation training materials, accessory information, help finding a dealer, or to register your product.
Contents Inspecting the Fuel Lines and Connections.................................................. 46 Servicing the Water Separator .......................... 46 Bleeding the Fuel System ................................. 46 Bleeding Air from the Injectors .......................... 47 Electrical System Maintenance ........................... 47 Electrical System Safety ................................... 47 Servicing the Battery......................................... 47 Servicing the Fuses ............
Safety This machine has been designed in accordance with EN ISO 5395 and ANSI B71.4-2017. 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. Do not engage in any activity that causes distractions; otherwise, injury or property damage may occur.
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.
decal121-3628 121-3628 Note: This machine complies with the industry standard stability test in the static lateral and longitudinal tests with the maximum recommended slope indicated on the decal. Review the instructions for operating the machine on slopes in the Operator’s Manual as well as the conditions in which you would operate the machine to determine whether you can operate the machine in the conditions on that day and at that site.
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.
decal138-6974 138-6974 1. Read the Operator’s Manual.
decal121-3620 121-3620 1. PTO—Disengage 7. Lock 2. PTO—Engage 8. Engine—Shut off 3. Move the cutting units right. 9. Engine—Run 4. Move the cutting units 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 Description 1 2 3 4 5 6 7 8 9 10 Use Qty. No parts required – Activate, charge, and connect the battery. Inclinometer 1 Check the angle indicator. Safety decal Production year decal CE Mark decal Hood-latch bracket Rivet Washer Screw (1/4 x 2 inches) Locknut (1/4 inch) Exhaust guard Self-tapping screw 1 1 1 1 2 1 1 1 1 4 No parts required – Adjust the lift arms.
WARNING 1 Charging the battery produces gasses that can explode. Activating, Charging, and Connecting the Battery • Keep sparks and flames away from battery. • Never smoke near the battery. No Parts Required Procedure Note: If the battery is not filled with electrolyte or activated, purchase bulk electrolyte with 1.26 specific gravity from a local battery-supply outlet and add it to the battery. 4. When the battery is charged, disconnect the charger from the electrical outlet and battery posts. 5.
2 Checking the Angle Indicator Parts needed for this procedure: 1 Inclinometer g031568 Figure 4 1. Negative (–) battery cable Procedure 2. Positive (+) battery cable 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. 9.
3 Installing the CE Decal Parts needed for this procedure: 1 Safety decal 1 Production year decal 1 CE Mark decal Procedure g278675 Figure 7 If this machine will be used for CE, affix the CE-warning decal over the corresponding English warning decal. 1. Serial plate 2. CE mark decal g278676 Figure 6 1. CE warning decal If this machine will be used for CE, affix the production year decal and CE mark decal next to the serial plate (Figure 7). 14 3.
4 Installing the Hood Latch CE Machines Only Parts needed for this procedure: 1 Hood-latch bracket 2 Rivet 1 Washer 1 Screw (1/4 x 2 inches) 1 Locknut (1/4 inch) g012629 Figure 9 1. CE lock bracket Procedure 1. Unhook the hood latch from the hood-latch bracket. 2. Remove the 2 rivets securing the hood-latch bracket to the hood (Figure 8). 2. Bolt and nut 5. Align the washers with the holes on the inside of the hood. 6. Rivet the brackets and the washers to the hood (Figure 9). 7.
g012631 Figure 11 1. Bolt 2. Nut 3. Arm of hood-latch bracket 5 g008875 Figure 12 Installing the Exhaust Guard 1. Exhaust guard 2. CE Models Only Parts needed for this procedure: 1 Exhaust guard 4 Self-tapping screw Procedure 1. Position the exhaust guard around the muffler while aligning the mounting holes with the holes in the frame (Figure 12). 16 Secure the exhaust guard to the frame with 4 self-tapping screws (Figure 12).
B. 6 Back off the jam nut on the cylinder (Figure 15). 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 13. g031573 Figure 15 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.
7 Adjusting the Carrier Frame No Parts Required Adjusting the Front Cutting Units g031575 Figure 17 1. Rear cylinder B. C. D. The front and rear cutting units require different mounting positions. The front cutting unit has 2 mounting positions depending on what height of cut and degree of cutting unit rotation you desire. 2. Adjusting nut Grasp the cylinder rod close to the nut with a pliers and rag, and rotate the rod. 1. Raise the cutting units and check the clearance.
Adjusting the Rear Cutting Unit The front and rear cutting units require different mounting positions. The rear cutting unit has 1 mounting position for proper alignment with the Sidewinder® unit under the frame. For all heights of cut, mount the rear cutting unit in the rear mounting holes (Figure 18). 8 Adjusting the Height of Cut g031577 Figure 19 No Parts Required 1. Spacer 3. Height-of-cut bracket 2.
9 10 Adjusting the Roller Scraper Installing the Mulching Baffle Optional Optional No Parts Required No Parts Required Procedure Procedure The optional rear roller scraper functions best when there is an even gap of 0.5 to 1 mm (0.02 to 0.04 inch) between the scraper and the roller. Contact your authorized Toro distributor for the correct mulching baffle. 1. Loosen the grease fitting and the mounting screw (Figure 21). 1.
Traction Pedals Product Overview Press the forward traction pedal to move forward. Press reverse traction pedal to move backward or to assist in stopping when moving forward (Figure 23). Controls 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 23).
Mow/Transport Slide Using your heel, move the mow/transport slide to the left to transport, and to the right to mow (Figure 24). Note: The cutting units operate only in the mow position. Important: The mow speed is set at the factory to 9.7 km/h (6 mph). You can increase or decrease the mow speed by adjusting the speed-stop screw (Figure 26). g031598 Figure 25 1. Fuel gauge g031596 Figure 26 2. Seat-adjustment lever 1.
Note: The lever does not need to be held in the forward position while you are lowering the cutting units. Alternator Light The alternator light should be off when the engine is running (Figure 24). Note: If it is on, check the charging system and repair it as necessary.
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. Operation 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.
• Do not add or drain fuel in an enclosed space. • Do not store the machine or fuel container where • Monitor seals, hoses, gaskets in contact with fuel there is an open flame, spark, or pilot light, such as on a water heater or other appliance. • Fuel filter plugging may occur for a time after you as they may degrade over time. convert to biodiesel blends.
Checking the Engine-Oil Level Attributes: • More lift and higher discharge velocity • Sparse or limp turf is picked up significantly at Before you start the engine and use the machine, check the oil level in the engine crankcase; refer to Checking the Engine-Oil Level (page 27). higher heights of cut • Wet or sticky clippings are discharged more efficiently reducing congestion in the cutting unit.
Choosing Accessories Optional Equipment Configurations Angle Sail Blade High-Lift, Parallel-Sail Blade (Do not use with the mulching baffle)(Not CE Compliant) 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 • Never leave a running machine unattended. • Before you leave the operator’s position, do the During Operation Safety following: General Safety – Disengage the power takeoff and lower the attachments. • The owner/operator can prevent and is responsible – Engage the parking brake. • • • • • • • • • • • • • • • – Park the machine on a level surface. for accidents that may cause personal injury or property damage.
Starting the Engine operation. Operating the machine on any slope requires extra caution. • Evaluate the site conditions to determine if the slope is safe for machine operation, including surveying the site. Always use common sense and good judgment when performing this survey. 1. Ensure that the parking brake is engaged and the cutting-unit-drive switch is in the DISENGAGE position. 2. Remove your foot from the traction pedal and ensure that the pedal is in the NEUTRAL position. 3.
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.
After Operation 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. General Safety • Shut off the engine, remove the key (if equipped), and wait for all movement to stop before you leave the operator’s position, Allow the machine to cool before adjusting, servicing, cleaning, or storing it.
Locating the Tie-Down Points Pushing or Towing the Machine There are tie downs located at the front and rear sides of the machine (Figure 30). 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. Note: Use properly-rated DOT-approved straps in 4 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.
Maintenance • Allow machine components to cool before Note: Determine the left and right sides of the machine from the normal operating position. • If the cutting units are in the transport position, use performing maintenance. the positive mechanical lock (if equipped) before you leave the machine unattended. Note: Download a free copy of the electrical or • If possible, do not perform maintenance while the hydraulic schematic by visiting www.Toro.
Maintenance Service Interval Maintenance Procedure Every 400 hours • Inspect the fuel lines and connections. • Replace the fuel filter. Every 500 hours • Grease the bearings in the rear axle. Every 800 hours • Drain and clean the fuel tank. • If you are not using the recommended hydraulic fluid or have ever filled the reservoir with an alternative fluid, change the hydraulic fluid.
For the week of: Maintenance Check Item Monday Tuesday Wednesday Thursday Friday Saturday Check the height-of-cut adjustment. Lubricate all the grease fittings.2 Touch up any damaged paint. Wash the machine. 1Check the glow plug and injector nozzles if starting is hard, there is excess smoke, or rough running is noted. 2Immediately after every washing, regardless of the interval listed. Important: Refer to your engine operator’s manual for additional maintenance procedures.
Pre-Maintenance Procedures Using the Cutting Unit Service Latch When servicing the cutting units, use the service latch to prevent injury. Preparing the Machine for Maintenance 1. Center the cutting unit sidewinder with the traction unit. 1. Ensure that the PTO is disengaged. 2. Raise the cutting unit to the transport position. 2. Park the machine on a level surface. 3. 3. Engage the parking brake. Engage the parking brake and shut off the machine. 4. Lower the cutting unit(s) if necessary.
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 41 • Mow/transport slide (Figure 42) g008898 Figure 38 • 2 left, front lift-arm pivots and lift cylinder (Figure 39) g008902 Figure 42 • Belt-tension pivot (Figure 43) g008899 Figure 39 • 2 right, front lift-arm pivots and lift cylinder (Figure 40) g008903 Figure 43 • Steering cylinder (Figure 44) g008900 Figure 40 • Neutral-adjustment mechanism (Figure 41) 41
Important: Do not lubricate the Sidewinder cross tube. The bearing blocks are self-lubricated. g008904 Figure 44 • 2 (per cutting unit) cutting unit spindle-shaft bearings (Figure 45) 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 Engine Safety • Shut off the engine and remove the key before checking the oil or adding oil to the crankcase. • Do not change the governor speed or overspeed the engine. Servicing the Air Cleaner Check the air-cleaner body for damage that could cause an air leak and replace it if it is damaged. Check the entire intake system for leaks, damage, or loose hose clamps.
Servicing the Engine Oil Checking the Engine-Oil Level Service Interval: Before each use or daily The engine is shipped with oil in the crankcase; however, check the oil level before and after you start the engine for the first time. The crankcase capacity is approximately 2.8 L (4 US qt) with the filter. Use Toro Premium Engine Oil or another high-quality, low-ash engine oil that meets or exceeds the following specifications: g032050 Figure 48 1. Rubber outlet valve 4.
4. Change the engine-oil filter as shown in Figure 52. g029301 Figure 50 Changing the Engine Oil and Filter Service Interval: After the first 50 hours g027477 Figure 52 Every 150 hours 1. Start the engine and let it run 5 minutes to allow the oil to warm up. 2. With the machine parked on a level surface, shut off the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. 3. Change the engine oil as shown in Figure 51.
Replacing the Fuel Filter Fuel System Maintenance Draining the Fuel Tank Service Interval: Every 800 hours—Drain and clean the fuel tank. Before storage—Drain and clean the fuel tank. In addition to the listed service interval, drain and clean the tank if the fuel system becomes contaminated or if you are storing the machine for an extended period. Use clean fuel to flush out the tank. 1. Clean the area where the filter mounts (Figure 53). 2. Remove the filter and clean the mounting surface. 3.
forcing air out around the air-bleed screw. Leave the key in the ON position until a solid stream of fuel flows out around the screw. Electrical System Maintenance Tighten the screw and turn the key to the OFF position. Electrical System Safety Note: The electric fuel pump will operate, 6. • Disconnect the battery before repairing the Note: Normally, the engine should start after machine. Disconnect the negative terminal first and the positive last.
Drive 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. Checking the Tire Pressure • Always disconnect the negative (black) battery cable before disconnecting the positive (red) cable. Service Interval: Before each use or daily • Always connect the positive (red) battery cable before connecting the negative (black) cable.
Adjusting the Traction Drive for Neutral 5. Start the engine and rotate the cam hex in both directions to determine the mid position of the neutral span. If the machine moves when the traction pedal is in the NEUTRAL position, adjust the traction cam. 6. Tighten the locknut securing the adjustment. 7. Shut off the engine. 8. 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. 1.
Cooling System Maintenance The capacity of the cooling system is approximately 5.7 L (6 US qt). Cooling System Safety If the engine has been running, the pressurized, hot coolant can escape and cause burns. CAUTION • Swallowing engine coolant can cause poisoning; keep out of reach from children and pets. • Do not open the radiator cap when the engine is running. • Discharge of hot, pressurized coolant or touching a hot radiator and surrounding parts can cause severe burns.
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 64).
High Viscosity Index/Low Pour Point Anti-wear Hydraulic Fluid, ISO VG 46 (cont'd.) Material Properties: Viscosity, ASTM D445 cSt @ 40°C (104°F) 44 to 48 140 or higher Viscosity Index ASTM D2270 Pour Point, ASTM D97 -37°C to -45°C (-34°F to -49°F) Industry Specifications: Eaton Vickers 694 (I-286-S, M-2950-S/35VQ25 or M-2952-S) g031641 Note: Many hydraulic fluids are almost colorless, Figure 65 making it difficult to spot leaks. A red dye additive for the hydraulic fluid is available in 20 ml (0.
Changing the Hydraulic Filter Service Interval: Every 1,000 hours—If you are using the recommended hydraulic fluid, replace the hydraulic filter (sooner if the service interval indicator is in the red zone). Every 800 hours—If you are not using the recommended hydraulic fluid or have ever filled the reservoir with an alternative fluid, replace the hydraulic filter (sooner if the service interval indicator is in the red zone). Use a genuine Toro replacement filter (Part No. 86-3010).
Checking the Hydraulic Lines and Hoses Cutting Unit Maintenance Service Interval: Before each use or daily Separating the Cutting Units from the Traction Unit Every 2 years—Replace moving hoses. Check the 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 the machine. 1.
3. Servicing the Blade Plane Remove the lynch pin or retaining nut securing the cutting unit carrier frame to the lift-arm-pivot pin (Figure 70). The rotary cutting unit comes from the factory preset at 5 cm (2 inches) height-of-cut and blade rake of 7.9 mm (0.31 inch). The left and right heights of cut are also preset to within ± 0.7 mm (0.03 inch) of the other. The cutting unit is designed to withstand blade impacts without deforming the chamber.
If any of these measurements are not within specification, proceed to Adjusting the Blade Plane (page 58). 8. Secure the carriage bolts and flange nuts. 9. Verify the 12, 3, and 9 o’clock heights. Adjusting the Blade Plane Servicing the Front Roller Start with the front adjustment (change 1 bracket at a time). Inspect the front roller for wear, excess wobble, or binding. Service or replace the roller or components if any of these conditions exist. 1.
into the roller housing until it contacts the spacer (Figure 73). 4. Install the roller assembly into the cutting unit frame. Important: Securing the roller assembly with a gap larger than 1.5 mm (0.06 inch) creates a side load on the bearing and can lead to premature bearing failure. 5. Verify that there is no more than a 1.5 mm (0.06 inch) gap between the roller assembly and the roller-mount brackets of the cutting unit frame. g011355 Figure 74 Note: If there is a gap over 1.5 mm (0.
g031648 Figure 75 1. Cutting edge 3. Damaged area (wear, slot, or crack) 2. Sail g276373 4. Inspect the cutting edges of all the blades. Sharpen the cutting edges if they are dull or nicked, sharpen only the top of the cutting edge, and maintain the original cutting angle to ensure sharpness (Figure 76). Figure 77 1. Cutting edge 2. Heel Note: The blade ends must be slightly lower than the center, and the cutting edge must be lower than the heel of the blade.
Storage 2. Remove and discard the oil filter. Install a new oil filter. Storage Safety 3. Refill the oil pan with designated quantity of motor oil. • Shut off the engine, remove the key (if equipped), 4. Turn the key in the switch to the ON position, start the engine, and run it at idle speed for approximately 2 minutes. 5. Turn the key in the switch to the OFF position. 6. Thoroughly drain all fuel from the fuel tank, lines, and the fuel filter/water separator assembly. 7.
EEA/UK Privacy Notice Toro’s Use of Your Personal Information The Toro Company (“Toro”) respects your privacy. When you purchase our products, we may collect certain personal information about you, either directly from you or through your local Toro company or dealer.
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 Conditions and Products Covered Parts 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 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).
